coffee manufacturing unit project report

8/16/2019 Coffee Manufacturing Unit Project Report

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SMB ENVIRONMENTAL PROJECTS PVT. LTD.Cell No : +91 98602 40852, 96650 40852, 96650 40852

PIONEERING GREEN TECHNOLOGIES

TECHNOLOGIES

Technical Know-how - A Gateway to Prosperity

A PROJECT REPORT ON

COFFEE MANUFACTURING UNIT

Prepared By S.A. AZAD ( alias Sk Burhaan )

B.Sc. Tech ( Chem Tech ) , DNIIT, DG, D!,

"#. Sr. ana$er % &PC' ( Prec* Plannin$)

C"+ SB "n-irnmen*al Prec*s (P) '*d.

!r

Mr !A"#R$%%IN #AR%&ARE&ALA,

CA, AL'#$RAIR !OO%S, %$BAI ($AE)Tel:- 04-3120150 PABX No. 04-3939633

"mail [email protected]

1

13 / 14, Seva Sadan Building, CA Road, NAGPUR – 440 001 ,Phone : +91 7263 – 259052, Mobile : +91 98602 40852Email: [email protected] [email protected]

Web : http://www.smb-project-consultants.com/

mailto:[email protected]:[email protected]://www.smb-project-consultants.com/project-consultancy.htmmailto:[email protected]:[email protected]://www.smb-project-consultants.com/project-consultancy.htm


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A PROJECT REPORT ON COFFEE

MANUFACTURING UNIT

S.No. CONTENTS Page No.

1. NTRO!UCTON 3

". #UA$T% STAN!AR!S 4

3. &AR'ET POTENTA$ 1"

4. BASS ( ASSU&PTONS 13

). PRO!UCTON ( TEC*NCA$ ASPECTS 1+

+. PROECT -AC$TES "

. COST SU&&AR%

( OPERATTNG EPENSES 3

. -NANCA$ ANA$%SS/ CAS* -$O2 4"

. P$ANT ( &AC*NERES SUPP$ERS 4)

$a Page o5 6e Re7o8 9999999 4)

"





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1.0 NTRO!UCTON

1.1 BAC'GROUN! :

Alg6u8ai8 -ood, !u;ai < UAE = is one of the highly reputed food chain group

of companies in the United Arab Emirates ( UAE), having its own manufacturing

and distribution network for domestic and export market. Along with other food

and !"# products, it is now proposing to establish its own in $ house "offee

making unit with a view to meet the growing demands of this region as well as

to cater to the export market.

or this pro%ect the group represented by "A !r akhruddin &ardwarewala has

approached S&B Envi8on>enal P8o?e@ Pv. $d 9 A;olue

Te@6nologie, a 'agpur based premier ndustrial "onsultancy organiation to

prepare a *echno+ Economical easibility cum ro%ect -eport. Accordingly, a

detailed *echno+commercial ro%ect -eport is prepared and presented as a

compact planning document to initiate and implement this time $ bound

pro%ect, keeping in view the specific conditions of the location and the client

1." $OCATON O- T*E PROPOSE! PROECT :

*he proposed plant would come up on a leased plot of land in ubai. *he

location is carefully selected being close to the coast of ubai for ease of

transporting imported raw material, which is likely to be imported from East

African countries e.g. /enya. *he location will also be ideal for logistic

advantage for dispatching the finished products in packed and bulk packaging to3





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the domestic distributors, retail outlets by employing transportation routes like

road and through the sea port for exporting to #ulf "ooperation "ountries

( #""s)

1.3 PRO!UCT & :

rimarily, the finished product from this unit shall be Arabica variety coffee

beans and powders, packed in 012 gms tins and packs.

. Cond ".0 #uali Sanda8d

". #UA$T% STAN!AR!S

".1 GENERA$:

t is generally estimated that the 3uality of the finished product in coffee

depends4

+ 526 on the field7plantation

+ 526 on primary processing

+ 026 on secondary7export processing

Unfortunately the ma%ority of investment, especially in the years since

liberaliation, has been made in the export processing. 8y that stage it is toolate to have a ma%or positive impact on the 3uality. *he need is to address the

issues of 3uality improvement both at plantation and primary processing level.

*here is a significant value+addition to be gained from the wet processing of

coffee, in order to produce what is called washed $ or fully washed coffee. (9ee

4





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*his re3uires a certain investment, but according to the 3uality produced, it is

estimated that this can provide a return on investment (-:) in the order of ;2

$ ;16 on the cost of installing and operating a small coffee processing unit

("U). *his return is derived from the premiums at which the washed coffee can

be sold compared to traditional primary processing methods, and should apply

for both arabica and robusta. t should also enable better prices to be paid to

farmers for their coffee

"." #UA$T% ASSURANCE &EASURES:

'evertheless, *he pro%ect envisages a full fledged 3uality control laboratory with

competent staff and a systematic


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1. 9ample roaster shall be employed and for accurate evaluation of cup

characteristics.

>. "up scores shall be tabulated and used for design mixes.

?. Also, a complete


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2.3. COFFEE GA!E":

T#e $ollo%i&' Co$$ee G(a)e* a(e +(o+o*e) ,o be ma&$a,(e) i& ,#e +la&,:

N*eSree-

No.Be*-. 'r*/e

See

S*-/*r/%e.r3o- Re*r.

Araica

ild C//ee

Plan*a*in

AA

Be*0een

12 3 14

Clean, ld

uni/rm si5e666

789 y

0ei$h*

s*andin$ in

2 mm sie-e

Superir

/la-ur,

s*ren$*h and

arma

Cnnisseur:s

chice

Araica Be*0een Bld, $reenish6 6666 789 y Gd, clean, 666





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Plan*a*in

(;ashed)

Plan*a*in A

1< 3 12

$rey, 0i*h li$h*ca*in$, display

resul*s and

clean

prepara*in

0ei$h*

s*andin$ in

< mm sie-e

s/* cup,$d dy

/ /air

acidi*y

Plan*a*in

PB666 =und eans

Clean

$arled, N

/la*s (AB)

suec* * a

*lerance /

>9 y

0ei$h*

?9 y

0ei$h* /

Peaerry

Tria$e

Superir

/la-ur,

S*ren$*h 3

Arma

66

Plan*a*in B 1@ Small eans

Clean

$arled.

Des n*

cn*ain PB

suec* *

*lerance /

>9 y

0ei$h*. Can

cn*ain ?9

y 0ei$h* / *ria$e

N* less

*han 2@9

s*andin$ n

a sie-e / <

mm. N*

mre *han

1.@9

passin$

*hru$h a

@.@ mmsie-e

Gd Arma 66

Plan*a*in CBe*0een

1? 3 1

Includes li$h*,

a*6shaped

and sp**ed

eans (less *han

a uar*er /

ean sur/ace)

N lack r

dama$ed eans

Cnsis*s /

*ria$e and

small 0hle

eans /

prescried

sie-e si5e

2@9 y

0ei$h*.

S*andin$ n

a @.@ mm

sie-e, u*

1889

0ei$h*.

S*andin$ n

@ mm sie-e

Gd Arma 66

Araica

Cherry

(n0ashed)

Araica

Cherry AB

1@ i#*ure / A 3

B

Clear

$arled. N

PB suec*

* a

*lerance /

>9 y

0ei$h*.

N* less

*han 789

y 0ei$h*

s*andin$ n

< mm sie-e.

N* mre

*han 1.@9

Na*ural

Arma

66





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Cn*ains?9 y

0ei$h* /

*ria$e

passin$*hru$h

@.@8 mm

sie-e

Araica

Cherry PB66 =und eans

N /la*s

(AB)

suec* *

*lerance /

>9 y

0ei$h*.

Cn*ains

?9 y

0ei$h* /

*ria$e

?9 y

0ei$h* /

Peaerry

Tria$e

Na*ural

Arma66

Araica

Cherry C

Be*0een

1? 3 1

'i$h*, a*

shaped and

sp**ed eans

(less *han 1 /

eam sur/ace)

Des n*

cn*ain mre

*han >9 lacksr0n

andr i*s

Cnsis*s /

Tria$e and

small 0hle

eans /

prescried

sie-e si5e

2@9

s*andin$ n

@.@ mm

sie-e, 1889

y 0ei$h*

s*andin$ n@ mm sie-e

Na*ural

Arma66

0.5 E9"-*:' : A-:U9 '9&E ":EE #-AE9 4

+ A8a;i@a &ild Co55ee : lantation AA 8etween =? B =C "lean, bold

uniform sie 4 D26 by weight standing in ? mm sieve 9uperior flavor,

strength and aroma "onnoisseurs choice

+ A8a;i@a Planaion B =? 8old, greenish+grey, with light coating,

display results and clean preparation4 D26 by weight standing in >

mm sieve good, clean, soft cup, good body of fair acidity





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+ lantation 84 -ound beans "lean garbled, 'o flats (A8) sub%ect to a

tolerance of 06 by weight ;6 by weight of ea berry *riage 9uperior

flavor

#reen "offee 8eans

-oasted "offee beans

+ 9trength B Aroma4 lantation 8 =1 9mall beans "lean garbled. oes

not contain 8 and is sub%ect to tolerance of 06 by weight. "an

10





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contain ;6 by weight of triage not less than ?16 standing on a dieve

of > mm. 'ot more than =.16 passing through a 1.1 mm sieve good

Aroma

+ lantation " 8etween =; B =54 ncludes light, boat+shaped and spotted

beans (less than a 3uarter of bean surface) 'o black or damaged

beans "onsists of triage and small whole beans of prescribed sieve sie

?16 by weight. 9tanding on a 1.1 mm sieve but, =226 weight.

9tanding on 1 mm sieve #ood Aroma

+ Arabica "herry (Unwashed) Arabica "herry A8 =1 !ixture of A B 8

"lear garbled. 'o 8 sub%ect to a tolerance of 06 by weight. "ontains

;6 by weight of triage not less than D26 by weight standing on > mm

sieve. 'ot more than =.16 passing through 1.12 mm sieve 'atural

Aroma

+ Arabica "herry 84 -ound beans 'o flats (A8) sub%ect to tolerance of

06 by weight. "ontains ;6 by weight of triage ;6 by weight of eaberry *riage 'atural Aroma

+ Arabica "herry " 8etween =; B =54 Fight, boat shaped and spotted

beans (less than =75 of beam surface) does not contain more than 06

blacks7brown and7or bits "onsists of *riage and small whole beans of

prescribed sieve sie ?16 standing on 1.1 mm sieve, =226 by weight

standing on 1 mm sieve 'atural Aroma

G !arket otential followsG

11





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3.0 &AR'ET POTENTA$

Approximately seven million tons of green coffee is produced worldwide each

year. *he prices in the world market have recovered since the absolute lows of

022=720. According to the ":, global consumption has been growing by over

06 per annum in the C years 0222 $ 022C. Even with the recent recession,

coffee consumption has shown itself to be resilient, and rising incomes in many

new consuming markets show promise of continuing strong growth in the years

ahead.

At present, the world depends for about 126 of total supply on %ust two origins,

8rail and ietnam. Hith consumption expected to rise by around = million tons

in the coming > $ C years, it is anticipated that the coffee market will give

efficient producers good returns in the coming years.

*he critical issue will be the capacity to remain competitive as a producer. *his

will depend on two main factors4

a) roductivity, as coffee faces competition from food crops and bio+fuels for

available land and other resources.

b)


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4.0 BASS ( ASSU&PTONS

4.1 PRO!UCTON -AC$TES :

*he plant will have a capacity of 05 * processing of green coffee beans, to be

constructed on a =2,222 s3 meter plot of leased land. t shall comprise, one or

more units of green bean separators, huller, processing unit, vibrating screens

graders, vacuum or pressure type de+stoners, gravity separators, graders

machines and packing machines for tin and pouch packaging.

4." 2OR'NG :

*he plant is expected to work on round the clock basis, 05 hours and ;22 days

in a year. -est of the period will be utilied for maintenance activities. -e3uired

redundancy has been built in the plant design so that spare e3uipment are

available to ensure continuous and un+interrupted production even when some

of the e3uipment are taken off from the service for routine maintenance.

4.3 -NANCE:

*he ratio of own 4 loan funds is taken as = 4 5. *he owners share of fixed and

working capital shall be arranged from the own internal resources. *he balance

funding shall be arranged from mid $ term, six year loan bearing an interest I

13





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1.16. *otal overall investment including the borrowings should not exceed 5

million Euros e3uivalent of =C.> million AE ( = AEd J 2.0=1 Euro)

4.4 ADA$AB$T% O- RA2 &ATERA$ ( UT$TES :

*he raw materials i.e Arabica variety of coarse 3uality coffee beans shall be

imported mostly from East African countries like /enya up to the ubai sea port

in containers. rom the sea port, the raw materials shall be transported by road

to the production plant.

*he power and water shall be provided by ubai Electricity and Hater Authority

( EHA) by installing a captive substation. *he EHA also provides sufficient

backup in case of power failure and therefore, there is no need to provide any

power back up facilities. *he cost of power at present is ;2 fils 7 /H.

4.) &P$E&ENTATON SC*E!U$E :

1. e'i*,(a,io& / o,#e( Fo(mali,ie* : 1 mo&,#

2. Ai*i,io& o$ ea*e) la&) : 1 mo&,#

3. P(e+a(a,io& o$ !e,aile) E&'' / !e*i'&: 3 mo&,#

4. A((a&'eme&, o$ Fi&a&e : 2 mo&,#*

5. Bil)i&' o&*,(,io& : 3 mo&,#*6. A((a&'eme&, o$ Po%e( : 1 mo&,#

. P(o(eme&, o$ Pla&, / a#i&e(: 4 mo&,#

. E(e,io& o$ Pla&, / a#i&e( : 3 mo&,#

9. A++oi&,me&, o$ *,a$$ / labo( : 1 mo&,#

10. T(ial +(o),io& /

T(oble - *#oo,i&' : 1 mo&,#14





15/45



C!C"##$!% &!' ($)"$!%*&+ &C%*,*%*$( :

O, o$ aboe li*,e) a,ii,ie*7 i& o()e( ,o mi&imi8e ,#e oe(all im+leme&,a,io& ,ime7 ,#e

a,ii,ie* a& be )ii)e) a&) +(*e) i&,o $ollo%i&' o&((e&, a&) *ee&,ial +(oe,

+#a*e*.

hases roup o concurrent activities %otal %ime

P#a*e e'i*,(a,io&7 la&) Ai*i,io&7 !e,aile) E&''. A&) A((a&'eme&, o$ Fi&a&e 3 mo&,#*

P#a*e Bil)i&' Co&*,(,io&7 P(o(eme&, a&) E(e,io&

O$ Pla&,* / a#i&e(ie*7 A((a&'i&' Wa,e( / Po%e(

"++lie*

Ne;, 4 mo&,#*

P#a*e Commi**io&i&'7 T(ail +(o),io&7 e(i,me&, o$

a&+o%e(7 Comme(ial P(o),io& / a(


16/45



).1 CO--EE &ANU-ACTURNG < -8o> 6e Seed o 6e Cu7 = :

).1.1 Planing

A coffee bean is actually a seed. Hhen dried, roasted and ground, it is used to

brew coffee. "offee seeds are generally planted in large beds in shaded

nurseries.

After sprouting, the seedlings are removed from the seed bed to be planted in

individual pots in carefully formulated soils. *hey will be watered fre3uently and

shaded from bright sunlight until they are healthy enough to be permanently

planted. lanting often takes place during the wet season, so that the soil

around the young trees remains moist while the roots become firmly

established. ).1.". *a8veing 6e C6e88ie

epending on the variety, it will take approximately ; or 5 years for the newly

planted coffee trees to begin to bear fruit. *he fruit, called the coffee cherry,

1+





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turns a bright, deep red when it is ripe and ready to be harvested. n most

countries, the coffee crop is picked by hand, a labor+intensive and difficult

process, though in places like 8rail, where the landscape is relatively flat and

the coffee fields immense, the process has been mechanied. Hhether picked

by hand or by machine, all coffee is harvested in one of the two ways4

S8i7 Pi@ed + the entire crop is harvested at one time. *his can either be done

by machine or by hand. n either case, all of the cherries are stripped off of the

branch at one time.

Sele@ivel Pi@ed + only the ripe cherries are harvested and they are picked

individually by hand. ickers rotate among the trees every C + =2 days,

choosing only the cherries which are at the peak of ripeness. 8ecause this kind

of harvest is labor intensive, and thus more costly, it is used primarily to

harvest the finer arabica beans.

n most coffee+growing countries, there is one ma%or harvest a yearK though

in countries like "olombia, where there are two flowerings a year, there is a

main and secondary crop. A good picker averages approximately =22 to 022

pounds of coffee cherry a day, which will produce 02 to 52 pounds of coffee

1





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beans ( about 026 by weight). *he days harvest (cherries) is then combined

and transported to the processing plant.

).1.3. P8o@eing 6e C6e88ie

:nce the coffee has been picked, processing must begin as 3uickly as possible

to prevent spoilage. epending on location and local resources, coffee is

processed in one of the two ways.

A. T6e !8 &e6od

*his is the age+old method of processing coffee and is still used in many

countries where water resources are limited. *he freshly picked cherries

are simply spread out on huge surfaces to dry in the sun. n order to

prevent the cherries from spoiling, they are raked and turned throughout

the day, then covered at night, or if it rains, to prevent them from getting

wet. epending on the weather, this process might continue for several

weeks for each batch of coffee. Hhen the moisture content of the cherriesdrops to == percent, the dried cherries are moved to warehouses where

they are stored

B. T6e 2e &e6od

n wet method processing, the pulp is removed from the coffee cherry

after harvesting and the bean is dried with only the parchment skin left

on.

1





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*here are several actual steps involved. irst, the freshly harvested

cherries are passed through a pulping machine where the skin and pulp is

separated from the bean. *he pulp is washed away with water, usually to

be dried and used as mulch. *he beans are separated by weight as they

are conveyed through water channels, the lighter beans floating to the

top, while the heavier, ripe beans sink to the bottom. 'ext they are

passed through a series of rotating drums which separate them by sie.

Arabica Plantation - washed

1





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After separation, the beans are transported to large, water+filled fermentation

tanks. epending on a combination of factors ++ such as the condition of the

beans, the climate and the altitude ++ they will remain in these tanks for

anywhere from =0 to 5C hours. *he purpose of this process is to remove the

slick layer of mucilage (called the parenchyma) that is still attached to the

parchmentK while resting in the tanks, naturally occurring enymes will cause

this layer to dissolve. Hhen fermentation is complete the beans will feel rough,

rather than slick, to the touch. At that precise moment, the beans are rinsed by

being sent through additional water channels. *hey are then ready for drying.

).1.4. !8ing 6e Bean

f the beans have been processed by the wet method, the pulped and

fermented beans must now be dried to approximately == percent moisture to

properly prepare them for storage. *hese beans, still encased inside the

parchment envelope (the endocarp), can be sun dried by spreading them ondrying tables or floors, where they are turned regularly, or they can be

machine dried in large tumblers. :nce dried, these beans, referred to as

parchment coffee, are warehoused in sisal or %ute bags until they are readied

for export.

).1.). &illing 6e Bean

8efore it is exported, parchment coffee is processed in the following manner4

a. *ulling

!achines are used to remove the parchment layer (endocarp) from wet

processed coffee. &ulling dry processed coffee refers to removing the

entire dried husk ++ the exocarp, mesocarp B endocarp ++ of the dried

cherries.

"0





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b. Poli6ing

*his is an optional process in which any silver skin that remains on the

beans after hulling is removed in a polishing machine. Hhile polished

beans are considered superior to unpolished ones, in reality there is little

difference between the two.

c. G8ading ( So8ing

8efore being exported, the coffee beans will be even more precisely

sorted by sie and weight. *hey will also be closely evaluated for color

flaws or other imperfections.

*ypically, the bean sie is represented on a scale of =2 to 02. *he number

represents the sie of a round holes diameter in terms of =7>5s of an inch. A

number =2 bean would be the approximate sie of a hole in a diameter of =27>5

of an inch and a number =1 bean, =17>5 of an inch. 8eans are sied by being

passed through a series of different sied screens. *hey are also sortedpneumatically by using an air %et to separate heavy from light beans.

'ext defective beans are removed. *hough this process can be accomplished

by sophisticated machines, in many countries, it is done by hand while the

beans move along an electronic conveyor belt. 8eans of unsatisfactory sie,

color, or that are otherwise unacceptable, are removed. *his might include over+

fermented beans, those with insect damage or that are unhulled. n many

countries, this process is done both by machine and hand, insuring that only the

finest 3uality coffee beans are exported

).1.+. EH7o8ing 6e Bean

*he milled beans, now referred to as green coffee, are ready to be loaded

onto ships for transport to the importing country. #reen coffee is shipped in

"1





22/45



either %ute or sisal bags which are loaded into shipping containers, or it is bulk

shipped inside plastic+lined containers.

).1.. Taing 6e Co55ee

At every stage of its production, coffee is repeatedly tested for 3uality and

taste. *his process is referred to as cupping and usually takes place in a room

specifically designed to facilitate the process. irst, the taster ++ usually called

the cupper ++ carefully evaluates the beans for their overall visual 3uality. *he

beans are then roasted in a small laboratory roaster, immediately ground and

infused in boiling water, the temperature of which is carefully controlled. *he

cupper LnosesL the brew to experience its aroma, an integral step in the

evaluation of the coffees 3uality. After letting the coffee rest for several

minutes, the cupper Lbreaks the crustL by pushing aside the grounds at the top

of the cup. Again the coffee is nosed before the tasting begins.

*o taste the coffee, the cupper LslurpsL a spoonful with a 3uick inhalation. *he

ob%ective is to spray the coffee evenly over the cuppers taste buds, and thenLweighL it before spitting it out. 9amples from a variety of batches and different

beans are tasted daily. "offees are not only analyed this way for their inherent

characteristics and flaws, but also for the purpose of blending different beans or

determining the proper roast. An expert cupper can taste hundreds of samples

of coffee a day and still taste the subtle differences between them.

).1.. Roaing 6e Co55ee

-oasting transforms green coffee into the aromatic brown beans that we

purchase, either whole or already ground, in our favorite stores. !ost roasting

machines maintain a temperature of about 112 degrees ahrenheit. *he beans

are kept moving throughout the entire process to keep them from burning and

when they reach an internal temperature of about 522 degrees, they begin to

turn brown and the caffeol, or oil, locked inside the beans begins to emerge.

""





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Roasted Arabica Cofee beans

*his process, called pyrolysis is at the heart of roasting. t is what produces

the flavor and aroma of the coffee we drink. Hhen the beans are removed from

the roaster, they are immediately cooled either by air or water. -oasting isgenerally performed in the importing countries because freshly roasted beans

must reach the consumer as 3uickly as possible.

).1.. G8inding Co55ee

*he ob%ective of a proper grind is to get the most flavor in a cup of coffee. &ow

coarse or fine the coffee is ground depends on the method by which the coffee

is to be brewed. #enerally, the finer the grind the more 3uickly the coffeeshould be prepared. *hat is why coffee ground for use in an espresso machine

is much finer than coffee which will be brewed in a drip system.

).1.10. Gene8al:

"3





24/45



*he sustained production and processing of high 3uality coffee is to a very large

extent dependent on efficient and cost effective engineering inputs. "offee

3uality is dependent on production management practices at the farm level

such as fertiliation, spraying against infection, tillage practices, and irrigation

and harvesting. *he 3uality is also dependent on processing operations at

factories such as reception, pulping, pre+grading, fermentation, grading,

conditioning, drying, storage and waste management. *ransport of cherry and

parchment must also be effected efficiently to ensure a cost effective operation.

recise milling of coffee also contributes to the final 3uality and productivity.

).1.11 !i55e8en P8o@eing &e6od and Te8> Ued in 6e Co55ee

ndu8:

a= Ca5I nau8e $ dry+processed or sun+dried coffee. *his is generally the

-obusta coffee but some Arabica@s are also prepared this way.

n this case, the ripe red cherry, once harvested, is spread out in the sun to dry.*he two MskinsN round the bean, the cherry skin and the parchment skin, dry

together, and are removed, once the coffee reaches a moisture content of about

=06, through a single milling or hulling process. *he McleanN coffee (cafO

marchand tout venant) is then sorted and graded before export.

;= 2a6ed @o55ee 9 which is generally used for the Arabica coffee, consists of

the de+pulping of the coffee immediately after harvest. *his is done mainly

using small manual machines, which s3ueee the cherries between a disc or

drum, and the coffee bean and its parchment skin come through the process.

*he cherry skin is discarded. *he MNparchmentN, or Mparchment coffeeN as it

is then called, needs to be MfermentedN, in order to break down the mucilage

coating round the parchment skin. *his takes =0 to 5C hours, depending on

"4





25/45



temperatures and types of coffee. After fermentation, the parchment is then

washed in a channel, and is then spread out in the sun to dry. t may also be

mechanically dried, but a minimum of ?0 hours of sun+drying is generally

thought to improve cup 3uality. *he dry parchment coffee is then milled or

MhulledN, after which it is sorted to remove defective beans and may be graded

for bean sie before export. *his washing process may be done by hand, using a

hand+pulper, or otherwise a larger central processing facility.

@= -ull9Fa6ed @o55ee + *his uses a slightly larger mechanically powered

pulping machine, which provides for some sorting of the cherry before pulping.

*he fermentation and washing process, by virtue of a better scale, can generally

be better monitored to achieve higher 3ualities. *hese units may be called

Co55ee 2a6ing Saion


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immediately, without fermentation or washing. *he advantages of this type of

machinery are4

+ much reduced water utiliation. -educes water use by C2 to D26

compared to traditional systems by eliminating the fermentation and

washing processes, it reduces the labour re3uirement for processing

+ the fermentation process re3uires skilled management, since if the coffee

is allowed to ferment for too long, it can over+ferment producing a very

bad cup 3uality. 8y eliminating this stage in the process, it reduces the

management re3uirement of the "H9

+ the time of processing is reduced. ermentation can take anything from C

$ 5C hours, depending on temperatures etc. Again, this simplifies the

management and control of the process

+ the 3uality is generally considered to be e3ually good as the classical

method.e= Ouu8n 7e8@enage

*he profitable operation of any coffee processing facility re3uires the very

careful monitoring and control of the outturn percentages. *his term refers to

the net weight of coffee which remains after one stage in the processing,

expressed as a percentage of the net weight of the coffee before the

processing.

A-A8"A $ &and+pulped parchment

+ *he farmers pass their fresh cherry through hand+pulping machines on

their farms, and then dry the parchment.

"+





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+ rom small+holder produced parchment, the normal outturn percentage of

clean coffee is about ?26, because the coffee includes numerous

defective beans which need to be removed when sorting.

A-A8"A $ "entrally processed

+ *he normal outturn percentage of clean coffee from parchment is C26, due

to removal of defective beans during processing.

-:8U9*A $ ry processed7NnatureN

+ 'ormally 0.1 kgs of fresh cherry are re3uired to produce = kg of dry

cherry $ outturn percentage 526

+ 'ormally 0kgs of dry cherry are re3uired to produce = kg of clean coffee $

outturn percentage 126

+ *he 3uality of cherry coming from the farmers makes a significant

difference. *he outturn percent of clear coffee from dry cherry can be upto 116

-:8U9*A $ Het+processed7washed

+ 'ormally 5 kgs of fresh cherry produce = kg of parchment coffee $

outturn percentage 016

+ 'ormally =.01kgs of parchment produce = kg of clean coffee $ outturn

percentage C26

Again, this may be considerable impacted by the 3uality of the cherry from

the small+holders

A CO&P$ETE PROCESSNG SC*E&E -OR &ANU-ACTURNG CO--EE< -RO& P$ANTATON TO T*E -NS*E! CO--EE PAC'AGNG =

"





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P #reen 8een 9eparator

P isc ulper ( or wet process )

P ry 9toner

P &uller

P !ucilage -emover

P olisher

P #rader

P "onveyor

P #ravity *able 9eparator

P &and picking belts

PP Heighing and bagging

PP "entral ust "ollection Unit

PP Electrical 9witch and "ontrol anel

+.3.". $a;o8ao8 Eui7>en

+ eeler+olisher+&and :perated

+ eeler+olisher+!otorised

+ 'o. > Africa &uller !otor :perated

+ Africa &uller+ &and :perated

+ !ini Fab #rader

+ 9ampling "atador

+ &and *est 9ieves with -ack

De*ailed Dra0in$s de*ailin$ 0i*h *he a-e s*ruc*ures and /acili*ies shall e de-elped and /inali5ed

a* *he *ime / de*ailed en$$. / *his prec*, nce *he /inancial appr-als are accrded.

30





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+.3.3 P*OTOS O- SO&E &PORTANT E#UP&ENT:

PO$S*ER !E9STONER

"+,$#*($#

31





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CO$OR SORTNG &AC*NE

DBRO 9 C$EANER

3"





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33





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34





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D=E P=+C"SSING P'ANT

A T%PCA$ PAC'E! CO--EE PO2!ER N A POUC*

3+





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+.3.4 PO$$UTON CONTRO$ &EASURES :

*he plant is expected to generate coffee dust during the process. *herefore, a

ust "ollection 9ystem shall be provided as part of the pollution control

measure and the sust so collected shall be recycled back to the process at the

appropriate stage. ust content in the work one shall be limited to 1 mg7' cu

m over.

*he system will be designed in such a way that no solid waste will be

discharged outside the system, the solid waste that is the dust generated in the

system will be recycled back to the system itself.

. Co Su>>a85olloF

3





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.0 COST SU&&AR% ( OPERATNG EPENSES

.1 CAPTA$ EPEN!TURE < -ig in AE! = :

.1.1 $AN! ( BU$!NG

+ FA'4 Fand is proposed to be taken on lease rental. *he expected rental is

hm one million per year. *herefore, this expenses shall be the part of

operating expenses and working capital, rather than fixed capital.

+ 8UF'#4 building re3uirement is estimated as follows4

Q Administration 8uilding + ;222 s3. feet

Q Faboratory area + =222 s3. feet

Q "hemical 9torage + =122 s3 feet

Q 9tore &ouse and Hare &ouse + ;222 s3 feet

Q Horkshop + =222 s3 feet

Q 9hed "onstruction for lant B !achinery + 1222 s3 feet

*otal 8uilt up re3uirement + =5122 s3 feet

",00,000 AE!

.1." P$ANT ( &AC*NERES : < B8eau7 o ;e 8evalidaed =

9.'o tems 8road 9pecs "ost in hm= "offee re+"leaner0 #reen 8een 9eparator

; ry 9toner5 &uller1 !ucilage -emover> olisher? #raderC "onveyer 9ystemD #ravity *able

9eparator

3





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=2 &and picking belts== Heighing and

packaging=0 "entral ust

"ollection Unit=; Electrical 9witch and

"ontrol anel=5 ire ighting acilities

TOTA$ – P ( & 1000,000

Noe :

S7e@i5i@aion ( B8ea u7 5o8 individual eui7>en o ;e Fo8ed ou a6e i>e o5 78e7a8ing deailed engg and ende8ing do@u>en a5e8 6e5inan@ial a778oval o5 6e 78o?e@.

+ eeler+olisher+!otorised

+ 'o. > Africa &uller !otor :perated

+ Africa &uller+ &and :perated

+ !ini Fab #rader

+ 9ampling "atador

+ &and *est 9ieves with -ack

+++++++++++++++++++++++++++++++++++++++++++++++++

Co o5 $a; eui7>en AE! 100,000

TOTA$ -E! CAPTA$


40/45



.".1 $eae Renal 5o8 $and: AE! 1000,000

."." T8an7o8aion o5 8aF >ae8ial: AE! 1000,000

.".3 PoFe8 ( Uiliie: 1"0 *P

< in@lude ad>in ;ldg..= – 0 o5 @onne@ed load

M AE! 1)0,000

.".4 &an7oFe8 8eui8e>en:

All figs in AE

9.'o !anpower position 'o Rearlyackage

*otal yearlyexpenses

= actory !anager = =>2,222 =>2,2220 !aintenance 9upervisor = =52,222 =52,222; Accounts :fficer = =02,222 =02,2225 lant :perators 5 52,222 =>2,2221 lant *echnicians 5 ;1,222 =52,222> Accounts "lerk ; ;1,222 =21,222? 9tore &ouse 9upervisor 0 52,222 C2,222C ispatch 9upervisor 0 ;2,222 >2,222D 9ecurity personnel 1 02,222 =22,222=2 "asual Faborers =2 =1,222 =12,222

*:*AF !A':HE- ;0 =,0=1,222

Add erks I 02 6 of salaries 4 05;,222

T6e8e5o8e ea8l >an7oFe8 eH7ene : 14),000

.".) : Pa@aging and Ad>ini8aive EH7ene $ S : "00,000

Toal O7e8aing Co 7e8 %ea8 : AE! 3,0,000 / annu>

Co o5 RaF &ae8ial M 10,000 T H AE! 3000 / T M 30,000,000 < ") 78o@eing Faage and di@a8d=

Toal Co o5 P8odu@ion 7e8 ea8 M 33,0,000

40





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2o8ing Ca7ial 5o8 3 >on6 M 4)",000 a ,)00,000

TOT$A CAPTA$ EPEN!TURE MM -E! CAPTA$ L 2OR'NG CAPTA$

J 5,222,222 S C,122,222 J 1",)00,000 AE! Noe :T6e @o o5 78o?e@ i a77H. Euivalen o : ",+,)00 Eu8o < 1 AEd M0."1) Eu8o, O8 a a77H. ". >illion Eu8o.

.3 -NANCNG O- T*E PROECT:

As per promoters@ plan, the total pro%ect shall be financed by deploying

016 of the capital cost from its internal resources and balance ?1 6

shall be borrowed from the financial institutions I 1.1 6 yearly

interest. *he first year will be a moratorium year.

T6e8e5o8e, 78o>oe8 6a8e ") M AE! 3,1"),)00( ;alan@e ) 68oug6 6e >id e8> loan M AE! ,3),000

Ca6 -loF ( -inan@ial Anali 5olloF.

.0 CAS* -$O2 ( -NANCA$ ANA$%SS

41





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.1 ASSU&PTONS :

1. 100 @a7a@i uiliaion ") TP! o8 )00 Tonne 7e8

ea8.

". P8een elling 78i@e o5 @o55ee 7oFde8 / ;ean: AE!

10,00 7e8 Tonne.

3. n@8eae in 8evenue ) 7e8 ea8 due o 8ie in 78i@e.

4. n@8eae in @o o5 78odu@ion < in@luding 8aF >ae8ial

) 7.a.

). !e78e@iaion o5 Building 10 on 8aig6 line ;ai

+. !e78e@iaion o5 Plan ( >a@6ine 1+.++ on 8aig6

line ;ai

. ne8e @o ).) on 6e de7leing ;alan@e o5 oal

ouanding a5e8 loan 8e7a>en.

." CAS* -$O2 – TAB$E

-ig. n >illion AE!4"





43/45



S.No/

%ea8

e> 1 " 3 4 ) Toal

1 %ea8l

Revenue

0.") 4."+ .4 ".0 .40

" Co o5

78odu@ion

33.1 3).)0 3." 3.14 41.0

3 !e7 o5

;ldg..10

0." 0." 0." 0." 0."

4 !e7 o5 P (

& 1+.++

0.1 0.1 0.1 0.1 0.1

) G8 P8o5 ;4

ine8e

4). 4." )0.0 )3." )).4

+ $oan

nall>en

).00 ).1+ Nil Nil Nil

ne8e on

de7leing

O/

0.)" 0." Nil Nil nil

Ne 78o5i

a5e8

ine8e

4).4) 4.0" )0.0 )3." )).4

P8o5i /

inve 8aio

3.+3 3.4 4.0 4."+ 4.4

10 P8o5i a

o5 ale

)+.+ )+. ).)" )." ).33

Noe :

1. An EH@ie, ale aH and an o6e8 ;uine aHe a8e no aen

ino a/@. 5 an, 6e a>e 6all ;e ;uil ino elling 78i@e and

8e@ove8ed 58o> 6e @uo>e8.

43





44/45



". No Co87o8ae n@o>e TaH i aen ino a/@ F6ile @al@ulaing 6e

ne 78o5i. 5 an, 6e ne 78o5i and 6e @a6 5loF Fill 6ave o

8eaeed ;aed on a@ual in@iden@e o5 6e @o87o8ae in@o>e aH.

." -NANCA$ ANA$%SS ( CONC$USONS :

1. T6e 78o?e@ i e@eono>i@all 6ig6l a8a@ive, a i i

gene8aing 78o5i 58ig6 58o> 6e 5i8 ea8 iel5.

". T6e 78o?e@ Fill ;e a;le o 8e7a 6e laon in " ea8 i>e.

3. T6e 78o?e@ Fill @on8i;ue igni5i@anl o 6e @o87o8ae

@a6 5loF and Fill gene8ae enoug6 u87lu o ae @a8e o5

no onl 6e 8ouine >ainenan@e o5 6e 7lan, ;u alo 5o8

eH7anion and dive8i5i@aion in 6e nea8 5uu8e.

. Cond .0 Plan ( &a@6ine8ie Su77lie8

1. P$ANT ( &AC*NERES SUPP$ERS

1. Ci>;e8ia *eid, G>;* &eid Herkstrasse $ 5 A $ 0222 9tockerau, Austria hone4 (S5;) 00>> >DD Email4 heidIcimbria.at Hebsite 4www.heid.cimbria.com

44



mailto:[email protected]:[email protected]:[email protected]://www.smb-project-consultants.com/project-consultancy.htmmailto:[email protected]:[email protected]:[email protected]://www.smb-project-consultants.com/project-consultancy.htm


45/45



". S7e@8u> ndu8ie, Email4 www.spectrumindustries.org

!obile4 L(D=)+DC5525;DD2

3. *hermal Engg "orporation, E+ =>C, /avinagar ndustrial Area, #haiabad, U. ( ndia) $ 02= 220

hone4 SD= =02 0?2250D,Email4 thermaengggbIyahoo.co.in

Hebsite 4 www.thermalengg.com

4. *ei5ie Angelon Ele@8oni@ Co $d., *el4 C> $ 11= $ 1C5 ?C== Email4 salesIangelon.com 2e;ie : 67://FFF.a?long.@n/en/de5aul.a7

). inan !ou;le 2in Agile &anu5a@u8ing Te@6nolog Co., $d 2e;ie : ?>in?ie.en.ali;a;a.@o>

+. An6ui *ong6i O7oele@8oni@ *ig69Te@6 Co., $d.2e;ie : 67://a66ong6i.en.ali;a;a.@o>/a;ouu.6>l

0000000000000000000000 roject #eport $nds 000000000000000000000

4)
http://www.spectrumindustries.org/mailto:[email protected]%26bcc%[email protected]?subject=Coffee%20Processing%20-%20Enquiry%20through%20FLORET%20MEDIAmailto:[email protected]%26bcc%[email protected]?subject=Coffee%20Processing%20-%20Enquiry%20through%20FLORET%20MEDIAmailto:[email protected]://www.thermalengg.com/mailto:[email protected]://ahhongshi.en.alibaba.com/aboutus.htmlhttp://www.spectrumindustries.org/mailto:[email protected]%26bcc%[email protected]?subject=Coffee%20Processing%20-%20Enquiry%20through%20FLORET%20MEDIAmailto:[email protected]://www.thermalengg.com/mailto:[email protected]://ahhongshi.en.alibaba.com/aboutus.html

coffee manufacturing unit project report

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