Establishment of a Multipurpose Gamma Irradiation Facility (MGIF) in Sri Lanka
by
Samantha KulatungeHead
Radiation Processing SectionAtomic Energy Authority
No. 60/460, Baseline RoadOrugodawatte, Wellampitiya
Content:
What is radiation and related units? What is Gamma irradiator? What are the applications of Gamma radiation and why
do we use radiation? Multipurpose Gamma Irradiation Facility in Sri Lanka Selection of land Throughput (Capacity) of the facility Potential revenue Estimated Irradiation Market Profit & Loss Analysis
What is radiation?
Electromagnetic radiation
Measurements:QUANTITIES UNITS
Length Meters or Km
Dose Grays or kGy
Activity (Source strength) Curie or kCi
Dose: The quantity of energy that the irradiated product absorbs. 1GRAY (Gy) = 1J/kg
Activity: Number of curies. Also improperly called source strength.1 Curie (Ci) = Activity of 1g of 226Ra1g of 226Ra disintegrate 3.7x1010 atoms per second 1 Ci = 3.7 x 1010 dis/s
Emitted when radioisotope cobalt-60 decays
Beta Particle
Gamma Rays(photons)
GAMMA RADIATION
Made from cobalt-59Half life : 5.24 years
Becomes nickel
How Co-60 produces gamma radiation
How it can be used in processing of How it can be used in processing of products?products?
g :- Surgical gloves
Sterilized rubber glove
Kills microorganisms
Co-60 radioactive source
(gamma rays)
PROCESSING WINDOW Minimum dose : threshold to achieve effect
Maximum dose : threshold of undesirable effect
When a product expose to radiation;
OVER PROCESSING
UNDER PROCESSING
Delivered energy = dose (in Grays = Joules per kilogram)
Multipurpose Gamma Irradiation Facility (MGIF)
Source rack in pool
Conveyor unloading
Bunker
Conveyor loading
Multipurpose Gamma Irradiation Facility
Gamma Irradiator Principle
Source rack in poolConveyor
Bunker
Slug & Pencil of cobolt-60 (Buiding
blocks of a radiation source rack)
Cobolt 60 slug Cobolt 60 source element (an
inner capsule containing slug of
cobolt-60) Source pencil (contain 2 source
elements) Source module (contains up to
48source pencils) Source rack (contains modules in
different configurations, depending
on irradiator design)
GAMMA IRRADIATOR
Ozone formed by irradiation of oxygen in airAir continuously ejected through chimneyOzone concentration < 1 ppm in limit of site
Radiation stopped by walls
Radiation stopped by water and ground
Pool water is safe to drink
No radioactivity in the air
Sources returned to supplier after 20 years of usage. No longer radioactive after 180 years
Pose no environmental problem
Control panel of the irradiator
Application of MGIF:Application of MGIF:
Immediate applicationsImmediate applications Sterilization of surgical gloves & medical productsSterilization of surgical gloves & medical productsDecontamination of spices, dried vegetablesDecontamination of spices, dried vegetablesDecontamination of medicinal herbs, Ayuvedic Decontamination of medicinal herbs, Ayuvedic
products, health diet supplementsproducts, health diet supplementsSterilization of food and pharmaceutical packagingSterilization of food and pharmaceutical packagingDecontamination of dried pharmaceutical and cosmetic Decontamination of dried pharmaceutical and cosmetic ingredientsingredients
Mid term applicationMid term application Quarantine treatment of wooden objects and coir pithQuarantine treatment of wooden objects and coir pithPasteurization of frozen or fresh seafoodPasteurization of frozen or fresh seafood
Long term applicationsLong term applications Sprouting inhibition of onions and garlicSprouting inhibition of onions and garlic
Why Radiation Sterilization ? No recontamination Non-toxic No chemical residues Reliable & safe Treated product can be used immediately Complete product penetration Gamma irradiation produces no heat( therefore
preserves properties & characteristics) Precise and reproducible treatment process Proven use for 30 years Environmental friendly
Radiation Sterilization of Medical Products
Human Tissue Sterilization:
PHARMACEUTICAL PRODUCTS
EXAMPLES
Medicinal herbs and food supplements
Antibiotics in dried form
Eye ointments and veterinary products with antibiotics
COSMETIC PRODUCTS
EXAMPLES
Plants, Seaweeds
Talcum powder
Clay and sea mud
Mineral and organic dyes
Shampoo and shower gel
Brushes
Contd..
Food Irradiation
Application: Delay in ripening Disinfestation / Insect control Microbial control Quarantine treatment Shelf life extension Sprout inhibition Sterilization
Why food Irradiation ?
No chemical residues Preservation can be done after packaging Environmental friendly process Proven for more than 30 years
Insect Control
Shelf-life extension
Sprout Inhibition
Food Item Purpose Max Dose (kGy)
Spices Microbial control
Disinfestation
10
1
Rice
Rice products
Disinfestation
Disinfestation
1
1
Potatoes Sprouting inhibition 0.15
Garlic Sprouting inhibition 0.15
Onions Sprouting inhibition 0.15
Vegetables Disinfestation 1
Meat Microbial control 7
Other Applications
Preservation of antiques, artefacts, mummies
Sanitation of rawhide pet toys
Quarantine treatment of wooden pallets, souvenirs and handicrafts
Sanitation of stuffed toys
Coloration of glass
Etc.
Multipurpose Gamma Irradiation Facility in Sri Lanka
MGIF in Sri Lanka
Required land area :02 acres
Total area of the building :3250 M2
Activity :3 million ci
Initial activity :150 kCi
Power requirement : 45 kw (200kw)
Water : comparable to a
large house
Capital costCapital costCost Component Estimated cost
( Rs. Million)Project Management 7.03Land 15Consultancy 25.6Civil Construction 320Machinery 151.7Taxes 65Vehicles 7.5Others 18
Total 609.83
Operating Costs (per year)Operating Costs (per year)
Item Amount (1000Rs)Salaries (Manager, Engineer, secretary, 2 Operators and 6 Helpers)
3,000
Maintenance and repairs 1,000
Utilities and communication 1,000
Miscellaneous supplies and services 1,000
Annual replacement and up-grading of Co-60(12.5% of initial load)*
40,000
Total 46,000
** Can vary depending on the demand for irradiation servicesCan vary depending on the demand for irradiation services
Total Cost for the facility:Total Cost for the facility:
purpose Estimated Cost (1000SLRs)
Capital Cost 610,00
Operating cost (including annual replacement and upgrading of Co-60 which is 12.5 % of initial load)
46,000
Total Cost 656,000
Selection of a locationSelection of a location
Criteria for selection of a location:Criteria for selection of a location:
Absence of opposition to the projectAbsence of opposition to the project Relative proximity to main usersRelative proximity to main users Good accessibility to main roads and portGood accessibility to main roads and port Privileges that can be obtainedPrivileges that can be obtained Price of land and management feePrice of land and management fee Security of the locationSecurity of the location Absence of vulnerability to natural hazards such Absence of vulnerability to natural hazards such
as floods and landslidesas floods and landslides Soil characteristicsSoil characteristics
Proposed site for Irradiator
Area to be acquired to provide vehicular access for non BOI products
RETAINING WALL
Site Levelling
RETAINING WALL
6.0m. min.
6.0m.
min.
VEHICULAR ACCESS FOR
BOI PRODUCTS
VEHICULAR ACCESS FOR NON
BOI PRODUCTS
ENTRANCE FOR OFFICE
PROPOSED
BUILDING
Throughput or Capacity of the Throughput or Capacity of the facilityfacility
Throughput of the facilityThroughput of the facility
Potential throughput is proportional to the source Potential throughput is proportional to the source activityactivity
Actual throughput depend onActual throughput depend on Proportion of the time that facility is used forProportion of the time that facility is used for Downtime for maintenanceDowntime for maintenance Lack of products at certain periodsLack of products at certain periods
Throughput of a Gamma Irradiator with 150 kCi Throughput of a Gamma Irradiator with 150 kCi will be 100,000 kGy of products will be 100,000 kGy of products With a density of 0.2 tons/m3With a density of 0.2 tons/m3 If facility operates for 7880 hrs per annum (or If facility operates for 7880 hrs per annum (or
utilization ratio is 90%)utilization ratio is 90%)
Product Minimum dose (kGy)
Throughput per annum
Product density
Onions - Sprouting inhibition
0.1 500,000 tons 0.5 ton / m3
Cereal products- Insect control
0.5 30,000 tons 0.6 ton / m3
Dried fruit- Insect control 0.5 60,000 tons 0.3 ton / m3
Spices-Microbial control 5 6,000 tons 0.3 ton / m3
Latex gloves- Sterilization
25 4,000 m3 0.2 ton / m3
The quantity of products that can be irradiated with
the initial capacity of 150,000 Ci
Potential revenue
Potential revenue for different products Potential revenue for different products
with an activity of 150,000 curieswith an activity of 150,000 curies Potential revenue Potential revenue for different for different products with an products with an activity of 150,000 activity of 150,000 Curies Curies
MinimumMinimum dose dose
(kGy) (kGy)
ThroughputThroughput per annum per annum
ProductProductdensitydensity (ton / m(ton / m3)3)
TentativeTentative unit priceunit price (1) (1)
PotentialPotential revenuerevenue per annum per annum
(2) (2) USDUSD
Onions Onions Sprouting inhibition Sprouting inhibition 0.1 0.1 500,000 tons500,000 tons 0.5 0.5 10 USD / ton 10 USD / ton 5,000,0005,000,000
Cereal products Cereal products Insect control Insect control 0.5 0.5 30,000 tons30,000 tons 0.60.6 20 USD / ton 20 USD / ton
1,200,000 1,200,000
Dried fruit Dried fruit Insect control Insect control 0.5 0.5 60,000 tons60,000 tons 0.30.3 20 USD / ton 20 USD / ton
1,200,000 1,200,000
Spices Spices Microbial control Microbial control 5 5 6,000 tons6,000 tons 0.30.3
100 USD / 100 USD / ton ton
600,000 600,000
Latex gloves Latex gloves Sterilization Sterilization 25 25 4,000 m4,000 m3 3 0.2 0.2 60 USD / m60 USD / m3 3 240,000 240,000
Estimated Irradiation MarketEstimated Irradiation Market
Estimated Irradiation MarketEstimated Irradiation MarketYear Year Volume (m3)Volume (m3) Need Need
(m3 x (m3 x kGy)kGy)
Source Source
(kCi) (kCi)
Gloves Gloves
(% (% total)total)
Free Free capacity capacity
Total Total Lalan Lalan Prime Prime Glob Glob SurgSurg
SpiceSpice Total Total
20102010 11,927 11,927 7,000 7,000 3,333 3,333 260 260 1,333 1,333 316,691 316,691 443443 95%95% 85%85%
20112011 16,694 16,694 11,00011,000 3,500 3,500 527 527 1,667 1,667 450,964 450,964 631631 94%94% 79%79%
20122012 22,902 22,902 16,500 16,500 3,675 3,675 727 727 2,000 2,000 621,305 621,305 870870 93%93% 71%71%
20132013 24,619 24,619 17,500 17,500 3,859 3,859 927 927 2,333 2,333 665,090 665,090 993993 92%92% 69%69%
20142014 26,345 26,345 18,500 18,500 4,052 4,052 1,127 1,127 2,667 2,667 709,213 709,213 1,0331,033 91%91% 68%68%
20152015 +4 % +4 % 1,0741,074 67%67%
20162016 1,1171,117 66%66%
20172017 1,1621,162 64%64%
20182018 1,2081,208 63%63%
20192019 61%61%
20202020 60%60%
Why starting with small Co 60 activity?Why starting with small Co 60 activity? It limits the cost of decay during the learning phase. It limits the cost of decay during the learning phase. Time is needed Time is needed
To test and commission the plant, perform the safety various tests that To test and commission the plant, perform the safety various tests that need to be done and characterize the dose distribution pattern within a need to be done and characterize the dose distribution pattern within a range of products of different densities used as models range of products of different densities used as models
To implement a quality system that is not only on paper but tested in To implement a quality system that is not only on paper but tested in reality. This is required by organizations that will have to certify the reality. This is required by organizations that will have to certify the quality system to ISO 9000, ISO 13485 and EN 552, certificates that quality system to ISO 9000, ISO 13485 and EN 552, certificates that are necessary to sterilize medical products that are exported to Europe, are necessary to sterilize medical products that are exported to Europe, the US, Japan or Australia. the US, Japan or Australia.
For the personnel to learn the jobFor the personnel to learn the job
For the customers to learn how to use the facility (packing, logistics, For the customers to learn how to use the facility (packing, logistics, paper flow, etc.). This amount of cobalt-60 can be transported in a paper flow, etc.). This amount of cobalt-60 can be transported in a single F-168 type transportation container, thus minimizing the cost of single F-168 type transportation container, thus minimizing the cost of source transportation. source transportation.
C0-60 purchase costC0-60 purchase cost
Year 1 2 3 4 5 6 7 8 9 10
Installed kilo Installed kilo curies curies
150150 443443 631631 870870 931931 993 993 1033 1033 1074 1074 11171117 1162 1162
Occupied Occupied design design capacity capacity
5%5% 15% 15% 21% 21% 29% 29% 31%31% 33%33% 34%34% 36%36% 37%37% 39%39%
Purchased Purchased curies (kCi)curies (kCi)
311311 241 314 166 174 159 165 172 179 186Cost of Cost of decay decay
(‘000LKR)(‘000LKR) 39283928
13,966
20,683
29,635
32,993
36,589
39,574
42,804
46,297
50,074
Cost of Cost of purchased purchased cobalt cobalt (‘000LKR)(‘000LKR)
67,87267,872 63,311
85,787
47,040
51,233
48,785
52,766
57,072 61,729
66,766
Export of spices: Export of spices: TonsTons 20012001 20022002 20032003 20042004 20052005
Cinnamon Cinnamon 10,444 10,444 10,837 10,837 11,025 11,025 11,391 11,391 12,367 12,367
Pepper Pepper 2,161 2,161 8,026 8,026 7,859 7,859 5,003 5,003 8,248 8,248
Cloves Cloves 1,964 1,964 4,044 4,044 2,489 2,489 3,428 3,428 5,517 5,517
Nutmeg & Nutmeg & Mace Mace
1,138.1 1,138.1 1,665 1,665 1,833 1,833 1,368 1,368 1,935 1,935
Cardamom Cardamom 33 33 44 44 1111
Total Total 15,710 15,710 24,574 24,574 23,210 23,210 21,194 21,194 28,078 28,078
Profit & Loss Analysis
Profit & Loss Analysis (b)Profit & Loss Analysis (b)Project Year 0 1 2 3 4 5 6 7 8 9 10
Calendar Year 2010 2011 2012 2013 2014 2015 2016 2017 2018 2019 2020
TURNOVER 76,498
104,827
142,877
153,032
162,616
169,121
175,885
182,921
190,238
197,847
COST
Staff (418)
(850)
(1,003)
(1,158)
(1,254)
(1,317)
(1,383)
(1,452)
(1,525)
(1,601)
(1,681)
Insurance (1,000)
(1,030)
(1,061)
(1,093)
(1,126)
(1,159)
(1,194)
(1,230)
(1,267)
(1,305)
Other operating cost (830)
(4,500)
(4,680)
(4,867)
(5,062)
(5,264)
(5,475)
(5,694)
(5,922)
(6,159)
(6,405)
General Administration cost
(1,850)
(3,600)
(2,386)
(2,481)
(2,581)
(2,684)
(2,791)
(2,903)
(3,019)
(3,140)
(3,265)
Total Depreciation (51,601)
(56,456)
(62,616)
(64,200)
(65,795)
(66,821)
(67,888)
(68,997)
(70,151)
(71,352)
Cobalt- 60 Depreciation
(11,452)
(16,308)
(22,468)
(24,051)
(25,647)
(26,672)
(27,739)
(28,849)
(30,003)
(31,203)
Plant and equipment Depreciation
(40,149)
(40,149)
(40,149)
(40,149)
(40,149)
(40,149)
(40,149)
(40,149)
(40,149)
(40,149)
TOTAL COST (3,098)
(61,551)
(65,556)
(72,184)
(74,189)
(76,186)
(77,630)
(79,131)
(80,693)
(82,318)
(84,008)
Earnings Before Interest and Tax
(3,098)
14,947
39,271
70,694
78,843
86,430
91,491
96,754
102,228
107,920
113,840
Interest
- (31,750)
(30,186)
(28,388)
(26,320)
(23,941)
(21,206)
(18,061)
(14,444)
(10,285)
(5,501)
Earnings Before Tax
(3,098)
(16,802)
9,085
42,306
52,523
62,489
70,285
78,693
87,784
97,636
108,338
Taxation @ 15%
-
- (1,363)
(6,346)
(7,879)
(9,373)
(10,543)
(11,804)
(13,168)
(14,645)
(16,251)
Net profit (loss) (3,098)
(16,802)
7,723
35,960
44,645
53,115
59,742
66,889
74,616
82,990
92,088
Cumulative profit (loss)
(3,098)
(19,900)
(12,177)
23,783
68,428
121,543
181,285
248,174
322,791
405,781
497,869
Profit & loss analysis (a)Profit & loss analysis (a)Project Year 0 1 2 3 4 5 6 7 8 9 10
Calendar Year 2010 2011 2012 2013 2014 2015 2016 2017 2018 2019 2020
TURNOVER 63,632
87,333
119,050
127,642
135,760
141,190
146,838
152,711
158,820
165,172
COST
Staff (418)
(850)
(1,003)
(1,158)
(1,254)
(1,317)
(1,383)
(1,452)
(1,525)
(1,601)
(1,681)
Insurance (1,000)
(1,030)
(1,061)
(1,093)
(1,126)
(1,159)
(1,194)
(1,230)
(1,267)
(1,305)
Other operating cost (830)
(4,500)
(4,680)
(4,867)
(5,062)
(5,264)
(5,475)
(5,694)
(5,922)
(6,159)
(6,405)
General Administration cost
(1,850)
(3,600)
(2,386)
(2,481)
(2,581)
(2,684)
(2,791)
(2,903)
(3,019)
(3,140)
(3,265)
Total Depreciation (32,790)
(36,999)
(42,337)
(43,709)
(45,092)
(45,981)
(46,906)
(47,868)
(48,868)
(49,908)
Cobalt- 60 Depreciation (9,925)
(14,133)
(19,472)
(20,844)
(22,227)
(23,116)
(24,041)
(25,002)
(26,002)
(27,043)
Plant and Equipment Depreciation
(22,865)
(22,865)
(22,865)
(22,865)
(22,865)
(22,865)
(22,865)
(22,865)
(22,865)
(22,865)
TOTAL COST (3,098)
(42,740)
(46,098)
(51,905)
(53,699)
(55,483)
(56,790)
(58,149)
(59,563)
(61,034)
(62,564)
Earnings Before Interest and Tax
(3,098)
20,892
41,235
67,145
73,943
80,276
84,400
88,689
93,148
97,786
102,608
Interest -
(19,060)
(18,121)
(17,042)
(15,800)
(14,373)
(12,731)
(10,843)
(8,671)
(6,174)
(3,302)
Earnings Before Tax (3,098)
1,832
23,114
50,103
58,142
65,904
71,670
77,846
84,477
91,612
99,306
Taxation @ 15% -
(275)
(3,467)
(7,516)
(8,721)
(9,886)
(10,750)
(11,677)
(12,672)
(13,742)
(14,896)
Net profit (loss) (3,098)
1,557
19,647
42,588
49,421
56,018
60,919
66,169
71,806
77,870
84,410
Cumulative profit (loss)
(3,098)
(1,540)
18,107
60,695
110,116
166,134
227,053
293,222
365,028
442,898
527,308
Thank you