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Processing Sector
Coconut Development Board
1
Coconut leaves
Coconut shell
Coconut trunk
Coconut
inflorescence
Coconut fruit
Significance of Coconut
Domestic demand
Coconut in India
o Coconut is cultivated in 18 states and 3
union territories in the country
o India is the second largest producer in the
world.
o Coconut occupies 1.9 million ha.
o 98% coconut holdings are owned by small
and marginal farmers in the country.
o Annual production of coconut is 16 billion
nuts.
o Coconut contributes more than Rs.8000
crores annually to GDP
4
Item
2010-2011
2011-2012*
Qty
Value
Qty
Value
Coconuts (fresh)
15751.89
2267.77
17633.21
3837.46
Coconuts (dried)
3889.62
1342.99
6327.50
3586.01
Desiccated coconut
900.00
950.00
3881.64
1777.63
10960.17
3080.93
13100.50
5821.54
30.17
19.26
553.32
408.29
5840.00
6130.00
6000.00
5900.00
1056.67
53.20
60.00
27.22
Oilcake (Solvent/expellers)
213.77
49.68
9.60
3.53
1870.35
364.80
716.76
203.30
10
Shell charcoal
15522.78
2915.44
21924.00
5468.23
11
Copra
29625.03
10935.64
25000.00
17500.00
12
38712.12
25550.00
35000.00
30000.00
Total
53659.71
74533.20
6
6
Packaged Tender
Coconut Water
Minimal Processing
of Tender coconut
Coconut jelly
Nata-de-coco
Coconut Vinegar
Spray Dried
Coconut Milk powder
10
Coconut Chips
Coconut jam
Coconut milk
Pinacolada
(coconut milk with pineapple
juice)
10
Margarine
Dietary fibre
from
coconut residue
11
Coconut Flour
Coconut Honey
Coconut Souffle
11
COCONUT NEERA
Sweet nutritious and
Refreshing Beverage
12
12
13
Refined Sugar
13
Organic palm sugar from neera sold in USA, for US$4 per 430gm from
14
14
Indonesia
Coconut
palm sugar
15
15
15
Activated Carbon
16
16
16
Coconut Leaf
Leaf Midrib
Coirpith
Coir geotextiles
17
17
Leaf Midrib
Coirpith
18
Coir geotextiles
18
Coconut Handicrafts
19
19
Product
Raw material
Investments
(Excluding land)
Returns
(IRR)
5000 Tender
Coconuts
45-50 lakhs
20%
10000
coconuts
50-55 lakhs
18%
5000 coconuts
60-65 lakhs
18%
Tender Coconut
Water
Desiccated Coconut
Coconut milk
20000
coconuts
330-350 lakhs
22%
16666
coconuts
75-80 lakhs
22%
Copra
7000 coconuts
10-12 lakhs
15%
Shell Powder
12000 shells
55-60 lakhs
16%
Shell Charcoal
30000 shells
25-30 lakhs
16%
Activated Carbon
3 T of shell
charcoal
470-500 lakhs
(9 T capacity)
24%
10000
coconuts
40-45 lakhs
22%
10
Coconut Chips
20
20
20
21
21
21
22
23
PROCESS FLOW
COCONUT WATER
FILTERING
ADDITIVE MIXING
CONCENTRATION
PACKING
RETORTING
COOLING
FINISHED PRODUCT
24
24
25
25
25
Global Brands
26
26
26
Global Brands
27
27
27
60 cents
Rs.20 lakhs
Rs.40 lakhs
Rs.10 lakhs
Rs. 5 lakhs
Rs.15 lakhs
Rs.90 lakhs
Machinery
Feed Conveyors for washed nuts
Automatic boring and sucking system
TCW collection tank
TCW filtering unit
Treatment Chamber
Double Head Filling Machine
Pouch Sealing Machine
Can Seaming Machine
28
28
28
Machinery
Conveyor for filled pouches/cans
Steam boiler
Pasteurizer
Thermal validation system
UV Chamber
Air Compressor
Packaging machine for pouches
Product yield
10000 coconuts would yield about 2000 litres of
tender coconut water
Internal Rate of Return - 20-22 %
29
29
29
ECONOMIC FEASIBILITY
Capacity
Sales turnover
IRR
Payable period
Employment potentialSource of TechnologyKnow how fee
-
30
31
Process Flow
Harvesting of Tender Coconut
Trimming the husk manually
Dipping in preservation solution
Shrink wrapping
Storing in cooler
Transporting to selling place
32
50 cents
Rs.27.0 lakhs
Rs.5.0 lakhs
Rs.5.0 lakhs
Rs.2.0 lakhs
Rs.3.0 lakhs
Rs.6.0 lakhs
Financial Projections
Annual Sales Revenue
Breakeven point
IRR
- Rs.270 lakhs
- 45%
- 21 %
33
DESICCATED COCONUT
The dehydrated shredded flesh of
coconut 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 amount to
about 2000 Tones
34
34
34
Process Flow
Matured Kernel
Washing
Cutting
Blanching
Disintegration
Drying
Packing
Storage
35
35
DESICCATED COCONUT
Project Cost (One Ton/Day capacity)
50 cents
Rs.18 lakhs
Rs.25 lakhs
Rs. 5.00 lakhs
Rs.5.00 lakhs
Rs.10.00 lakhs
Rs.63.00 lakhs
Raw material
10,000 coconuts
Desiccated coconut
1 tone
Internal Rate of Return
18-20 %
36
36
36
COCONUT OIL
Project Cost (3 tonnes/day capacity)
Land (cost variable)
30 cents
Building 2000 sq.ft.
Rs 15.00 lakhs
Plant and Machinery
Rs.20.00 lakhs
Preliminary and pre- op expenses
Rs. 5.00 lakhs
Electrification
Rs 5.00 lakhs
Working capital (Margin Money)
Rs.10.00 lakhs
Total
Rs.55.00 lakhs
Machinery
Copra cutter
Bucket elevator
Steam jacketed kettle
Oil expeller
Screw conveyor
Crude coconut oil storage tanks
Filter press
Micro filter
Filtered oil storage tanks
Volumetric filling machine
Baby boiler
Yield
Raw material
5 tonnes of copra
Finished product
3 tonnes Coconut oil
Internal rate of Return
16-18%
37
Coconut Chips
38
39
Coconut
chips sold at Rs.120/- for 40gm in China, produced in Thailand 39
Process Flow
Coconut
Removal of shell
Removal of Testa
Cutting in to pieces
Slicing of Kernel
Blanching
Osmotic Dehydration (1 hr/40 min)
Drying (4 hrs)
Packaging
40
Project Cost
Land
Building -2000 sq ft @ Rs. 800 per sq ft
Plant & Machinery
Electrical Installations
Preoperative Expenses
Working Capital Margin
Total
- 40- 50 cents
- 16.00
- 18.00
- 3.00
- 1.00
- 4.00
- 42.00
Machinery
Coconut Slicing machine
Hot air Owen
Mixing tank for sugar coating
Steel utensils and vessels
Nitrogen flush packing machine
Yield
Raw Material Per day : Fully ripened Coconut - 10000 per day
Yield per day :Coconut Chips - 1000 kg
Internal rate of Return -22%
41
Ready
to
use
product
for
households recipes, beverages, ice
creams, sweets, desserts etc.
Fresh taste of coconut without the
bother
Very convenient for house holds,
hotels,
bakeries.
Blends easily with food preparation.
Keeps fresh for a period of 6 months
with all nutrients in tact.
42
42
42
Machinery / Equipment
Hammer mill
Elevator
Screw press
Coconut milk storage tanks
Vibrating sieving machine
Coconut residue mixer
Additive mixing tank
Emulsifier
Homogenizer
Pasteurizer
Volumetric filling machine
43
20-22 %
44
with
45
Process Flow
46
46
1 acre
Rs. 60 lakhs
Rs.175 lakhs
Rs. 30 lakhs
Rs. 25 lakhs
Rs. 40 lakhs
Rs.330.00 lakhs
MACHINERY
Hammer mill
Elevator
Screw press
Coconut milk storage tanks
Vibrating sieving machine
Coconut residue mixer
Additive mixing tank
Emulsifier
Homogenizer
Pasteurizer
Volumetric filling machine
47
47
47
MACHINERY (Contd.)
Exhaust box
Can seaming machine
Horizontal rotary retort
Spray drier
Agro waste vertical boiler
Sterilization tank
Coconut residue storage bins
Product yield
20000 coconuts would yield about 1000 kgs of coconut milk powder
Internal Rate of Return
22-24 %
48
48
48
and
virgin
49
49
49
Process Flow
Fresh Coconut meat
Coconut milk
Centrifugation
Fermentation
Separation of oil
Removal of residual moisture
50
50
51
51
51
Machinery (Contd.)
52
52
52
12,000 shell
1 tonne
18%
53
53
53
54
54
54
55
Activated Carbon
56
56
56
Activated Carbon
Project cost (9 tons/day)
Land
Building 12000 sq.ft
Plant & Machinery
Preliminary & pre-op expenses
Electrification
Working capital (Margin Money)
Total
Machinery
Jaw crusher
Hammer mill
Vibrating feeder
Elevator
Carbonisation kiln
Soaking tanks
Cyclones
Pneumatic filling machine
Coolers
Centrifuge
Rotary drier
pulverizer
Sieving machine
Rotary kiln with heat recovery unit
Yield
Raw material
Activated carbon
90,000 shells
1 tonne
57
57
57
58
58
58
59
59
60
MISSION STRUCTURE
Management of insect
pests and diseases
Technical
support,
evaluation
and emergent
requirements
Technology
Mission on
Coconut
Processing and
Product
diversification
61
DEVELOPMENT OF
TECHNOLOGIES
ICAR/CSIR Institutes
SAUs
NGOs
ANY RESEARCH
ORGANIZATIONS
HAVING CAPACITY
DEMONSTRATION
OF TECHNOLOGIES
ICAR/CSIR Institutes
SAUs
NGOs
ADOPTION OF
TECHNOLOGIES
FARMERS
REGISTERED
COOPERATIVE
SOCIETIES/GROU
P OF FARMERS
ENTREPRENEURS
62
62
62
Kernel Based
Coconut cream,
Spray Dried Milk
Powder, Desiccated
coconut powder,
virgin Coconut oil,
Ball copra
Shell Based
Shell Charcoal,
Activated Carbon,
Shell powder
63
63
PATTERN OF ASSISTANCE
Processing and product diversification
(a) Development of technologies
- 100% of the project cost limited to Rs.75 lakhs for all the Govt.
institutions and cooperative societies.
- 50% of the project cost limited to Rs.35 lakhs for NGOs,
Individual entrepreneurs and other research organizations
(b) Demonstration of technologies
- 100% of the cost limited to Rs.75 lakhs all the Govt.
cooperative societies.
- 50% of the cost limited to Rs.35 lakhs for the NGOs,
entrepreneurs and other organizations.
(c) Adoption of technologies
-
institutions
and
Individual
64
PATTERN OF ASSISTANCE
Market research and promotion
(a) Market research
-
65
Chemical Lab
Microbiology Lab
66
66
67
for
68
68
69
69
Project cost
Financial assistance
Capacity
Products
: Rs.153.96 lakhs
: Rs.34.225 lakhs
: 10000 nuts per day
: Tender Coconut water
70
70
70
71
71
71
72
72
72
73
73
73
74
74
74
75
75
75
Project cost
Financial assistance
Capacity
Products
: Rs.58.79 lakhs
: Rs.13.56 lakhs
: 10000 nuts per day
: Virgin coconut oil
76
76
76
: Rs.191.5 lakhs
: Rs.39.66 lakhs
: 20000 nuts per day
: Virgin Coconut Oil
77
77
77
78
78
78
79
79
79
: Rs.74.75 lakhs
: Rs.11.25 lakhs
: 5000 coconut per day.
: Coconut oil
80
80
80
81
81
81
82
82
82
Project cost:
Rs.3.21Crores
Financial assistance:
Rs. 50 lakhs
Capacity:
200 MT / day
Products: Coconut Oil
83
83
83
: Rs.108.00 lakhs
: Rs.19.457lakhs
: 30000 nuts per day
: Desiccated Coconut Powder
84
84
84
85
85
85
86
86
86
87
88
88
88
Project cost
Financial assistance
Capacity
Products
: Rs.12.80 lakhs
: Rs.3.20 lakhs
: 15 lakhs ball copra per year
: Ball copra
89
89
: Activated Carbon
90
90
90
Project cost
Financial assistance
Capacity
Products
: Rs.103.10 lakhs
: Rs.20.58 lakhs
: 1.50 MT per day
: Activated carbon
91
91
91
92
92
92
M/s.Srinithi Agro
Industries, Salem, TN
Project cost
Financial assistance
Capacity
Products
: Rs.92.35 lakhs
: Rs.20.15 lakhs
: 15 MT shells / day
: Shell powder
93
93
93
94
94
94
M/s. Kongunad
Agro Products,
Kangayam
95
95
95
96
96
96
97
97
97
98
98
98
99
99
99
E-mail: kochi.cdb@gov.in
Website: http://www.coconutboard.gov.in
100100
101101