1

PROBLEM STATEMENT

Prepare a Feasibilty Report on Production of 100 kl per day ethanol from potato .

INTRODUCTION:Ethanol, also called ethyl alcohol, pure alcohol, grain alcohol, or drinking alcohol, is a volatile,
flammable, colorless liquid. It is a psychoactive drug, best known as the type of alcohol found in
alcoholic beverages and in modern thermometers. Ethanol is one of the oldest recreational drugs known to
man. In common usage, it is often referred to simply as alcohol or spirits.
Ethanol is a straight-chain alcohol, and its molecular formula is C2H5OH. Its empirical formula is C2H6O.
An alternative notation is CH3-CH2-OH, which indicates that the carbon of a methyl group (CH3-) is
attached to the carbon of a ethylene group (-CH2-), which is attached to the oxygen of a hydroxyl group (OH). It is a constitutional isomer of di methyl ether. Ethanol is often abbreviated as EtOH, using the
common organic chemistry notation of representing the ethyl group (C 2H5) with Et.
The fermentation of sugar into ethanol is one of the earliest organic reactions employed by humanity. The
intoxicating effects of ethanol consumption have been known since ancient times. In modern times,
ethanol intended for industrial use is also produced from by-products of petroleum refining.
PHYSICAL PROPERTIES OF ETHANOL
1.
2.
3.
4.
5.
6.
7.
8.
9.

Appearance : Colorless liquid

Melting point:-1300C
Boiling point:780C
Specific gravity:0.789
Vapor pressure:1.59
Flash point:560F
Explosion limit:3.3%-24.5%
Auto ignition temperature: 6830F
water solubility: Miscible in all Proportions

USES:Ethanol is often called drinking alcohol or pure alcohol as it is the prime ingredient in alcoholic
beverages. Ethanol is the intoxicating substance in alcohol.
Ethanol can be used as a fuel for motor vehicles. Ethanol makes a good fuel for cars because it reduces
the emission of harmful gases such as carbon monoxide. Brazil is one of the leaders in the production of
cars that run on ethanol. Over 20% of cars in Brazil are able to run on 100% ethanol fuel.
Lightweight rocket-powered racing aircraft often use ethanol as rocket fuel.
Ethanol is used in antiseptic and some antibacterial soaps and wipes. Ethanol is effective against viruses,
fungi and most bacteria but is ineffective against bacterial spores.

Ethanol is occasionally used to treat poisoning by other alcohols that are more deadly (methanol is one
particular example).
As ethanol is soluble in water, it can be used in a variety of different products. These include paint,
permanent markers, perfumes and deodorants. Ethanol may also be used as a solvent in cooking, such as
vodka sauce.
Ethanol is considered a feedstock into the chemical industry as it is used to make other important
chemicals.
KINDS OF ETHANOL
Grain ethanol, from corn, sorghum, barley, wheat, potato
Sugar ethanol, from cane sugar or beets
Cellulose ethanol, from plant fiber
Synthetic ethanol, from ethylene in a petroleum refinery or petrochemical plant
All the same product but made from different raw material
Synthetic ethanol is not used for fuel in the U.S., because it does not get tax credits that are
available for ethanol from biological sources
ETHANOL CHARACTERISTICS
Advantages
Gasoline substitute
Improves octane
Dilutes sulfur and aromatic compounds
Reduces carbon dioxide emissions
Every car can use 10% ethanol
Some newer vehicles can burn E85, with up to 85% ethanol
Disadvantages
One gallon of ethanol has 2/3 energy of one gallon of gasoline
Increases gasoline volatility
HISTORICAL PERSPECTIVE:The preparation of distilled alcohol spirit s was first described in the 12th century version of Mappe
Clavicula (Underwood, 1935; Forbes,1970), with the first reported (nonbevearge) uses of spirits as an
incendiary, a solvent and later medicinally. The preparation of absolute alcohol (by repeated distillation
over potassium carbonate) was first reported in 1796.
Extensive industrial use of ethyl alcohol began in the late 1800s with the growth of the
synthetic chemical industry and expanded rapidly in the United states after 1906 when tax regulations
were amended to allow the tax free preparation of denatured alcohol for industrial use (US Denatured

Alcohol act, 1906). Following the repeal of prohibition, regulations were further tightened to separate
beverage and industrial alcohol production, thus establishing the industrial ethanol fermentation industry
(US department of Treasury, 1942).
Industrial alcohol has been valuable as a solvent , germicide , antifreeze, fuel and chemical
raw material, and use in the US grew to 564 million liters per year in 1941(77% by fermentation). During
the World War II, US industrial alcohol production was increased 3.8 fold (BATF,1984) on an emergency
basis to provide alcohol for synthetic rubber ( via butadiene) and smokeless powder production.
The availability after World War II of cheap ethylene (as a by product of natural gas
recovery and of gasoline production) led to the rapid growth of the synthetic ethanol industry based on the
esterification-hydrolysis of ethylene in concentrated sulphuric acid water solution (Sherman and
Kavasmaneck, 1978).Pressure from this source combined with the excess capacity left after the war
emergency led to the mothballing or dismantling of many fermentative ethanol plants. the adoption in the
late 1960s and 1970s of the less capital intensive catalytic vapor phase ethylene hydration process
(Sherman and Kavasmaneck,1978) further reduced ethanol production cost, supplanting the earlier
sulphuric acid process.
ETHANOL POTENTIAL IN INDIA

The ethanol program in India is dependent on molasses from sugar industry major constraint
India has lots of rotten and out of date food grain.
4 mill tones of grains can produce 1.5 bill L of Ethanol per year
Sugar occupies about 4 mill ha of land which is less than 7% irrigated land
An increase of 1 mill ha will produce 75 mill T of sugarcane that can give additional 5.0 bill L of
Ethanol
This can also be achieved by raising the yield to 100T/Ha
Once Biomass to Ethanol is commercialized it can
become a source of almost limitless source of Biofuels.
Ethanol with a consumption of 4 to 5 Bill. L (20-25% blending by 2015) Can have a retail turn
over of Rs 140,000 million per year
Export Potential of 4 to 5 bill L.
Total Potential of Ethanol 10 bill. L by 2015
India has developed alcohol technology which is sold all over the world dehydration technology
licensed

BENEFITS TO INDIAN ECONOMY

Enhancing Energy Security management of risk

Rural employment and development of economy
Large multiplier/low capital intensity/higher employment per unit capacity
Decentralized
Environment and Climate change
Increases octane number
Safer/cheaper Oxygenate as it replaces MTBE

MARKET SURVEY:Now a day India is one of the largest country in the alcohol production. There is a steady increase in
the production of last 15 years, according to fresh statistics India is a dominant producer of alcohol in
the southeast Asian region, with 65% of total share and contributes around 7% of the total alcohol
beverage imports into the region.
CLASSIFIEDS OF INDIAN ETHANOL MANUFACTURERS:
Hanil Era Textiles Ltd. (Ethanol Div)
[India]
Products/Services : Ethanol, Ethyl Alcohol
No. of Employees : Above 1000 People
Street Address:New Era Mills Compound, Mogul Lane, Matunga ( W)
City:Mumbai
Province/State:Maharashtra
Country/Region:India
Zip:400016
Telephone:91-22-24362085
Fax:91-22-24378279

STERLING CHEMICALS AND ALCOHOLS PVT LTD

[India]
Products/Services : All Types Of Alcohol,ethyl Alcohol hydrus /unhydrus from molases /grain,Mixed
solvents of all kinds,Pharma formulation of all kinds and bulk drugs,Ethyl Alcohol,Absolute
Alcohol,Grain Alcohol,Alcohol molases,Extra Neutral Aalcohol sugarcane,Grain Extra ...
No. of Employees : 11 - 50 People
Management Certification : ISO 9001:2000, ISO 9001:2008
Company Name:STERLING CHEMICALS AND ALCOHOLS PVT LTD
Street Address:202 A, Eshwar Residency, Dharam Karam Road, Ameerpet
City:Hyderabad
Province/State:Andhra Pradesh
Country/Region:India
Zip:500016
Telephone:91-40-23745983
Mobile Phone:919490653838
Fax:91-40-23745983
Alcobev International
[India]
Products/Services : Ethanol - hydrous,Ethanol - anhydrous,Extra Neutal Alcohol,Ethanol in HDPE
drum,Ethanol in IBC,Ethanol in ISO Tank,Ethanol For Perfume,Ethanol For Pharma,Ethanol from

Molesses,Ethanol from Grain,Beer in bottle & cans,Brandy,Gin,Rum,Vodka,Whisky

No. of Employees : 11 - 50 People
Management Certification : ISO 9001:2000
Company Name:Alcobev International
Street Address:Plot No. C 5 / 13, M. Town
City:Delhi
Province/State:Delhi
Country/Region:India
Zip:110006
Telephone:91-11-2722
Mobile Phone:9811322876
Fax:91-11-22722
SUBHASH LIQUORS PVT LTD
[India]Products/Services : Alcohol,Doctor Brandy,Golden Kingz Whiskey,Highland Prince,XXX Fighter
Rum,Whisky,Alcohol Beverages,Green Berry,Natural Alcohol Beverages,Flavour Vodka,Alcohol Spirits,Casino,Wine,Vodka,Liquor,Scotch Blended Whisky,Malt Beverages,Spirits,Party Vodka,...
No. of Employees : 101 - 200 PeopleCompany Name:SUBHASH LIQUORS PVT LTD
Street Address:15 / A, Mumbai-Pune Road
City:Pune
Province/State:Maharashtra
Country/Region:India
Zip:411003
Telephone:91-20-66032882
Mobile Phone:09673003780
Fax:91-20-66032889
Website:http://www.subhashliquors.com DECCAN ALCOHOL PVT. LTD- India
Add-plotE45 ,midc Chikalthana India

INDO MINES LTD-India

Add-W-38/39,M.I.D.C, Phase II,Dombivli E, thane dist,Maharastra India
PRITHVI EXPORTS

Add :A3/29, Vridavan, Dongre Park Society, Near Rcf Colony,,

Mumbai, Maharashtra

PHOENIX INDUSTRIES
Add :A-20, MIDC, BARAMATI, Maharashtra
ETHIMAX BIOFUELS R & D PVT. LTD.
Add :Ring Road, Surat, Gujarat
PRAJ INDUSTRIES LTD.
Add :Praj House, Bavdhan, Pune, Maharashtra
RADHA MURARI PETROFILLS PVT.LTD
Add :3/28 Tirumala Khatriwad Junathana Navsari, GUJARAT

POTENTIAL AGRO CHEMICALS PVT. LTD.

Add :7, Rustom Sidhwa Marg,, Mumbai, Maharashtra
HEERA INDU INFRASTRUCTURE CO. LTD.
Add :Station Road Above Hotel Heera Palace, Nandurbar 425412, Maharashtra

EXPORT IMPORT DATA

YEAR

IMPORT(in lacs)

EXPORT (in lacs)

2001-2002

12,901.20

133.04

2002-2003

25679.60

131.92

2003-2004

28102.79

59.73

2004-2005

48841.28

298.18

2005-2006

42856.73

535.17

2006-2007

50,489.11

1376.24

2007-2008

57,949.33

6682.41

2008-2009

90,246.69

56,256.69

2009-2010

140,898.54

61,506.31

117,462.16

81,945.43

2010-2011
2011-2012(april-june)

24,179.59

28,923.43

EXPORT FROM INDIA IN 2010-11

Sr. no

Countries

1
2
3
4
5
6
7
8
9

U arab emirates
Angola
Ghana
Singapore
Nepal
Netharlands
Oman
Tanzania
srilanka

Quantity(in metric
ton)
19774.67
19818.34
16163.97
10018.45
6404.00
200.76
1263.87
4059
4207.34

Values( in lakhs)
18592
17113.27
5709.89
4236.87
2861.98
2662.53
1507.23
1434.67
1414

CHEMICAL SAFETY DATA OF ETHYL ALCOHOL:Common synonyms

Formula
Physical properties

Principal hazards

Safe handling

Emergency

Disposal

Protective equipment

Ethanol, alcohol, grain alcohol, fermentation

alcohol, fermentation ethanol
C2H5OH
Form: colourless fragrant liquid Stability:
Stable, but highly flammable Melting point: 144 C Boiling point: 78 C Water solubility:
miscible in all proportions Specific gravity:
2.12 Explosion limits: 3.3 - 24.5%
Contact with the eyes can cause considerable
irritation. "One-off" consumption of small
amounts of ethanol is not likely to be harmful,
but consumption of large amounts can be (and
has been) fatal. Chronic (long-term) ingestion
of ethanol may lead to damage to a variety of
organs, such as the liver, and may increase the
risk of cancer. Ethanol is very flammable, so
constitutes a fire risk.
Wear safety glasses. Ensure that no sources of
ignition, such as a gas flame, hot plate or hot
air gun, are present in the working area.
Check that ventilation is good; use a fume
cupboard if possible.
Eye contact: Flush the eye with plenty of
water. If irritation persists call for medical
help. Skin contact: Wash off with water. If
swallowed: If the quantity swallowed is large,
call for medical help
Small amounts of ethanol can be flushed
down a sink with a large quantity of water,
unless local rules prohibit this. Do not forget
that this material is very flammable, so
precautions must be taken to ensure that
flammable vapour does not build up in the
sink or drains.
Safety glasses

10

RAW MATERIALS
Potato:- After wheat, rice and maize, potato is the most important food crop in the world. It is the fifth
largest produced agricultural crop and the largest produced tuber and root crop in the world.
It has good food value and is rich in carbohydrates and also contains proteins, phosphorus, minerals like
calcium and potassium and vitamins like vitamin C & A. The protein calorie ratio is high. Boiling
potatoes increases their protein content and almost doubles their calcium content. It is vastly consumed as
a vegetable and is also used in various forms such as starch, flour, alcohol, dextrin and livestock fodder.
It is a high yielding short duration crop. International Production Scenario Potatoes are grown in ~150
countries throughout the world and more than a billion people worldwide eat it
India being a highly populated nation, for feeding its population, no crop other than potato can make an
impact. Potato is the third most important staple crop in the world and is largely consumed in India.
Potatoes were not produced in India till in the 17th century.
The Portuguese introduced this crop and cultivated it in Surat for the first time. Then onwards, it spread
over all of India quite rapidly. With a production of around 26 million metric tonne (MT) in 2007, India
ranks fourth in area and third in global potato production. It produces around 8% of the worlds total
produce.
Between 1960 and 2000, potato production increased by almost 850 percent, partly in response to
growing demand from Sometimes, farmers are not able to even cover their cost of production. The states
of Uttar Pradesh, West Bengal, and Bihar accounting for more than 75 percent of area under cultivation
and about 80 percent of total production; higher-income urban populations.
There are two major cropping seasons in India:
Kharif, during the south-west monsoon (June/July through September/October), when agricultural
production takes place both in rain fed areas and irrigated conditions;
Rabi, during the winter, when agricultural activities take place only in the irrigated areas. ~80% of the
crop is raised during winter season.
Trading centres in India
Agra (Uttar Pradesh)
Hathras (Uttar Pradesh)
Kanpur (Uttar Pradesh)
Meerut (Uttar Pradesh)
Farukhabad (Uttar Pradesh)
Jalandhar (Punjab)
Ludhiana (Punjab)
Phul (Punjab)
Patiala (Punjab)
Ujjain (Madhya Pradesh)
Indore (Madhya Pradesh)
Dewas (Madhya Pradesh)

11

Hoogly (West Bengal)

Burdwan (West Bengal)
Howrah (West Bengal)
Factors affecting price of Potato
Area under cultivation in the growing areas.
Weather in key growing regions particularly cold wave and heavy rains during tuber formation.
Price of other vegetables
Demand of potato from the major cities and food processing industries
Potato price tends to firm up during the planting period and eases down during the harvesting period.
Transportation charges from one place to another.
Potato growers and traders hoard the commodity before selling in expectation of better prices. Potato can
be kept in cold storages without spoilage for 5-6 months.
List of Potato varieties released by CPRI and AICPIP(central potato research institute and All
India Coordinated potato improvement project)
Year of
Release

Variety

Salient features and Adaptability

1958

Kufri Kisan

Late-maturing. North Indian plains

1958

Kufri Kuber

Medium-maturing. Bihar and Maharashtra

1958

Kufri Kumar

Late-maturing and moderately resistant to late blight. North Indian hills

1958

Kufri Kundan

Medium-maturing,moderately resistant to late blight and good keeping

quality. Himachal Pradesh and hills of Uttar Pradesh

1958

Kufri Red

Medium-maturing and good keeping quality. Plains of Bihar and West

Bengal

1958

Kufri Safed

Late-maturing and good keeping quality. North Indian Plains

1963

Kufri Neela

Late-maturing and moderately resistant to late blight. Nilgiri Hills

1967

Kufri Sindhuri

Late-maturing, essentially short day adapted variety with red tuber.

Heavy yielder even on low inputs. North Indian plains

12

1968

Kufri Alankar

Medium-maturing. North Indian plains

1968

Kufri Chamatkar Late-maturing and resistant to early blight

1968

Kufri
Chandramukhi

Early-maturing and good for processing. North Indian plains and plateau
region of peninsular india

1968

Kufri Jeevan

Late-maturing. Himachal Pradesh

1968

Kufri Jyoti

Medium-maturing, good for processing, field resistant to late and early

blights and immune to wart, and tolerant to viruses. Wide adaptablity

1968

Kufri Khasigaro

Late maturing and resistant to both late and early blight. Hills of
Meghalaya

1968

Kufri Naveen

Late maturing and resistant to late blight and immune to wart. Northern
hills of West Bengal and Meghalaya

1968

Kufri Neelamani Late maturing and resistant to late blight. Nilgiri hills

1968

Kufri Sheetman

Medium to late-maturing and resistant to frost. North Indian plains and

tarai area of Uttar Pradesh

1971

Kufri Muthu

Medium-maturing and resistant to late blight. Nilgiri hills

1972

Kufri Lauvkar

Early-maturing and rapid bulking under warmer conditions, suitable for

processing. Plateau region of peninsular India

1973

Kufri Dewa

Medium maturing, good keeping quality and resistant to frost. Tarai area
of western Uttar Pradesh

1979

Kufri Badshah

Medium- maturing, resistant to both late and early blights and PVX.
North Indian plains and plateau region of peninsular India

1980

Kufri Bahar

Medium-maturing and heavy yielder. North Indian plains

1982

Kufri Lalilma

Medium-maturing with red tuber and resistant to virus 'X' North Indian
plains

1983

Kufri Sherpa

Medium-maturing, resistant to late blight and immune to wart.Hills of

west Bengal

13

1985

Kufri Swarna

Medium-maturing, resistant to late blight and cyst nematode. Nilgiri hills

1989

Kufri Megha

Medium-maturing, late blight resistant. Hills of Meghalaya

1996

Kufri Ashoka

Short duration(75days). Plains of central and eastern Uttar Pradesh, Bihar

and West Bengal

1996

Kufri Jawahar

Medium-maturing, resistant to late blight and ideal for intercropping.

Punjab, Haryana and the plateau regions of Madhya Pradesh, Gujarat and
Karnataka

1996

Kufri Sutlej

Medium-maturing and resistant to late blight. Western and central IndoGangetic plains

1997

Kufri Pukhraj

Medium-maturing and resistant to late blight. Northern plains and plateau

region

1997

Kufri Chipsona-1

Medium-maturing and resistant to late blight. Excellent for chip making.

Indo-Gangetic plains

1997

Kufri Chipsona-2

Medium-maturing and resistant to late blight. Excellent for Chipping.

Indo-Gangetic plains

1997

Kufri Giriraj

Medium to late-maturing and resistant to late blight. North western hills

1998

Kufri Anand

Medium maturing and resistant to late blight. Heavy yielder. Northern

plains

Potato type:
Among them, I have chosen kurfi jyoti potato because of the following reasons:
1. Starch content is 16.37% which is quite good comparing potatoes of the same cost.
(Dry matter 20%,sugar 0.29%)
2. This species cultivated in a large amount in Hooghly, Howrah and Burdwan.
3. Potato mash is Less sticky, so easy to pumping the slurry.
4. peel of this kind of potatoes are easily removable.
5. Peel percentage is less, so loss also less during lye peeling and cutting.

14

AMYLASE
An amylase is an enzyme that breaks starch down into sugar. Amylase is present in human saliva, where
it begins the chemical process of digestion. Foods that contain much starch but little sugar, such as rice
and potato, taste slightly sweet as they are chewed because amylase turns some of their starch into sugar
in the mouth. The pancreas also makes amylase (alpha amylase) to break down dietary starch into di- and
trisaccharides which are converted by other enzymes to glucose to supply the body with energy. Plants
and some bacteria also produce amylase. As diastase, amylase was the first enzyme to be discovered and
isolated (by Anselme Payen in 1833).[citation needed] Specific amylase proteins are designated by different
Greek letters. All amylases are glycoside hydrolases and act on -1,4-glycosidic bonds.
-Amylase
Main article: alpha-Amylase
(EC 3.2.1.1 ) (CAS# 9014-71-5) (alternate names: 1,4--D-glucan glucanohydrolase; glycogenase) The amylases are calcium metalloenzymes, completely unable to function in the absence of calcium. By acting
at random locations along the starch chain, -amylase breaks down long-chain carbohydrates, ultimately
yielding maltotriose and maltose from amylose, or maltose, glucose and "limit dextrin" from amylopectin.
Because it can act anywhere on the substrate, -amylase tends to be faster-acting than -amylase. In
animals, it is a major digestive enzyme and its optimum pH is 6.7-7.0. [1]
In human physiology, both the salivary and pancreatic amylases are -Amylases. They are discussed in
much more detail at alpha-Amylase.
Also found in plants (barley) , fungi (ascomycetes and basidiomycetes) and bacteria (Bacillus).
USES
Amylase enzymes are used extensively in bread making to break down complex sugars such as starch
(found in flour) into simple sugars. Yeast then feeds on these simple sugars and converts it into the waste
products of alcohol and CO2. This imparts flavour and causes the bread to rise. While Amylase enzymes
are found naturally in yeast cells, it takes time for the yeast to produce enough of these enzymes to break
down significant quantities of starch in the bread. This is the reason for long fermented doughs such as
sour dough. Modern bread making techniques have included amylase enzymes (often in the form of
malted barley) into bread improver thereby making the bread making process faster and more practical for
commercial use.
Bacilliary amylase is also used in detergents to dissolve starches from fabrics.Workers in factories that
work with amylase for any of the above uses are at increased risk of occupational asthma. 5-9% of bakers
have a positive skin test, and a fourth to a third of bakers with breathing problems are hypersensitive to
amylase.
An inhibitor of alpha-amylase called phaseolamin has been tested as a potential diet aid. [4]
Blood serum amylase may be measured for purposes of medical diagnosis. A normal concentration is in
the range 21-101 U/L. A higher than normal concentration may reflect one of several medical conditions,

15

including acute inflammation of the pancreas, macroamylasemia, perforated peptic ulcer, and mumps.
Amylase may be measured in other body fluids, including urine and peritoneal fluid.
AMYLASE SUPPLIERS IN INDIA

Lumis Biotech Pvt Ltd

Swemed biomedicals pvt ltd
Varuna Biocell Private Limited
Aumgene Biosciences Pvt. Ltd.
BioRich
Shri GBS Biotech (P) Ltd.
National Chemical Industries
Stallion Impex (P) Ltd
Egenix Biotech Pvt. Ltd.
triton chemicals

YEAST
Yeasts are eukaryotic microorganisms classified in the kingdom Fungi, with about 1,500 species currently
described; they dominate fungal diversity in the oceans. Most reproduce asexually by budding, although a
few do so by binary fission. Yeasts are unicellular, although some species with yeast forms may become
multi cellular through the formation of a string of connected budding cells known as pseudohyphae, or
false hyphae as seen in most molds. Yeast size can vary greatly depending on the species, typically
measuring 34 m in diameter, although some yeast can reach over 40 m
The yeast species Saccharomyces cerevisiae has been used in baking and fermenting alcoholic beverages
for thousands of years. It is also extremely important as a model organism in modern cell biology
research, and is the most thoroughly researched eukaryotic microorganism. Researchers have used it to
gather information into the biology of the eukaryotic cell and ultimately human biology. Other species of
yeast, such as Candida albicans, are opportunistic pathogens and can cause infection in humans. Yeasts
have recently been used to generate electricity in microbial fuel cells. and produce ethanol for the biofuel
industry.
Yeasts do not form a specific taxonomic or phylogenetic grouping. At present it is estimated that only 1%
of all yeast species have been described. The term "yeast" is often taken as a synonym for S. cerevisiae,
but the phylogenetic diversity of yeasts is shown by their placement in both divisions Ascomycota and
Basidiomycota. The budding yeasts ("true yeasts") are classified in the order Saccharomycetales.
Yeasts are chemo organotrophs as they use organic compounds as a source of energy and do not require
sunlight to grow. The main source of carbon is obtained by hexose sugars such as glucose and fructose, or
disaccharides such as sucrose and maltose. Some species can metabolize pentose sugars like ribose,
alcohols, and organic acids. Yeast species either require oxygen for aerobic cellular respiration (obligate
aerobes), or are anaerobic but also have aerobic methods of energy production (facultative anaerobes).

16

Unlike bacteria, there are no known yeast species that grow only anaerobically (obligate anaerobes).
Yeasts grow best in a neutral or slightly acidic pH environment.
Yeasts will grow over a temperature range of 10 C (50 F) - 37 C (99 F), with an optimal temperature
range of 30 C (86 F) - 37 C (99 F), depending on the type of species (S. cerevisiae works best at about
30 C (86 F). Above 37 C (99 F) yeast cells become stressed and will not divide properly. Most yeast
cells die above 50 C (122 F). If the solution reaches 105 C (221 F) the yeast will disintegrate. There is
little activity in the range of 0 C (32 F) - 10 C (50 F). The cells can survive freezing under certain
conditions, with viability decreasing over time.
Yeasts are very common in the environment, but are usually isolated from sugar-rich material. Some good
examples include naturally occurring yeasts on the skins of fruits and berries (such as grapes, apples or
peaches), and exudates from plants (such as plant saps or cacti). Some yeasts are found in association with
soil and insects. Yeast is generally grown in the laboratory on solid growth media or liquid broths.
Common media used for the cultivation of yeasts include; potato dextrose agar (PDA) or potato dextrose
broth, Wallerstien Laboratories Nutrient agar (WLN), Yeast Peptone Dextrose agar (YPD), and Yeast
Mould agar or broth (YM). The antibiotic cycloheximide is sometimes added to yeast growth media to
inhibit the growth of Saccharomyces yeasts and select for wild/indigenous yeast species. This will change
the yeast process.
YEAST SUPPLIERS
Agfa India Pvt Ltd
ADD: 503 Surya Kiran Building K G M... Delhi, Delhi. India

Allengers Medical Systems Ltd

ADD:E-35,1st Floor, Rajouri Garden... Delhi, Delhi. India

Amx Medical Systems

ADD:G H-5&7/441, Paschim Vihar, Delhi, Delhi. India

Hindrays
ADD:1b/12a Nit Phawra Singh Chowk ...Delhi, Delhi. India

Medilux Systems
ADD:E1-11/1, Sector-15, Rohini, De...Delhi, Delhi. India

17

Cosmic Quality
ADD:No27/ B, Hosur Road Bangalore, Bangalore, Karnataka. India

PROJECT INFORMATION
PLANT CAPACITY:
The plant Capacity is 100 kl per day or 1 L.litre/day, taking 330 working days in a year on 24
hours a day working time (3 shift).

SITE SELECTION:
A geographical location of the final plant has a strong influence on the success of an industrial venture.
Primarily, the plant should be located where the minimum cost of production and distribution can be
obtained though there are many other important points to be considered. After considering all these
parameters, it has been decided to install the plant at Tarakeshwar, dist: Hooghly, west Bengal. The
facilities of this site is given below.

Location:

Tarakeswar

Temperature: Summer- 40 0 C & winter- 8 0 C, Avg-30 C

Comfort level: 34 C
Dew point:

24 C

Barometer:

1012 millibars

Humidity:

71%

Visibility:

2 km

Wind:

4 km/h from 140 Southeast

Area:

185 km 2

Population:

5,138,208 (approximate)

Languages:

Bengali, Hindi, English, & some regional languages.

18

1. RAW MATERIALS:
Following the harvesting of the `Aus' paddy crop, potato cultivation is on in full swing in West
Bengal. Among all the potato producing states in the country, West Bengal ranks No.2 in terms of
potato production after Uttar Pradesh. However, with regard to productivity in terms of yield per
hectare, West Bengal is ranked No 1. Sixty per cent of the potato produced in West Bengal is
grown in the two adjacent districts of Bardhaman and Hooghly.
According to latest statistics - 2010-11 available with the State Government, the total land in
the State under potato cultivation is 3,18,200 hectares. The total potato production in the State in
2010-11 was pegged at 70,76,050 tonnes at an average production of 22.23 tonnes per hectare.
While most of the potato crop comprises the `Jyoti' variety, the other potato varieties that are
cultivated include `Chandramukhi' and `Asha.' A new variety, Chipsona I and II, with less sugar
content and more dry matter, is gradually being introduced for processing purposes only. The Jyoti
variety of potato - which gives higher yield per hectare compared with the Chandramukhi variety accounts for 80 per cent of the total potato production in the State.
Cold storages in hooghly:LIST OF COLD STORAGES IN HOOGHLY
Name &
address of
coldstorage
Adyashakti Cold Storage Pvt.
Ltd., Narayanpur
Alokananda Coldstorage (P)
Ltd.Haripal
Amarnath Cold Storage Pvt.
Ltd., P.O. Puinan
Anand Coldstorage,
Bangshipur,P.O. Chopa
Ananda Cold Storage,
Shahalalpur, Hooghly
Annapurna Himghar (P) Ltd.,
P.O. Rahimpur
Arambagh Himghar Pvt. Ltd.,
P.O. Arambagh
Ashutosh Cold Storage, Vill.
Bhanjipur,
Ashutosh Himghat Pvt. Ltd.,
Vill. Ratanpur
Aviman Coldstorage (P) Ltd,
Tarakeswar

CapSector Commodity
MT
7100

Pvt

Potato

14000

Pvt

Potato

18644

Pvt

Potato

6412

Pvt

Potato

14000

Pvt

Potato

12785

Pvt

Potato

8668

Pvt

Potato

7712

Pvt

Potato

9326

Pvt

Potato

14000

Pvt

Potato

19

Baba Satyanarayan Himghar

Pvt. Ltd,
Baidyabati Ice & Cold Storage,
51, G.T. Road,
Baidyanath Cold Storage,
Boregori,
Bainchi Berela Sech 'o'SKUS
Ltd. Berala.
Balaka Cold Storage Pvt. Ltd
Balaram Cold Storage (P) Ltd
Basudevpur Cold Storage, Vill.
Basudevpur,
Bhaktimore Cold Storage (P)
Ltd
Bhanderhati Cold Storage, P.O.
Bhanderhati
Bholanath Cold Storage,
Chilladingi.
Bholasankar Cold Storage, P.O.
Khanpur
Biswarup Cold Storage, P.O.
Rameshwarpur
Boinchee CADP FSCS Ltd.,
Vill. Bantika,
Boinchee Cold Storage &
Industries (P) Ltd.,
Champadanga Cold Storage (P)
Ltd.,
Chinsurah Cold Storage, P.O.
Chinsurah
Chiranjee Cold Storage (P)
Ltd., P.O. Tayer
Chittaranjan Cold Storage (P)
Ltd.,
Dahalania Cold Storage,
Gopinagar,
Dakhineswari Cold
Storage, Hooghly
Damal Cold Storage, P.O.
Gopinagar
Damodar Cold Storage, Vill.
Singti,
Debendra Cold Storage (P) Ltd.,

19627

Pvt

Potato

5399

Pvt

Potato

4862

Pvt

Potato

10000 Co-op

Potato

11600
13750

Pvt
Pvt

Potato
Potato

9082

Pvt

Potato

13002

Pvt

Potato

10008

Pvt

Potato

5419

Pvt

Potato

13387

Pvt

Potato

12813

Pvt

Potato

7047 Co-op

Potato

5552

Pvt

Potato

4027

Pvt

Potato

20000

Pvt

Potato

22555

Pvt

Potato

10264

Pvt

Potato

22040

Pvt

Potato

14300

Pvt

Potato

4761

Pvt

Potato

4536

Pvt

Potato

10530

Pvt

Potato

20

Dehibatpur Cold Storage (P)

Ltd.,
Deshbandhu Industries & Cold
Storage
Dhaniakhali Thana Samabay
Himghar Ltd
Dhirendra Narayan Cold Storage
Pvt. Ltd.,
East India Cold Storage Pvt. Ltd
Gangadhar Cold
Storage, Hooghly
Gangapati Himghar (P) Ltd.,
Goshat-II
Gourhati Coldstorage,
Arambagh
Gourhati Samabay Himghar
Samity Ltd
Haraparbati Cold Storage (P)
Ltd.,
Harinkhola Ice & Cold Storage
Ltd,
Himadri Cold Storage Pvt. Ltd
Himalaya Cold Storage, Vill.
Harua
Hooghly Cold Storage, P.O.
Tinna
India Diary Corporation Cold
Storage, Chanditola
Jagadhatri Swarupnarayan
Tushargriha
Jalaram Coldstorage (P) Ltd,
Dhaniakhali
Jangipara Cold Storage Pvt.
Ltd.,
K.R.S. Cold Storage (P) Ltd.,
Boinchee
Kailashpati Cold Storage (P)
Ltd.
Kalpataru Cold Storage (P) Ltd
Kashinath Cold Storage, P.O.
Baidyabati
Kathgora Srikrishna Krishak
Himghar (

14700

Pvt

Potato

3106

Pvt

Potato

10000 Co-op

Potato

20788

Pvt

Potato

9242

Pvt

Potato

14000

Pvt

Potato

9960

Pvt

Potato

9166

Pvt

Potato

4157 Co-op

Potato

12646

Pvt

Potato

10800

Pvt

Potato

36390

Pvt

Potato

9874

Pvt

Potato

10343

Pvt

Potato

200 Co-op

Potato

8416

Pvt

Potato

7000

Pvt

Potato

7840

Pvt

Potato

6466

Pvt

Potato

13407

Pvt

Potato

19264

Pvt

Potato

4200

Pvt

Potato

14000

Pvt

Potato

21

Khanakul Thana,
KrishijataSamabay Himghar Ltd
Khanpur Cold Storage Pvt. Ltd
Kochamali Boragory SKUS Ltd,
Boinchi
Kodernath Cold Storage, Vill.
Jagjiwanpur
Kohinoor Cold Storage Pvt.
Ltd.,
Krishakbandhu Samabay
Himghar Ltd., Rasulpur
Lalkar Marines (P) Ltd, Haripal
Laxmi Mata Himghar Pvt.
Ltd., Hooghly
M. P. Cold Storage, P.O.
Dekshi, Rasulpur
Ma Monosa Cold Storage Pvt.
Ltd
Maa Kankali Himghar, Goghat
Mahaprabhu Cold Storage Pvt.
Ltd
Mallick Coldstorage (P) Ltd,
Singur
Matangini Cold Storage (P)
Ltd.,
Mohanlal Prem Ratan Delux Ice
& Cold Storage, 44,
Murli Cold Storage Pvt. Ltd.,
P.O. Boinchoo
N.R.S. Cold Storage Pvt. Ltd.,
P.O. Pandua
Nalikul Cold Storage Pvt. Ltd,
Narayan Cold Storage (P) Ltd.,
P.O. Vastore
Narayanpur Cold Storage, Vill.
Narayanpur,
Navina Cold Storage, Vill.
Kanaria,
Netai Charan Dey Cold Storage
(P) Ltd
Nishapati Cold Storage, P.O.
Kannadi

14000 Co-op

Potato

20072

Potato

Pvt

10000 Co-op

Potato

8564

Pvt

Potato

5618

Pvt

Potato

5000 Co-op

Potato

14200

Pvt

Potato

14000

Pvt

Potato

26000

Pvt

Potato

10945

Pvt

Potato

14000

Pvt

Potato

12850

Pvt

Potato

14000

Pvt

Potato

10251

Pvt

Potato

4699

Pvt

Multi
Purpose

24184

Pvt

Potato

5000

Pvt

Potato

20482

Pvt

Potato

20840

Pvt

Potato

10199

Pvt

Potato

6213

Pvt

Potato

16446

Pvt

Potato

9012

Pvt

Potato

22

Pallishree Pvt. Ltd., P.O.

Arambagh
Panchanan Cold Storage (P) Ltd
Pandua Cold Storage Pvt. Ltd
Pareshnath Cold Storage,
Pati Durga Cold Storage
Pioneer Himoudyog (P)
Ltdkeswar
Polba-Dadpur Co-op. Cold
Storage, Balikakhar, Harit
Prakash Paddar (P) Ltd., Vill.
Kantagoria,
Purna Cold Storage, Vill.
Jayrampur
Rabindra Cold Storage Pvt. Ltd
Radha Madhab Cold Storage (P)
Ltd.,
Raj Ballav Himghar (P) Ltd.,
P.O. Haripal
Raja Ram Mohan Roy Cold
Storage
Raja Rammohan Roy
Samabayhimghar Ltd
Ratan Cold Storage Ltd
Ratanpur Cold Storage (P) Ltd.,
P.O. Singur
S. N. Cold Storage Pvt. Ltd.,
S. R. Cold Storage Panchghara,
Sachimata Cold Storage (P)
Ltd.,
Santa Cold Storage Pvt. Ltd.,
P.O. Pandua
Shankar Colstorage
(P)Ltd,Dhaniakhali
Sharada Himghar, Vill.
Impaharpur
Sheoraphulli Cold Storage
Singur Cold Storage Pvt. Ltd
Snehlata Cold Storage (P) Ltd,
Soumil Coldstorage (P) Ltd,
Khanakul
Sree Bishnu Potato Storage (P)

5323

Pvt

Potato

10300
5753
14375
14946

Pvt
Pvt
Pvt
Pvt

Potato
Potato
Potato
Potato

8330

Pvt

Potato

4290 Co-op

Potato

11371

Pvt

Potato

17732

Pvt

Potato

23683

Pvt

Potato

7000

Pvt

Potato

9633

Pvt

Potato

9168

Pvt

Potato

4504 Co-op

Potato

6684

Pvt

Potato

20600

Pvt

Potato

10462
5073

Pvt
Pvt

Potato
Potato

10346

Pvt

Potato

18666

Pvt

Potato

5000

Pvt

Potato

4900

Pvt

Potato

4000
23372
20137

Pvt
Pvt
Pvt

Multipurpose
Potato
Potato

14000

Pvt

Potato

29334

Pvt

Potato

23

Ltd
Sree Gouranga Himghar (P)
Ltd., P.O. Seakhala
Sree Pashupatinath Potato
Storage (P) Ltd.,
Sri Agro Himghar (P(
Ltd,Haripal
Sri Gopikishan Industries Pvt.
Ltd
Sri Jagannath Coldstorage (P)
Ltd,Jangipara
Sri Ramkrishna Cold Storage,
Muktarpur
Sri Sri Mahadev Cold Storage, ,
Sri Sri Sitaram Cold Storage
Pvt. Ltd.,
Sribalaji Cold Storage, Hooghly
Tapati Cold Storage, P.O.
Mogra
Tarakeswar Cold Storage Pvt.
Ltd
Tarakeswar Pursurah Co-op.
Cold Storage
Taraknath Cold Storage Pvt. Ltd
Tunu Cold Storage
U.C.O. Farmers' Service Co-op.
Society Ltd
Uma Himghar (P) Ltd, Polba
Dadpur
Vibek Cold Storage Pvt. Ltd.,
P.O. Jangipara
Vibekananda Himghar, Vill. &
P.O. Mandra
Vikrant Ref. (P) Ltd,Jangipara
Hoogly Total

15908

Pvt

Potato

22358

Pvt

Potato

14000

Pvt

Potato

19222

Pvt

Potato

14000

Pvt

Potato

5000

Pvt

Potato

3400

Pvt

Potato

18564

Pvt

Potato

14000

Pvt

Potato

10079

Pvt

Potato

6330

Pvt

Potato

10798 Co-op

Potato

12982
11098

Potato
Potato

Pvt
Pvt

4000 Co-op

Potato

14073

Pvt

Potato

5312

Pvt

Potato

19049

Pvt

Potato

7000
126 1485719

Pvt

Potato

2. POWER AND SUPPLY:

Electricity can be obtained from West Bengal State Electricity Board and so it is unnecessary to
set up a captive power unit. So considering factor is available from the W.B.S.E.B nearly a 11 KV
line. For load shedding, a generator of 125 KVA is also provided in this project.

24

Name of utility
West Bengal State Electricity
Board
(WBSEB)
West Bengal Power Development
Corp. Ltd.
(WBPDCL)

Durgapur Projects Ltd.

(Govt. of W.B. Undertaking)
(DPL)
Damodar Valley Corporation
(DVC)

National Thermal Power

Corporation
(Govt. of India Undertaking)
(NTPC)

Installed capacity(MW)
Use area
1284.01
Entire State excepting areas
under other utilities WBSEB,
supplies the bulk power to CESC
Ltd.
1470.00
No command area of its own.
WBSEB distribution of entire
power generation by WBPDCL.
2nd Unit at Bakreswar of 210
MW capacity has also been
synchronized.
395.00
Supplies power to part of
Durgapur. Surplus power is fed
to WBSEB grid.
Damodar Valley Corp. is jointly
Thermal : 980.00
owned by the Govt. of India, Govt.
Hydel
: 60.00
-------------------of West Bengal and Govt. of
Total
: 1040.00
Bihar) is a multipurpose river
(in West Bengal)
valley project set up under Act No.
XIV
of
1948
for
unified development
of
the
Damodar
Valley
area.DVC
supplies power at 33 KV in the
districts
of
Bankura,
Bardhaman, Howrah, Hooghly
and Purulia in WB. Caters to
the core sector consumers like
Railways, Collieries, Steel, Other
Industries and WBSEB and
CESC Ltd. at 132 KV and 33
KV. Connected load is 479.2
MVA in WB.

1600.00

WBSEB has the following share

from Central Power Station of
Eastern Region including NTPC.
NTPC at Farakka(1600 MW)
(W.B.) 33.12%(530 MW)
NTPC at Kahelgaon
(840MW)(Bihar) 21.43%(180
MW)
Chukha Hydro
(320MW)(Bhutan)

25

37.46%(116MW)
Rangit NHPC(60MW)(Sikkim)
23.33%(14 MW)
Total WBSEB share - 840
MW From C.S.Power Station

Calcutta Electric Supply

Company Ltd.
(CESC Ltd.)
Dishergarh Power Supply
Company Ltd.
(DPSCL)

1155.00

26.38

Source: http://wbpower.nic.in/utility.html

3. CLIMATE:
Climate is highly favorable. It is not too cold thereby does not require any extra effort to dry the
final alcohol product. The variation in temperature is also not too high to create any thermal stress
problem. Thus the climate is highly pleasant and favourable as compared to Western India.
4. TRANPORTATION FACILITIES:
Hooghly has good quality surface transport facilities. It is well connected to other parts of India by
railways, by means of which products can be cheaply and conveniently to other parts of India
within a short time. Superb road transport and train services are available for comfortable journey
of employees.

Major Highways of Hooghly

Main Communication
1.

Eastern Railway Howrah-Burdwan Main Line

2.

Howrah-Burdwan Cord Line

3.

Howrah-Tarakeswar Main Line

26

4.

Howrah-Katowa Main Line

Main Road

1.

National Highway-I : 1. (106 K.M.)

2.

State Highway : 8 (197 K.M.)

3.

Metal Led Road : 35 (348 K.M.)

4.

Market Link Road 15 (53 K.M.)

5.

Rural Road : 407 K.M.

6.

Other District Road : 199 K.M.

7.

District Road : 274 K.M.

8.

No. Of Rail Road :4 (202 K.M.)

27

5. WATER SUPPLY:
Process water is available from nearby water project at a nominal price. There is a provision for
own deep tube well, water storing and circulation in this project. River Hooghly is the main water
source.

28

Water Charges
Bulk domestic :
(Including Govt. Hospitals/Housing complexes
(both rental & ownership) or owned by State &
Central Govt. & other public bodies as well as
private housing estates with less than 25% of nonresidential use)
Government Hospitals

Bulk ICI
(Private Hospt., Defence Estab. (other than
housing complexes) Railway Estab. & other
Commercial Estab.)
Multistoried Buildings
(With 25% or more commercial areas)
Other than KMC area
a) Domestic
b) ICI
c) Domestic + Partly Commercial

Rs. 7/- Per K.L.

Rs. 7/- Per K.L.

Daily Avg.
Daily Avg.
Consumption
Consumption
upto 30 KL
more than 30 KL
Rs. 12/- Per K.L.

Rs. 15/- Per K.L.

Rs. 9/- Per K.L.

Rs. 12/- Per K.L.

Rs. 12/- Per K.L.

Rs. 18/- Per K.L.
Rs. 15/- Per K.L.

6. MANPOWER SUPPLY:
West Bengal has Indias one of the best work force. Presence of numerous Graduation Colleges,
Engineering colleges, Management Institutes including IIM at Joka and IIT, kharagpur is capable
of supplying managers, engineers, scientists, accountants and other service persons.
There is also huge cheap ye efficient labour available from near bent villages. There are
ever more in nearer districts. It may sound sad but it is true that West Bengal is suffering from
closer man industries. But this provides lots of experinced workers say from HFC, ICI, Show
Wallance etc. and due lack of this work force will be higjly stable. Moreover. West Bengal is
unable to provide job to the large work force present over here. Therefore huge cheap yet efficient
labours will be easily available.

State
INDIA
West Bengal

Statewide Population in India

(Census 2001)
Total
Male
%
1027015247
80221171

531277078
41487694

51.7
51.7

Female

495738169
38733477

48.3
48.3

29

Demographic, Socio-economic and Health profile of West Bengal State as compared to India
figures:
Sr. NO.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.

7.

Item
Total population (Census 2001) (in
millions)
Decadal Growth (Census 2001) (%)
Crude Birth Rate (SRS 2008)
Crude Death Rate (SRS 2008)
Total Fertility Rate (SRS 2008)
Infant Mortality Rate (SRS 2008)
Maternal Mortality Ratio (SRS 2004 2006)
Sex Ratio (Census 2001)
Population below Poverty line (%)
Schedule Caste population (in millions)
Schedule Tribe population (in millions)
Female Literacy Rate (Census 2001) (%)

West Bengal
80.18

India
1028.61

17.77
17.5
6.2
1.9
35
141

21.54
22.8
7.4
2.6
53
254

934
27.02
18.45
4.41
59.6

933
26.10
166.64
84.33
53.7

TAXATIONS AND LEGAL RESTRICTION:

This is also not a problem, some states with high industry density is trying to impose same
restriction like cam pulsation of taking son of sails (Gujrat). But we cannot do this luxury. Tax
and other legal formalities are also highly friendly and will not be a problem.

8.

SITE CHARACTERISTICS:
Tarakeshwar is situated near Hooghly River. So, obviously the land is flat and plane with very
little, if any ups and downs. So, little energy will be needed to make it sufficiently smooth. The
soil is not so hard to offer any resistance toward drilling or erection of equipments but enough
powerful to bean the weight of equipments and machineries. So site characteristics are also
favourable.

9.

COMMUNITY FACTOR
Tarakeshwar is a fully grown town with all facilities like school, college, hospital, cinema, sport
ground, hotel etc. being available; this will adequately satisfy all human requirements completely.
Again Kolkata is not far from it. This is an added advantage.

10. UNION PROBLEM AND WORK ATMOSPHERE:

If there is any disadvantage in West Bengal then it is for this reason. But the situation is changing
Workers have understood what is good and what is not. So they are now trying to improve their
productivity. Union leaders have also taken lessons from the examples of jute industries. So we
must hope better.

30

11. INFRASTRUCTURE:
District Wise Business Opportunities

Districts
Burdwan
North 24
Parganas
Mark
Steel/Purulia
South 24
Parganas
Hooghly
Howrah
Bardhaman
Darjeeling
Bankura
Nadia
North Dinajpur
Purulia
Cooch Behar
South Dinajpur

Industries
Iron&steel, Fertiliser, Mining, Equipment Manufacturing and Cement
Printing and Bookbinding, Cement, Oilseed Milling and General Electrical Works
44
Cement, Agro Industry, Chemicals and Equipment Manufacturing
Rice mills, Rubber Factories and Chemical Factories
Foundry, Re-rolling Mills, Basic Metal & Metal Products, Electrical & Electronic,
Transport Equipments & Spares and Rubber Moulded Goods
Rice and Oilseed Mills, Cutlery and Tool Manufacturing
Tea and Tourism
Food-Processing, Textiles, Ply-Wood and Veneer Mills, Paper and Particle Board
Food Processing, Jute, Pipes & Tubes and Electronic / Computer Peripherals
Food Products, Hosiery & Garments, Chemicals, Engineering & Fabrication
Sponge Iron and Non-Metallic Mineral Products
Fertiliser, Jute, Electrical Casing, Mustard Oil Mill and Fruit Processing
Agro and Food-Based, Mineral & Forest-Based ,Chemical Based, Handicrafts,
Engineering, Automobiles Servicing, and ITeS

Petroleum & petrochemicals

Reliance Industries
Indian Oil Corporation
Mitsubishi Chemicals Corporation
Haldia Petrochemicals Ltd
South Asian Petrochem Ltd.
Gas Authority of India's (GAIL)
Styrene Butadiene Rubber (SBR)
Iron and Steel
JSW Steel
SAIL
Agro-Based Industry
IFB
UB etc.

31

12. AVILABILITY OF LAND:

After having decided to choose Tarakeshwar we must now see how land is available and in what
price. There are lots of empty lands in Tarakeshwar and even more land are going to be added in
near future as WBIDC is taking land from farmers for this. The cost of land is also very cheap as
compared the Mumbai or Gujrat. It is approximately Rs. 5-7lakhs per acre.From the above factors
Tarakeshwar does score the maximum as the most suitable plant site for rice based ethanol
production.
Reason for this feasibility:Ethyl alcohol at 1st used as beverages. But after 1925, when Henry Ford told a New York Tme reporter
that ethyl alcohol was the fuel of future, since then it is blended with gasoline which is known as power
alcohol, to reduce the consumption of gasoline and now a days in many country it is mandatory to blend
alcohol with gasoline. e.g. Brasil government as a response of oil crisis in the year 1973, they made
mandatory to blend from the year 1975, they generally use 25% alcohol & 75% gasoline for blending.
So,as time goes, the use/consumption amounts of alcohol also increases. According to survey the
consumption of alcohol increases by 106% in the last 15 years. So in India, as time goes, the demand of
alcohol also increases. Now days the production of alcohol must be increased. In india, alcohol is
prepared conventionally from sugarcane. In the case of sugarcane production, India is in the 2 nd position
after brasil. India produces 285,029,00 tonnes of sugarcane in the year of 2010 after Brasil. But the
problem is, west Bengal is not among the top 10 states in India, in the case of producing sugarcane. So if
industrialist are interested to install the alcohol industry, then raw material must brought from the other
states.
India also in the 3rd position in the year of 2010 to produce potatoes, after China and Russia. In the year
2010, india produced 26,280,000 tonnes potato and west Bengal is in the 1 st position among the states to
produce potatoes. In west Bengal, mainly in the south Bengal region, the potato cultivation is done. So for
this reason here in India, if we utilize the potato to prepare the ethyl alcohol then we can decrease the gap
between demand and supply.

PROCESS DESCRIPTION:Washing of potato:At 1st potato is washed to remove any dirt and unwanted material from it.
Lye peeling and cutting:Here by using lye peeler machine it is done.
Mashing and mixing:At 1st here mashing is done.then it is mixed with water and amylase. It is necessary because the yeast,
used later in the fermentation process, can be killed by high concentration of alcohol. Also, during the
mashing and conversion of starchy material, dilution is necessary to make the mash easier to stir and

32

handle. The object of dilution is to end up with a beer of 10% or more alcohol when fermentation is
complete. The dilution of water with the mash prepared is 400 ml for the 200 gm of potato.
Mash Cooling
After cooking, the content is diluted with water. It is allowed for cooling in the same
container. The temperature recorded is 45C. At this temperature of mash, yeast is added.
The amount of yeast added is 2 gm in the diluted mash prepared.
Fermentor
Batch fermentation begins with the production of an active yeast inoculum. Yeasts are grown in an
aerated and agitated semi work fermenter operated in fed batch mode. A large portion (20-25%) of the
previous batch is retained to provide an inoculum. A high nutrient medium is added and pH and
temperature are controlled. Sterile air is sparged at a rate of one eighth volume of air per fermenter
volume per minute. This high cell density allows the use of a proportionately smaller inoculum to the
final fermenter, and a smaller propagating fermenter can be used. However, aerobically grown yeast may
require additional time to acclimatize to anaerobic fermentation conditions, resulting in an increased lag
period between inoculation and rapid fermentation.
Cylindroconical Nathan vessels (Hudson, 1972) are preferred for fermentation as these
promote better circulation and allow thorough drainage for cleaning. For very large plants, sloped bottom
cone-roof tanks of up to 1 million liters volume are used and these large vessels are often agitated only by
carbon dioxide evolution during fermentation.
After emptying and rinsing from the previous batch, mash at 13-17 wt% sugar is pumped to the
fermenters. Once 20 % full, the inoculum is added to allow growth during the remainder of the filling
cycle, which can last 4-6 h.
Fermentation temperature is regulated by circulating cooling water through submerged coils,
circulating the mash through external heat exchangers, or simply spraying the vessel walls with cool
water (adequate for small fermenters only). The feed is generally introduced at 25-300C, and the
temperature allowed to gradually rise as heat is evolved. The temperature thus varies from 30-350C during
the initial period (which is optimal for yeast growth). Cooling is then used to prevent the temperature
from exceeding 35-380C, which is optimal for ethanol production. This temperature may be modified
depending on the yeast strain used.
The ethanol production rate is the product of specific (per cell) productivity and the concentration
of cells. Initially, the rate of alcohol production is quite low, but as the number of yeast cells increases the
overall rate increases, and with rapid carbon dioxide evolution the beer appears to boil. After 20 hrs a
maximum in ethanol productivity is reached. The fermentation continues at a decreasing rate until, at 36
hrs , 94% of the sugar is utilized and a final ethanol content of 69 g/lt is achieved.
Fermentation time will vary depending on yeast strain and substrate. Grain fermentation requires 40-50
hr to allow complete residual dextrin conversion.
For large fermenters, improved agitation and temperature control is achieved by rapidly circulating the
beer through an extern al heat exchanger. The cooled beer is pumped back into the head of the fermenter
tangentially and at a high velocity. The greatest portion of heat generation occurs during the boiling
fermentation period, creating a high peak cooling demand. Investment in cooling equipment can be
reduced by teaming three or four fermenters to share a single bank of exchangers . With improved
agitation, continuous pH control can be used.
Aseptic operation, with complete sterilization of the very large mash volume, was considered impractical
until recently. Growth of organisms other than the seed yeast is generally restricted by the adverse
conditions of low pH and high sugar or alcohol concentration, and the rapid growth of the yeast compared
with contaminants was relied upon in place of aseptic technical. The medium is heated by steam injection

33

to 135-1400CAnd held in plug flow for 1-2 min, resulting in essentially complete sterilization. Cooling is
by flashing top generate steam or by heat exchange to preheat incoming feed. The steam requirement is
only 3.5 kg steam per 100 kg mash.

Batch fermentation equipment layout incorporating teamed heat exchange and chemical sterilization systems

Process

Cycle time

Fermentation(h)
Simple
batch

32

Emptying
(h)
4

Product
concn( gI-1)

Volumetric
productivity
(gI-1 h-1)

Total(h)
36

79

2.2

ALCOHOL RECOVERY UNIT

Alcohol product recovery is energy intensive, typically accounting for more than 50 % of the total
fermentative ethanol plant energy consumption. Depending on recovery system design , recovery
equipment cost generally makes up 6-12% of the plant total capital investment.

34

Here in my project I have choiced Three- column othmer system for the recovery of alcohol. Beer at
typically 6-8 wt% alcohol concentration is fed to the top of the beer still. A reboiler, or direct steam
injection at the base of the still, provides the vapor flow to strip alcohol, aldehydes and fusel oil from the
descending beer. The alcohol depleted stillage is recovered as the bottom product. Vapor from the stripper
flows into the base of the rectifier and is concentrated by contact with the descending reflux.
Aldehydes, as the most volatile components, concentrate at the head of the column and a technical
grade heads alcohol is condensed to provide reflux with enough (2-5% of the total product ) withdrawn to
purge the aldehydes. The product alcohol side-draw from the rectifier is fed to the top plate of the
aldehyde column and , in descending, is stripped of volatiles to produce an essentially pure azeotropic
alcohol bottoms product. Aldehyde carrying vapors from the head of the acetaldehyde stripper are
returned to the rectifying column and a technical grade heads alcohol product is tapped from the rectifier
reflux to purge the aldehydes as in the simple two-column design. The main product is virtually free of
aldehydes and is of higher quality.
Heat for alcohol vapor boil- up in the aldehyde stripper reboiler is provided by condensation of a
portion of the stripper vapor product, which is then returned to the stripper as reflux to reduce the stripper
tray requirement. This reuse of heat increases energy efficiency and the steam requirement is not
increased over the simple two column design (2.4-3.0 kg per liter of 94 wt % product)

35

Beer feed

Aldehyde (heads
alcohol)
Wash water
Fusel
oil
Alcohol
laden wash
water

Aldehyde
stripper

Rectifying column

Beer still
stillage

Three column distillation system

FERMENTATION WASTE TREATMENT AND BY PRODUCT RECOVERY

Product
Alcohol

36

Waste treatment and by product recovery are extremely important factors in the economics of ethanol
production. Secondary products recoverable from the feed during sugar preparation and prior to
fermentation were considered. Here, post fermentation wastes and by products are reviewed. The ethanol
depleted spent beer stillage is the most important waste stream. Without backset, typically 10-15 lit.of
stillage are produced for every liter of alcohol product.
Above Figure shows the process for cattle feed production from rice stillage. Bulk solids are
removed by centrifugation or by screening followed by dewatering in a rotary press. These solids then are
dried to less than 5% water in rotary driers to produce the distillers light grains product. The pressed
liquid thin stillage is concerned to 35% solids in forced convection vertical evaporators and then dried to a
powder using drum or spray driers yielding distillers solubles. About 700-900 g stillage feed can be
recovered per liter of alcohol produced.

37

Process flow diagram:-

38

Road

Road

R a w m a t. s t o r a g e

Pond

Fire
f i g h-t i n g

Cycle
Stand

Garden

Road

Product storage

M e d i-c l e
room

Canteen

Toi let
Block

R&D
Road

Garden

W o r k e r' s
change
room

Pump
House

Boiler
House

Road

Main Road 6 m wide

Road

Time
Weighing
Office
Office

A s s e-m b l y
Point

Main plant

Main
Gate

Weighing
Bridge

Road

Road

Garage
Road

Road

Ad ministrative
Building

Land for future

expansion

Road

Guard room

Road

Water Storage
Workshop

FIG: SITE LAYOUT

Cooling
Tower

Power Substation

39

MATERIAL BALANCE:Data given:- 1 lakh litre/day alcohol from potato. Ethyl alcohol density= 0.789 g/c.c.
Per hour requirement of ethanol =4.17 kl.
Specific gravity of ethanol =0.79
Specific gravity of water =1.0
Assuming we want to produce fuel grade ethanol (i.e. 99.2 wt % ethanol)
Material balance detail calculation:Daily production 1 Llit/day.
Density of ethanol (normal)=0.789 g/c.c.
Per day alcohol must be prepared = 78900 kg/day.
Per hour = 3287.5 kg/hour.
Calculation is done per hour basis.
Material balance across potato washer:Residence time 10 min.
Poatato loss during washing is almost 1.47%.(depends on washer)
Potato required= 75566.14 kg.
Water required= 139797.359 kg.
So amount of potato comes out after washing is= 74449.4 kg.
75566.14 kg

74449.4 kg
1.47% loss

1116.5 kg

40

Material balance across lye peeler:Residence time 20 min.

Here 2.91 % loss takes place.
So, the outlet weight of potato=(
So potato comes out from lye peeler =72218 kg.

74,449.4 kg

2.9% loss

2168.44 kg

Material balance across mashing:Almost 83% of potato is water.

So during mashing excess water is not added.
0.00064 kg enzyme is required per kg of potatoes.
So here total enzyme added=46.21 kg.
So outlet =72327 kg.
Material balance across cooker:Residence time = 5 mins
Slurry in = 72327 kg

72,218 kg

41

Water comes out in the form of steam = 3074.4 kg.

So outlet comes out = 69252 kg.

3074.4 kg

72,327 kg

69252 kg

Material balance across mixing tank:Here again amylase is added. The aim of -amylase is to crack carbohydrates of starch to shorter
chains. This step is called liquefaction. Optimized reaction time for -amylase is 30 minutesand after
that the mash is cooled down to 60 oC. Termamyl enzyme, which modifies starch toglucose, is added
and allowed to react 30 minutes. This step is known as a saccharification. After that mash is cooled
down to 30 oC and yeast is added. Optimized fermentation time is 3 days. During fermentation the
mash is mixed daily. (Kilpimaa 2008, Liimatainen et al. 2004,Liimatainen et al. 2005).
Amylase added = 8507 kg.
So outlet = 77759 kg.
Material balance across fermentor:Potato slurry in = 77759 kg.
Yeast added = 5kg.
1g starch gives 1.11 g glucose.
Starch content in potato=16.37%.
Carbon dioxide produced = 34752 kg. (100 gm glucose produced 46.6 gm CO2).
As here Embden-meyerhoff path is followed so 1g glucose gives 0.51 g ethanol.
Beer produced = 43027.45 kg.

42

Material balance across fermentor:-

5 kg yeast

34732 kg CO2

77759 kg
43027.4 kg

Material balance across beer still:-

3442.12 kg

43027.45 kg

39585.33 kg

43

Material balance across rectifying column:From rectifying column, 95% ethanol comes out from the 8% ethanol.
So, here input contains 8% ethanol, and from 8% to 97% ethanol produced.
So,

3442.127 kg

3425.4 kg

16.72 kg
Material balance across molecular sieve:In molecular sieve from 95% ethanol to 99.9% ethanol comes.
So, here at inlet condition ethanol entering 3451.6 kg.

3425.4 kg

3287.5 kg

138.4 kg

44

75,566.14 kg
Potato

Raw
Potato

744
49.
4 kg

Washer

72,281 kg
Lye peeler
and cutter

46kg
(enz)

72,3
27kg

3074.4 kg

Potato
mashing
cooker

storage

2168.44 kg

69252 kg
8507 kg

1117.6 kg

16.72 kg

34732 kg
CO2

5 kg
yeast
3442.1
2 kg

Beer still

Rectifiers

Fermentor

43027.4
5 kg

77759 kg

Slurry
preparation
(mix. Tank)

39585.33 kg
Molecular
sieve
3287.5 kg

3425.4 kg

138.4 kg

OVERALL MATERIAL BALANCES IN BLOCK DIAGRAM (per hour

basis):-

45

Energy balance:Energy balance across cooker:Specific Heat of potato =1.13 kj/kg C.

Specific heat of water= 4.2 kj/kg C.
Energy balance across cooker:Initial temp=25C. temp. inside the cooker=110C.
3074.4 kg

72,281 kg, 25C

110C.

Heat energy required=m Cp T=

=25,804317 kj/hr=7167 KW.

Energy balance across re boiler on 1st beer still:Boiling point of ethyl alcohol at room temp. is=75C
Temperature of beer still=80C. specific heat value for ethyl alcohol=2.72 KJ/KgC.
Feed entering here at= 35C. mass entering=43,027 kg/hr.
So heat required= m Cp T =14629 KW. This temp. rise is done by steam.
At this condition latent heat of steam=2184 KJ/kg.
Amount of steam=6698 kg/sec=24113.73 t/hr.
Energy balance across reboiler on the aldehyde column:Temperature of beer still=80C. specific heat value for ethyl alcohol=2.72 KJ/KgC.
Feed entering here at= 75C. mass entering=10,407.403 kg/hr.
So heat required= m Cp T =39.31 KW. This temp. rise is done by steam.
At this condition latent heat of steam=2184 KJ/kg.

69207 kg

46

Amount of steam=6698 kg/sec=64 796kg/hr.=64.8 t/hr

Energy balance across the reboiler on the rectifying column:Temperature of beer still=80C. specific heat value for ethyl alcohol=2.72 KJ/KgC.
Feed entering here at= 75C. mass entering=10,355.6 kg/hr.
So heat required= m Cp T =39.12 KW. This temp. rise is done by steam.
At this condition latent heat of steam=2184 KJ/kg.
Amount of steam=63.98kg/hr.=64 t/hr
Total amount of steam required=(64 t+64.8 t+24113.73 t)=24241.7 T
Total power required= for 2 pumps+ agitator+ fan on cooling tower+ lightening and others=15818.18
KWH/day
SIZING OF EQUIPMENTS
Lye peeler:Power 1200 kw.
Dimension=(2mx1.2mx2m)
Weight=2 ton.
Potato masher:No. of potato masher=2.
MIXING TANK
Tank volume = 69252 kg(allowing 20% extra)
Taking L/D = 2.0
Tank diameter =1.448 m
Length = 2.9 m
Area of tank =1.645m2
MASH SACCHARIFIER
Residence time = 30 mins

47

Mash in = 69207 kg
Volume of the saccharifier = 6.08 m3
Volumetric flow rate = 0.05m3 / s
Velocity of slurry = 1.0 m/s (assuming)
Diameter of the saccharifier = 0.252 m
Length of the saccharifier = 121.6m
Let us consider 20 bends then length per bend =6 .1m
Storage tank:Volume of the tank =26000 m3
Taking L/D =2.0
Diameter D = 8.68 m
Length L = 17.36 m
Area of tank = 59.173 m2
FERMENTER
Total mash has to processed in 24 hrs= 77759 tons
Fermenter vessel (Nathan vessel) capacity = 950000 lt
No. of fermenter vessel = 16
Taking L/D = 1.5
Diameter D = 9.739 m
Area = 74.38 m2
BEER STILL
Beer in = 43.027 t/h
No. of trays = 20
Taking L/D = 8 & plate spacing = 0.5 m

48

Tower height = 19x0.5= 9.5 m

Diameter D = 1.18 m
ALDEHYDE STRIPPER
No. of trays = 45
Taking L/D = 8 & plate spacing = 0.5 m
Tower height = 22.5 m
Diameter D = 2.8125 m
RECTIFYING COLUMN
No. of trays = 30
Taking L/D = 8 & plate spacing = 0.5 m
Tower height = 15 m
Diameter D = 1.87 m
STORAGE TANK
Volume of the tank =32875kg
Taking L/D =2.0
Diameter D = 5.68 m
Length L = 11.36 m
Area of tank = 35m2
Total water consumption:
1.
2.
3.
4.

For -----------------------------------------------= 876.70 KL/day

Fermenting vessel washing--------------------------- --= 9.46 KL/day
For cooling purpose ---------------------------------------------= 238.46 KL/day
potato washing---------------------------------------------= 64.34 KL/day
Total

1188.96 KL/day

49

Cost of the Equipment:

Plant & machinery
Elevator
Potato reciever
Weight measuring

Specification
-Lift height 50 feet
---

Total in no.
3
2
1
3

Total cost in lakhs

1.07 each(=3.23)
0.995 each(=1.99)
0.3
0.75

Conveyer

20 length 18 width

6.62

Lye peeeler
Steels mashers

Capacity 1T/hr.
Jacketed with agitator
capacity 1000 gal
With agitator dia-20 (304
S.S.)
Capacity 2000 gal (304
S.S.)
400 ft2
300 ft2

2
1

55.2
60

44.16

5.98

1
1

0.5
0.3

Yeast culture vessel

Capacity 260 gal, (304

S.S.)

1.65

Balance tank

Capacity 260 gal, (304

S.S.)

1.65

7.2

Mixing tank

Plate heat exchanger

Plate heat exchanger

slurry pump
Yeast propagation
vessel

Capacity 520 gal, (304

S.S.)

7.725

Fermenters

--

240

Conditioning & cold

tank

Capacity 260 gal, (304

S.S.)

1.65

Beer pump

103 gpm, ductile iron

casting

2.69

Carbon di-oxide
section

--

260

50

30 HP

4.41

Temperature switch

Bimetallic

3.3

Regeneration heating
& cooling equipment

--

1.24

Boiler

Total Cost-

1275.92 lakhs

51

DETAILS OF SALARY AND WAGES:

SR
NO.

DESIGNATION

BASIC
NO.
SALARY
REQUIRED
(THOUSAND)

ADMINISTRATIVE STAFF:
1. General manger
30
2. Personnel manager
10
3. Accounts manager
10
4. Accountant
8
5. Cashiers
5
6. Fire cum security
8
officer
7. Security staff
4
8. Fire man
3
9. Typist/stenographer
3
Computer operator
10. Peon
3
11. Time keeper
2
12. Sweeper
2
13. Driver
1
14. Doctor
10
Total-------------------------------Production:
1. Production manager
2. Brew master
3. Engineer/chemists
4. Skilled operator
5. Unskilled operator
6. Mechanical Engineer
7. Electrical engineer
8. Electrician
9. Foreman
10. Material manager
11. Purchase officer
12. Store clerk
13. Store keeper
14. Computer operator
SR
DESIGNATION
NO.

15.
16.

Chief chemists
Analytical chemists

TOTAL BASIC
(THOUSAND)

ANNUAL
SALARY
(LAKHS)

ANNUAL
GROSS
SALARY
(LAKHS)

1
1
1
3
1
1

30
10
10
24
5
8

3.6
1.2
1.2
2.88
0.6
0.96

5.15
1.72
1.72
4.12
0.86
1.37

9
3
7

36
9
21

4.32
1.08
2.52

6.18
1.63
3.81

0.72
0.48
0.24
0.48
1.2
21.48

1.09
0.73
0.36
0.73
1.72
31.14

2
2
1
4
1
37

18
1
15
2
12
5
4
40
2.5
80
12
1
12
1
6
3
2.5
5
15
1
6
2
3
3
2.5
3
4
1
BASIC
NO.
SALARY
REQUIRED
(THOUSAND)
10
6

1
3

6
4
2
4
10
179
18
30
60
160
200
12
12
18
12.5
15
12
9
7.5
4
TOTAL BASIC
(THOUSAND)

10
18

2.16
3.09
3.6
5.15
7.2
10.3
19.2
27.46
24
36.32
1.44
2.06
1.44
2.06
2.16
3.09
1.5
2.27
1.8
2.57
1.44
2.06
1.08
1.63
0.9
1.36
0.48
0.69
ANNUAL ANNUAL
SALARY
GROSS
(LAKHS) SALARY
(LAKHS)
1.2
1.72
2.16
3.09

52

17.

Laboratory chemists

12

Total ----------------------------------------155

SR
NO.

DESIGNATION

Sales department:
1.
Sales officer
2.
Sales assistance
3.
Clerk
4.
Typist

610

BASIC
NO.
SALARY
REQUIRED
(THOUSAND)

10
5
2.5
2.5

73.20

2.06

106.98

TOTAL BASIC
(THOUSAND)

ANNUAL
SALARY
(LAKHS)

ANNUAL
GROSS
SALARY
(LAKHS)

10
20
5
2.5

1.2
2.4
0.6
0.3

1.72
3.43
0.91
0.45

37.5

4.5

1
4
2
1

Total-----------------------------------------

1.44

-8

6.51

Grand Total = 144.63 lakhs.

Benefits
Provident fund @ 8.33%
E.S.I @ 4%
H.R.A. @ 20 %
Bonus @ 8.33 %
Medical @ 10 %

For basic salary upto 3000 p.m.

10.00 %
4.00 %
20.00%
8.33 %
10.00 %

For basic salary exceeding 3000

p.m.
10.00%
4.00 %
20.00%
0.00 %
10.00%

53

Form V: particulars of Factory & non- Factory buildings

Sr.
no.
1.

2.
a.

b.
c.
d.

e.

f.

g.

Particulars

Type of
construction

Floor

Length(M)

Width
(M)

Height
(M)

Area
(M2)
968

Rate
(Rs. /
M2)
4000

44

22

12

38.72

15

10

150

2800

4.2

1
1
1

10
3
20

5
3
12

5
4
4

50
9
240

2800
2800
3000

1.4
1.4
7.2

15

10

150

2600

3.9

25

20

3.6

500

4000

20.0

15

Open

120

2500

3.0

MS fabricated
-structure, sand
cement plaster
on inside &
outside, RCC
roof
Factory building for auxiliary services:
Factory
building

Electric
substation

Masonry
structure, ACC
sheet roofing
over MS
fabricated
truss/portal,
PCC flooring,
sand cement
plaster on inside
& outside
D.G Room
Do
Operation cabin
Do
Laboratory
Masonry
structure, CB
wall, RCC
roofing, AS
flooring.
Workshop
Masonry
structure, CB
wall, RCC
roofing, AS
flooring.
Control room
RCC framed
structure, RCC
roof, necessary
work in carcus
wall, sand
cement plaster,
centralized AC.
Water treatment
MS tubular
plant
open wed
structure AC
roof cladding
IPS flooring

Total

54

h.
i.

Cooling tower
area
Effluent
treatment plant

j.

Fire fighting

k.
l.

Learning center
Boiler house

3.

4.
a.

b.

c.

d.

Open yard

10

Open

70

1100

0.77

MS tubular
open web
structure, Ac
roof, IPS
flooring
Masonry
structure. CB
wall, RCC
roofing, AS
flooring
Do.
MS tubular
open wed
structure, Ac
roof.

15

Open

120

2500

3.0

12

72

3000

2.16

1
1

9
9

6
6

4
--

54
81

3000
2800

1.62
2.27

49.77

RCC framed
structure, RCC
roof, Necessary
work in carcus
wall, sand
cement plaster
on inside &
outside,
Artificial stone
flooring,
centralized Ac,
Non-factory building.
Time &
Masonry
security office
structure. CB
wall, RCC
roofing, AS
flooring
Canteen.
Masonry
structure. CB
wall, RCC
roofing, AS
flooring
Cycle stand
MS tubular
open wed
structure.
Toilet block
Masonry
structure. CB
wall, RCC
Administrative
buildings

20

12

7.2

24.

Total
cost
6000

15

10

3.4

150

3000

4.5

15

3.6

120

3600

4.32

15

2.7

45

2500

1.13

2.5

50

3000

1.5

14.4

55

e.

Car parking

f.

Worker change
room

g.

Union
room/common
room

roofing, AS
flooring, tiles
on the floor, all
required water
supply fittings.
MS tubular
open wed
structure
Masonry
structure. CB
wall, RCC
roofing, AS
flooring
Masonry
structure. CB
wall, RCC
roofing, AS
flooring

15

3.5

120

2800

3.36

10

3.4

50

3000

1.5

10

3.4

40

3000

1.2

Total-----17.51
5.
6.
a.

b.

c.

7.
a.
b.

Water
Capacity 50 m3
reservoir
Stores /Godown, ware house.
Raw
Elevated.
material
storage.
Mash
Masonry structure.
storage .
CB wall, RCC
roofing, AS
flooring.
Product
Do.
storage.
Miscellaneous building /civil works
Pond
Garden

2.2

15

12

--

180

4000

7.2

12

--

72

4000

2.88

12

--

96

4000

3.84

Total

13.92

4o/m3
1000
Total

0.48
3.0
3.48

30
20

20
15

---

600
300

Grand total----140.00

56

Form VIII: Requirement of raw material, chemicals & utility:

Basis: 100Kl/day
Working days: 330 days/year.
Sr. no.

1.

Particulate

Specific
consumption
kg/hr

Annual
requirement
(Tons)

Delivered price
(Rs./ton)

Total cost.
(lakhs)

75565
.8325

5266 tons
65.99

9200

484.50
110.4

--

--

Specific
consumption

Annual
requirement

Delivered price

Total cost.
(lakhs)

15818.18
KWH/day
1188.96
KL/day
2.18 KL/day

5219999.40
KWH
392356.80 KL

7/- per KWH

365.79

5/- per KL

19.61

Raw material
a. Jyoti potato
b. Yeast
c. Other miscellaneous

Sr. no.

2.

Particulate

Utilities
a. Power
b. Water
c. Fuel oil

719.4 KL

-71.76
Total---------651.36

40/- per Liter

250.91
Total---------635.31

Sr. no.

Particulate

Specific
consumption

Annual
requirement

Delivered price

Total cost.
(lakhs)

3.

Alcohol container

133291 /day

43986096
/annum

4.85/- per
container

2133.32

Form IX: Estimated cost of project:

Sr.
No.
1.

Description.

Land & site development:

a. Cost of land @ 8 lakhs/acre for 4.13 acre
b. Cost of leveling (filling depth 0.5 m)
20% of land cost
c. Conveyance @ 8 % of land
d. Cost of soil testing & contour survey
e. Boundary wall(height 3m, width 25 cm, brick wall, RCC
column at 3 m center to center @ Rs. 800?- per meter

Cost (in lakhs)

Grand
total(in
lakhs)

33.04
6.60

33.04
6.60

2.64
0.30
4.59

2.64
0.30
4.59

57

(574m))
f. Cost of surface drain@ Rs. 800/- per meter (1147 meter)
g. Cost of internal road with 6 m width
h. Cost of gates @ Rs. 30000/2.

3.

4.

5.
6.

Building/civil work:
a. Main factory building
b. Factory building for auxiliary services
c. Non-factory building
d. Administrative building
e. Stores/ godown/ ware houses
f. Water reservoir
g. Miscellaneous
Main plant & equipment
a. Basic price
b. Excise duty @ 16 %
c. Sales tax @ 4%
d. Freight delivery @ 4%
e. Machinery stores/shapes@ 4%
f. Foundation & supporting structure @8 %
g. Cost of piping instrument, painting, & insulation @ 25 %
h. Erection & commissioning@ 10 %
i. Transit insurance @ 1 %
j. Handling charges @ 1 %
Technical knowhow & consultant fee:
a. Detailed design & Engg. Consultant fee@ 5.25 %
Expenses on foreign technician
Miscellaneous fixed asset:
a. Furniture
b. Office machinery

Sr.
No.

Description.

c.
d.
e.
f.
g.
h.
i.
j.
k.

Miscellaneous tools for erection

Vehicles-car / van/ ambulance
Work shop equipment
Laboratory equipment
Fie fighting equipment
100 KVA transformer & electrical equipment
Weigh bridge
EFT
D.G. Set

9.18
9.18
10.00
10.00
0.60
0.60
Sub Total (1)------------66.95
38.72
38.72
49.77
49.77
17.51
17.51
14.40
14.40
13.92
13.92
1.2
1.2
3.48
3.48
Sub Total(2)-----------140.00
1079.39
1079.39
172.69
172.69
43.174
43.174
43.174
43.174
43.174
43.174
86.34
86.34
626.03
626.03
107.93
107.93
10.79
10.79
10.79
10.79
Sub Total(3)-----------2223.48
56.66
Sub Total(4)
0.00

56.66
56.66
0.00

10.00
25.00

10.00
25.00

Cost (in lakhs)

Grand
total(in
lakhs)
12.00
30.00
10.00
50.00
10.00
80.00
14.00
60.00
12.00

12.00
30.00
10.00
50.00
10.00
80.00
14.00
60.00
12.00

58

l. Fuel storage & handling

m. Off site piping
n. Boiler(1 ton)
7.

5.00
5.00
10.00
10.00
9.00
9.00
Sub Total(6)------323.00

Preliminary Expenses:
a. Legal, Advertisement, postage, stationary expenses.
Preoperative Expenses:
a. Establishment cost
b. Interest & commitment charger on loan
c. Insurance during construction @ 1 % of fixed asset
d. Mortgage expenses(stamp duty registration charges & other legal
expenses)
e. Start up expenses @ 10 % for 1 month production cost.
f. Travelling expenses
g. Cost of feasibility report

8.

9.
10.

Contingency @ 5 % of sub Total 1+2+3+6+7+8

Margin money for working capital

25.00

25.00

15.83
191.03
25.82
33.36

15.83
191.03
25.82
33.36

13.23
13.23
4.00
4.00
5.00
5.00
Sub Total(8)------------288.27
153.33
153.33
137.65
137.65

Total cost of the Project3414.34 lakhs

Annexure I to Form IX
Interest on Term loan
Amount of Loan= 2276.227 lakhs.
ANNEXURE 1 TO FORM - IX
LOAN AMORTISATION SCHEDULE
Rs. In Lakhs
Loan amount = 2276.227 Lakhs
Rate of interest = 12.5 % p. a.
Operating
Year

Half
Yearly

Opening
Balance

Installment

Closing
Balance

Half-yearly
Interest

Yearly
Interest

1st

1
2

2276.227
2276.227

0
0

2276.22667
2276.22667

142.2641667
142.2641667

284.5283333

2nd

2276.227

126.457

2149.76963

142.2641667

276.6247685

59

2149.77

126.457

2023.31259

134.3606019

3rd

1
2

2023.313
1896.856

126.457
126.457

1896.85556
1770.39852

126.457037
118.5534722

245.0105093

4th

1
2

1770.399
1643.941

126.457
126.457

1643.94148
1517.48444

110.6499074
102.7463426

213.39625

5th

1
2

1517.484
1391.027

126.457
126.457

1391.02741
1264.57037

94.84277778
86.93921296

181.7819907

6th

1
2

1264.57
1138.113

126.457
126.457

1138.11333
1011.6563

79.03564815
71.13208333

150.1677315

7th

1
2

1011.656
885.1993

126.457
126.457

885.199259
758.742222

63.22851852
55.3249537

118.5534722

8th

1
2

758.7422
632.2852

126.457
126.457

632.285185
505.828148

47.42138889
39.51782407

86.93921296

9th

1
2

505.8281
379.3711

126.457
126.457

379.371111
252.914074

31.61425926
23.71069444

55.3249537

10th

1
2

252.9141
126.457

126.457
126.457

126.457037
0.00

15.80712963
7.903564815

23.71069444

Form VII
Means of finance:

Sl. No.
1
2
3
4
5
6
7
8
9
10

( Debt : Equity = 2 : 1 )
Particulars
Issue of ordinary share (Equity )
Issue of preference share
Issue of secured debenture
Secured long term loan
Soft loan as seed capital
Unsecured loan/Public Issue
State subsidy
Internal cash accrual
Deferred payment
Any other source
TOTAL

Rs. In Lakhs
853.585
0
0
2276.227
0
284.528
0
0
0
0
3414.340

60

FORM- VIII
ESTIMATED COST OF
PRODUCTION

raw material

Rs. In Lakhs
Operating Years
1st
2nd
3rd
4th
5th
6th
7th
8th
9th
10th
70%
80%
90%
90%
90%
90%
90%
90%
90%
90%
455.952 521.088 586.224 586.224 586.224 586.224 586.224 586.224 586.224 586.224

2
a.
b.

Utilities
Power
Water

146.153 167.032 187.911 187.911 187.911

13.727 15.688 17.649 17.649 17.649

187.911 187.911 187.911 187.911 187.911

17.649 17.649 17.649 17.649 17.649

117.945 123.842 130.034

5
7
9

136.536 143.363 150.531 158.058 165.961

6
4
6
2
1

136.573 143.402 150.572

166.006
6
3
4
158.101
1

174.306 183.021 192.172 201.781 211.870

4
7
8
4
5

34.1434 34.1434 34.1434 34.1434 34.1434

34.1434 34.1434 34.1434 34.1434 34.1434

17.7545 18.4715 19.2244 20.0149

17.0717
7
8
4
5

20.8449 21.7165 22.6316 23.5924 24.6013

8
1
2
8
9

Total Factory Overhead

187.788 195.300 203.187 211.468 220.164

7
2
4
9
4

229.294 238.881 248.947 259.517 270.615

7
6
8
3
3

COST OF PRODUCTION

910.600 1011.43 1112.91 1127.09 1141.98

1157.61 1174.02 1191.26 1209.35 1228.36

Sl.
No.

Particulars

Salary of Production Section

(with 5% increment per year)

Factory Overhead
Repair & maintenance (@4%
of
fixed asset with 5% increase
per yr.)
Insurance & Taxes (@ 1% of
fixed assets)
Misc. overhead [@ 10% of
(a+b)]

a.

b.

c.

106.98

112.329

61

62

FORM -VI B
MARGIN MONEY FOR WORKING CAPITAL
Rs. In Lakhs
Sl. No.
Particulars
Storage
Bank
100%
1st year ( 70% )
months/days Margin
capacity
Bank
Margin
(%)
value (Rs) Amount finance
money
1
RAW
1 month
75
32.568 22.7976 17.0982
5.6994
MATERIALS

2
a.
b.

UTILITIES
Power (IV)
Water

Salary &
wages (V)
[with 5% increase per
yr.]
Factory overhead (VIII)
Admn.
Expenses
( except
salary)(IX)
Sales Expenses
( except
salary)(IX)
Work in
progress
Finished goods
stock
Bills recievable/Debters

4
5

7
8
9

NET WORKING
CAPITAL

1 month
1 month

0
0

1 month

1 month
1 month

0
0

6.3269697 4.428879
0.59424242 0.41597
12.0525

12.0525

15.64833
9.342
6.5394

0 4.428879
0 0.41597
0

12.0525

0 15.64833
0
6.5394
0

1 month

5.29375 3.705625

0 3.705625
0

7 days

75

13.8167273 9.671709 7.253782 2.417927

1 month

75

102430.2 71701.14 53775.86 17925.29

1 month

75

1058.75 794.0625 264.6875

72835.15 54594.27 18240.88

63

AMOUNT TO BE BORROWED
FROM BANK
INTEREST
PER YR

[@11%per yr.]

MARGIN MONEY FOR WORKING

CAPITAL

54594.27

6005.37

18240.88

64

FORM -IX B (Contd.)

Margin Money for Working Capital

2 year ( 80% )
Bank
Margin
Amount
finance
money

Rs. In Lakhs
3rd year ( 90% )
Bank
Margin
Amount finance
money

26.0544

19.5408

6.5136

29.3112

21.9834

7.3278

5.06157576
4.75E-01

0
0

5.06157576
0.47539394

5.694273
0.534818

0
0

5.694273
0.534818

12.655125

12.655125

13.28788

13.28788

16.2750207
7.4736

0
0

16.2750207
7.4736

16.93228
8.4078

0
0

16.93228
8.4078

6.05

6.05

6.80625

6.80625

11.0533818

8.290036

2.76334545

81944.16

61458.12

20486.04

1210

907.5

302.5

nd

Sl. No.

Particulars

RAW
MATERIALS

2
a.
b.

UTILITIES
Power (IV)
Water

Salary & wages

[with 5% increase
per yr.]
Factory overhead
Admn. Expenses
( except salary)
Sales Expenses
( except salary)
Work in progress
Finished goods
stock
Bills
recievable/Debters

4
5
6
7
8
9

NET WORKING
CAPITAL

83239.2585 62393.45

12.43505 9.326291 3.108764

92187.18 69140.39
1361.25

23046.8

1020.938 340.3125

20845.8077 93641.84 70192.63 23449.21

65

AMOUNT TO BE BORROWED
FROM BANK

62393.45

70192.63

INTEREST PER YR (@ 11%

PER YEAR)

11230.82

12634.67

MARGIN MONEY ON
WORKING CAPITAL

20845.8077

23449.21

FORM -IX B (Contd.)

Margin Money for Working Capital

Sl. No.

1
2
a.
b.
3

4
5

Particulars

RAW
MATERIALS
UTILITIES
Power (IV)
Water
Salary & wages
[with 5% increase
per yr.]
Factory overhead
Admn. Expenses
( except salary)

4th year ( 90% )

Bank
Margin
Amount
finance
money

7.3278

Rs. In Lakhs
5th year ( 90% )
Bank
Margin
Amount finance
money

29.3112

21.9834

29.3112

21.9834

7.3278

5.69427273
0.53481818

0
0

5.69427273 5.694273
0.53481818 0.534818

0 5.694273
0 0.534818

13.9522753

13.9522753 14.64989

0 14.64989

17.6224046
8.4078

0
0

17.6224046 18.34703
8.4078
8.4078

0 18.34703
0
8.4078

66

6
7
8
9

Sales Expenses
( except salary)
Work in progress
Finished goods
stock
Bills
recievable/Debters

NET WORKING
CAPITAL

6.80625

12.4350545 9.326291
92187.18 69140.39
1361.25 1020.938

93643.1941 70192.63

6.80625

6.80625

3.10876364 12.43505 9.326291 3.108764

23046.795 92187.18 69140.39
340.3125

23046.8

1361.25 1020.938 340.3125

23450.5619 93644.62 70192.63 23451.98

AMOUNT TO BE BORROWED
FROM BANK

70192.63

70192.63

INTEREST PER YR (@ 11%

PER YEAR)

12634.67

12634.67

MARGIN MONEY FOR

WORKING CAPITAL

6.80625

23450.5619

23451.98

67

FORM -IX B (Contd.)

Margin Money for Working Capital

6 year ( 90% )
Bank
Margin
Amount
finance
money

Rs. In Lakhs
7th year ( 90% )
Bank
Margin
Amount finance
money

29.3112

21.9834

29.3112

5.69427273
0.53481818

0
0

15.3823835

th

Sl. No.

1
2
a.
b.
3

4
5
6

7
8
9

Particulars

RAW
MATERIALS
UTILITIES
Power (IV)
Water
Salary & wages
[with 5% increase per yr.]
Factory
overhead
Admn.
Expenses
( except salary)
Sales Expenses
( except salary)
Work in
progress
Finished goods
stock
Bills receivable/Debters

NET WORKING
CAPITAL

7.3278

21.9834

7.3278

5.69427273 5.694273
0.53481818 0.534818

0
0

5.694273
0.534818

15.3823835

16.1515

16.1515

19.1078954

19.1078954

19.9068

19.9068

8.4078

8.4078

8.4078

8.4078

6.80625

6.80625

6.80625

6.80625

12.4350545 9.326291 3.10876364 12.43505 9.326291 3.108764

92187.18
1361.25

69140.39
1020.938

23046.795
340.3125

92187.18 69140.39 23046.8

1361.25 1020.938 340.3125

93646.1097 70192.63 23453.4775 93647.68 70192.63 23455.05

AMOUNT TO BE BORROWED

70192.63

70192.63

68

FROM BANK
INTEREST PER YR (@ 11% PER
YEAR)

12634.67

MARGIN MONEY FOR WORKING

CAPITAL

12634.67

23453.4775

23455.05

FORM -IX B (Contd.)

Margin Money for Working Capital
th

Sl. No.

1
2
a.
b.
3

4
5
6
7
8

Particulars

RAW
MATERIALS
UTILITIES
Power (IV)
Water
Salary & wages
[with 5% increase
per yr.]
Factory overhead
Admn. Expenses
( except salary)
Sales Expenses
( except salary)
Work in process
Finished goods

8 year ( 90% )
Bank
Margin
Amount
finance
money

29.3112

21.9834

5.69427273
0.53481818

0
0

5.69427273 5.694273
0.53481818 0.534818

0 5.694273
0 0.534818

16.9590778

16.9590778 17.80703

0 17.80703

20.7456489
8.4078

0
0

20.7456489 21.62644
8.4078
8.4078

0 21.62644
0
8.4078

6.80625

12.4350545 9.326291
92187.18 69140.39

7.3278

Rs. In Lakhs
9th year ( 90% )
Bank
Margin
Amount finance
money

6.80625

29.3112

6.80625

21.9834

7.3278

6.80625

3.10876364 12.43505 9.326291 3.108764

23046.795 92187.18 69140.39 23046.8

69

stock
Bills
recievable/Debters

1361.25 1020.938

NET WORKING
CAPITAL

93649.3241 70192.63

340.3125

1361.25 1020.938 340.3125

23456.6919 93651.05 70192.63 23458.42

AMOUNT TO BE BPRROWED
FROM BANK

70192.63

70192.63

INTEREST PER YR (@ 11%

PER YEAR)

12634.67

12634.67

MARGIN MONEY FOR

WORKING CAPITAL

23456.6919

23458.42

FORM -IX B (Contd.)

Margin Money for Working Capital

Sl. No.

Particulars

Rs. In Lakhs
10th year ( 90% )
Bank
Margin
Amount finance
money

1
2
a.
b.

RAW
MATERIALS
UTILITIES
Power (IV)
Water

5.694273
0.534818

0 5.694273
0 0.534818

Salary & wages

18.69738

0 18.69738

29.3112

21.9834

7.3278

70

4
5
6
7
8
9

[with 5% increase per yr.]

Factory
overhead
Adman.
Expenses
( except salary)
Sales Expenses
( except salary)
Work in process
Finished goods
stock
Bills receivable/Debters

NET WORKING
CAPITAL

22.55127

0 22.55127

8.4078

8.4078

6.80625

6.80625

12.43505 9.326291 3.108764

92187.18 69140.39 23046.8
1361.25 1020.938 340.3125

93652.87 70192.63 23460.24

AMOUNT TO BE BORROWED
FROM BANK

70192.63

INTEREST PER YR (@ 11% PER

YEAR)

12634.67

MARGIN MONEY FOR

WORKING CAPITAL

23460.24

71

FORM- IX
ESTIMATE OF WORKING RESULTS

Sl.
No.

1st
70%
910.60
07

2nd
80%
1011.4
37

3rd
90%
1112.9
17

Rs. In Lakhs
Operating Years
th
4
5th
6th
90%
90%
90%
1127.0 1141.9 1157.6
96
83
15

144.63

151.86
15

159.45
46

167.42
73

175.79
87

184.58
86

193.81
8

203.50
89

213.68
44

224.36
86

21.694
5
14.463

22.779
23
15.186
15

23.918
19
15.945
46

25.114
1
16.742
73

26.369
8
17.579
87

27.688
29
18.458
86

29.072
7
19.381
8

30.526
34
20.350
89

32.052
66
21.368
44

33.655
29
22.436
86

180.78
75

189.82
69

199.31
82

209.28
41

219.74
83

230.73
58

242.27
25

254.38
62

267.10
55

280.46
07

6.51

6.8355

63.525

72.6

7.1772
75
81.675

7.5361
39
81.675

7.9129
46
81.675

8.3085
93
81.675

8.7240
23
81.675

9.1602
24
81.675

9.6182
35
81.675

10.099
15
81.675

TOTAL SALES EXPENSES

70.035

79.435
5

88.852
28

89.211
14

89.587
95

89.983
59

90.399
02

90.835
22

91.293
23

91.774
15

Total Cost of Production (A+B+C)

1161.4
23

1280.7

1401.0
87

1425.5
91

1451.3
2

1478.3
35

1506.7
01

1536.4
85

1567.7
58

1600.5
95

Particulars

A.

COST OF PRODUCTION--(VIII)

B.

ADMINISTRATIVE EXPENSES
1 Administrative salary with 5%
increse per year. (Form V)
2 Light, postage etc.[@ 15% of 1]
3 Travelling & Conveyance[@ 10%
of admn. salary]
TOTAL ADMN. EXPENSES

C.

D.

SALES EXPENSES
1 Sales salary with 5% increase per
yr.(Form V)
2 Publicity, commission travel etc.
[@ 0.5% of sales realization]

7th
90%
1174.0
29

8th
90%
1191.2
63

9th
90%
1209.3
59

10th
90%
1228.3
6

72

E.

SALES
REALISATION

12705

14520

16335

16335

16335

16335

16335

16335

16335

16335

F.

GROSS PROFIT BEFORE INT &

11543.
58

13239.
3

14933.
91

14909.
41

14883.
68

14856.
67

14828.
3

14798.
52

14767.
24

14734.
4

284.52
8
6005.3
7

276.62
11230.
82

245.01
05
12634.
67

213.39
63
12634.
67

181.78
2
12634.
67

150.16
77
12634.
67

118.55
35
12634.
67

86.939
21
12634.
67

55.324
95
12634.
67

23.710
69
12634.
67

6289.8
98

11507.
44

12879.
68

12848.
07

12816.
46

12784.
84

12753.
23

12721.
61

12690

12658.
38

DEPRECIATION (E D)
G.
FINANCIAL
EXPENSES
1 Interest on term loan
[@ 12.5% on long term loan][Annx1,Form IX]
2 Interest on short term loan
[@ 11%; Form - VI B]
TOTAL FINANCIAL EXPENSES

H.

DEPRECIATION(SLM)[Annexure- 2]

120.84
28

120.84
28

120.84
28

120.84
28

120.84
28

120.84
28

120.84
28

120.84
28

120.84
28

120.84
28

I.

OPERATING PROFIT(F-G-H)

5132.8
36

1611.0
16

1933.3
86

1940.4
96

1946.3
82

1950.9
81

1954.2
29

1956.0
59

1956.4

1955.1
77

J.

OTHER INCOME (IF ANY)

K.

Preliminary expenses written off

0.2

0.2

0.2

0.2

0.2

0.2

0.2

0.2

0.2

0.2

L.

Profit/Loss before tax (I+J-K)

5132.6
36

1610.8
16

1933.1
86

1940.2
96

1946.1
82

1950.7
81

1954.0
29

1955.8
59

1956.2

1954.9
77

M.

Provision for taxation(Annexure-3)

1799.6
28

537.36
42

679.90
65

700.63
29

716.43
34

728.39
86

737.34
04

743.86
15

748.40
69

751.30
31

73

N.

Turn Over Tax

O.

Profit After Tax (L-M-N)

3333.0
09
170.71
7

1073.4
52
213.39
63

1253.2
79
256.07
55

1239.6
63
256.07
55

1229.7
48
256.07
55

1222.3
82
256.07
55

1216.6
89
256.07
55

1211.9
98
256.07
55

1207.7
93
256.07
55

1203.6
74
256.07
55

3162.2
92
120.84
28
0.2

860.05
6
120.84
28
0.2

997.20
36
120.84
28
0.2

983.58
79
120.84
28
0.2

973.67
3
120.84
28
0.2

966.30
69
120.84
28
0.2

960.61
34
120.84
28
0.2

955.92
24
120.84
28
0.2

951.71
79
120.84
28
0.2

947.59
89
120.84
28
0.2

Less Installment [Annexure - 1]

3283.3
35
0

981.09
88
252.91
41

1118.2
46
252.91
41

1104.6
31
252.91
41

1094.7
16
252.91
41

1087.3
5
252.91
41

1081.6
56
252.91
41

1076.9
65
252.91
41

1072.7
61
252.91
41

1068.6
42
252.91
41

NET CASH
ACCURAL

3283.3
35

728.18
47

865.33
23

851.71
66

841.80
17

834.43
56

828.74
21

824.05
11

819.84
66

815.72
76

Less dividend ( @ 20% for 1st yr.,

25% for 2nd yr., 30% from 3rd yr. on
equity capital)
P.

RETAINED PROFIT
Add depreciation (SLM)[Annexure-2]
Add Preliminary Expenses

Q.

R.

GROSS CASH ACCURAL

74

ANNEXURE 2 TO FORM - IX
DEPRECIATION
A. DECLINING BALANCE METHOD
Rs. In Lakhs
Sl.
No.

Item
Deprecia
ble
Cost

2
3
4

Rate as
per
DBM

Operating Years
1st

2nd

3rd

4th

5th

6th

7th

8th

9th

10th

2.8226
88
4.3417
47
113.84
19
29.847
66
0.729

2.5404
19
4.1246
6
85.381
44
22.385
74
0.6561

2.2863
77
3.9184
27
64.036
08
16.789
31
0.5904
9

2.0577
4
3.7225
05
48.027
06
12.591
98
0.5314
41

1.8519
66
3.5363
8
36.020
29
9.4439
85
0.4782
97

1.6667
69
3.3595
61
27.015
22
7.0829
89
0.4304
67

1.5000
92
3.1915
83
20.261
41
5.3122
42
0.3874
2

(%)

Buildings
a. Factory

38.72

10

3.872

3.4848

b. Non-factory

101.28

5.064

4.8108

Plant
equipment
Misc. Fixed
Assets
Furniture &
Office
Equipments
Vehicles

1079.39

25

283

25

269.84
75
70.75

10

10

202.38
56
53.062
5
0.9

3.1363
2
4.5702
6
151.78
92
39.796
88
0.81

30

20

4.8

3.84

3.072

2.4576

1.9660
8

1.5728
64

1.2582
91

1.0066
33

0.8053
06

TOTAL

1542.39

356.53
35

269.44
37

203.94
27

154.65
5

117.54
6

89.586
76

68.503
59

52.589
21

40.561
64

31.458
06

75

B. STRAIGHT LINE METHOD (SLM)

Rs. In Lakhs
Sl.No.
1

2
3
4
5

Item
Buildings
a Factory
b Non-factory
Plant equipment
Misc. Fixed Assets
Furniture & Office Equipments
Vehicles
TOTAL

Rate as per SLM (%)

Depreciable Cost

Depreciation per year

3.34
1.63
8.48
8.48
3.34
6.78

38.72
101.28
1079.39
283.00
10.00
30.00

1.293248
1.650864
91.53227
23.9984
0.334
2.034

1542.39

120.8428

76

ANNEXURE 3 TO FORM - IX
PROVISION FOR TAXATION

Rs. In Lakhs
Sl.
No.

Particulars

PROFIT BEFORE TAX

ADD DEPRECIATION (SLM)

LESS DEPRECIATION (DBM)

TAXABLE INCOME (1 + 2 - 3)

CUMULATIVE TAXABLE INCOME

INCOME TAX
( @ 30% cumulative taxable income
+5% surcharge)

1st

2nd

3rd

4th

5132.63
637
120.842
784
356.533
5
4896.94
566
4896.94
566
1799.62
753

1610.81
64
120.842
78
269.443
73
1462.21
55
1462.21
55
537.364
2

1933.1
86
120.84
28
203.94
27
1850.0
86
1850.0
86
679.90
65

1940.2
96
120.84
28
154.65
5
1906.4
84
1906.4
84
700.63
29

Operating Years
5th
6th

1946.1
82
120.84
28
117.54
6
1949.4
79
1949.4
79
716.43
34

1950.7
81
120.84
28
89.586
76
1982.0
37
1982.0
37
728.39
86

7th

8th

9th

10th

1954.0
29
120.84
28
68.503
59
2006.3
69
2006.3
69
737.34
04

1955.8
59
120.84
28
52.589
21
2024.1
13
2024.1
13
743.86
15

1956.2

1954.9
77
120.84
28
31.458
06
2044.3
62
2044.3
62
751.30
31

120.84
28
40.561
64
2036.4
81
2036.4
81
748.40
69

77

PROFITABILITY ANALYSIS
1.

PAY BACK PERIOD

PROJECT COST = 3414.34 Lakhs
Operating
Year
1st
2nd
3rd
4th
5th
6th

Rs. In Lakhs
Opening
Profit Before
Depreciation
Closing
Balance
Tax
( SLM )
Balance
0
5132.636373
120.842784
5011.793589
5011.793589
1610.816442
120.842784
6501.767247
6501.767247
1933.185595
120.842784
8314.110059
8314.110059
1940.296326
120.842784
10133.5636
10133.5636
1946.18188
120.842784
11958.9027
11958.9027
1950.780998
120.842784
13788.84091
The Pay-Back Period is within the 1st Year of Operation

78

2. BREAK-EVEN POINT

BASIS :

2nd year of operation at 80% capacity

Sl. No.

Rs. In Lakhs
Value

Particulars

A.
B.
1
2
3
4
C.
1
2
3
4
5

SALES REALISATION
VARIABLE COST
Raw materials
Utilities
Interest on Working Capital
Variable sales expenses

14520

Total variable cost

651.35
182.72
11230.82
72.6
12137.49

Total fixed cost

151.8615
195.3002
89.6832
276.62
120.8428
834.3077

FIXED COSTS
Salary & wages
Factory overhead
Administrative expenses
Interest on term loan
Depreciation (SLM)

Breakeven point = C/(A-B) 80 %

= 27.97 %

79

1. RETURN ON INVESTMENT :
Return on investment is the percentage relationship between profits earned by a project and the investment.
The conventional method of computing the ROI is to divide the annual profit after taxes and depreciation
plus the interest paid on long term loan and soft loan by the investment cost of the project. The investment
cost for the various years is arrived at by subtracting depreciation (SLM) from the investment cost of the
previous year.
Operating Investment

Net Profit After Taxes

and
Depreciation
(B)

Rs. In Lakhs
Interest on Long
Term
Loan
(C)

(C+B)100%
A

ROI

Year

(A)

1st

3414.34

3333.009

284.53

105.951277

2nd

3402.99

1073.452

276.62

39.6731182

3rd

3391.64

1253.279

245.01

44.1759623

4th

3380.29

1239.663

213.4

42.9862428

5th

3368.94

1229.748

181.78

41.8983551

6th

3357.59

1222.382

150.17

40.879027

7th

3346.24

1216.689

118.55

39.9027681

8th

3334.89

1211.998

86.939

38.9499238

9th

3323.54

1207.793

55.325

38.0052087

10th

3312.19

1203.674

23.711

37.0566018

80

4. RETURN ON EQUITY: Return on equity has been calculated as the ratio of the net profit after
taxes and depreciation to the total equity. The return on equity for the first ten operating years has been
shown.

Rs. In Lakhs
Return On
Equity
A*100%
B

Operating

Net Profit After Taxes and

Equity

Year

Depreciation
(A)

(B)

1st

3333.009

853.585

2nd

1073.452

853.585

125.7580962

3rd

1253.279

853.585

146.8253423

4th

1239.663

853.585

145.2302251

5th

1229.748

853.585

144.068658

6th

1222.382

853.585

143.205702

7th

1216.689

853.585

142.5386945

8th

1211.998

853.585

141.9891282

9th

1207.793

853.585

141.4965538

10th

1203.674

853.585

141.0140014

390.4718152

81

5. DEBT SERVICE COVERAGE RATIO

Sl.
No.

A.

Particulars

GROSS CASH
AVAILABLE
FOR DEBT
SERVICING
1 Gross Cash Accrual
2 Interest on term loan
Total A

B.

DEBT TO BE
SERVICED
1 Term Loan Interest
2 Term Loan Repayment

Total B

D.S.C.R. (=A/B)

Rs. In Lakhs
Operating Years
5th
6th

1st

2nd

3rd

4th

3283.3
35
284.52
8
3567.8
63

981.09877
97
276.62

1118.24
64
245.010
51
1363.25
69

1104.630
7
213.3962
5
1318.026
95

1094.7157
39
181.78199
07
1276.4977
3

284.52
8
0

276.62
252.91407
41

245.010
51
252.914
07

213.3962
5
252.9140
74

284.52
8

529.53407
41

497.924
58

12.539
58

2.3751423
02

2.73787
83

1257.7187
8

AVERAGE DEBT SERVICE COVERAGE RATIO =

7th

8th

9th

10th

1087.3
5
150.16
77
1237.5
17

1081.6
56
118.55
35
1200.2
1

1076.9651
84
86.939212
96
1163.9043
97

1072.7
61
55.324
95
1128.0
86

1068.6
42
23.710
69
1092.3
52

181.78199
07
252.91407
41

150.16
77
252.91
41

118.55
35
252.91
41

86.939212
96
252.91407
41

55.324
95
252.91
41

23.710
69
252.91
41

466.3103
24

434.69606
48

403.08
18

371.46
75

339.85328
7

308.23
9

276.62
48

2.826501
76

2.9365292
97

3.0701
4

3.2309
95

3.4247260
24

3.6597
75

3.9488
59

4.075013031

82

FORM XIII
CASH FLOW STATEMENT
Sl.
No.
A

Particulars

1
2

Source of fund
Share issue
Profit before tax with
preliminary expenses and
interest added back
Depreciation
Increase in long term
loan
Increase in borrowing for
working capital
Other income (subsidy)

2nd
(80%)

3rd
(90%)

4th
(90%)

5th
(90%)

6h
(90%)

7th
(90%)

8th
(90%)

9th
(90%)

10th
(90%)

11475.7 13171.45
3

14866.0
7

14841.5
6

14815.8 14788.8
3
2

14760.4
5

14730.6
7

14699.3
9

14666.56

67.0975
0

67.0975
0

67.0975
0

67.0975
0

67.0975 67.0975
0
0

67.0975
0

67.0975
0

67.0975
0

67.0975
0

54594.2 15598.36
7
-

7799.18
1
-

66137.1 28836.91

22732.3
4

14908.6
6

3 Decrease in term loan

54449.6 64769.78
4
0 252.9141

4 Interest in long term loan

284.528

5 Interest in short term

loan

6005.37 11230.82

10257.9
5
252.914
1
245.010
5
12634.6
7

1.35451
8
252.914
1
213.396
3
12634.6
7

3
4
5
6

Total A
B

1st
(70%)

Disposition of Fund
1 Capital expenditure for
project
2 Increase in current assets

276.62

0
-

0
-

14827.5
5

14797.7
7

14766.4
9

14733.65

1.42224 1.49335
3
6
252.914 252.914
1
1
181.782 150.167
7
12634.6 12634.6
7
7

1.56802
3
252.914
1
118.553
5
12634.6
7

1.64642
5
252.914
1
86.9392
1
12634.6
7

1.72874
6
252.914
1
55.3249
5
12634.6
7

1.815183

14882.9 14855.9
3
2
0

252.9141
23.71069
12634.67

83

6 Taxation

1857.64 580.622
4
170.717 213.3963

712.121
2
256.075
5

724.588
1
256.075
5

734.214 741.566
4
9
256.075 256.075
5
5

747.065
3
256.075
5

751.018

Total B

62767.9 77324.16

24358.7
5

14083

14061.0 14036.8
8
9

14010.8
5

Net surplus (A - B)

3369.19 -48487.2
8
NIL 3369.198

-1626.4

3369.19
8

825.656
9

7 Dividend

Opening Balance

Closing Balance

-1626.4

755.1217

256.075
5

753.649
6
256.075
5

13983.2
7

13954.3
7

13924.31

825.656 821.848 819.023 816.699 814.498 812.125

9
5
9
3
2
1
-45118 -46744.4 -45918.8
- -44277.9 -43461.2 -42646.7
45096.9

809.3438

821.848
5

819.023 816.699
9
3

814.498
2

812.125
1

809.343
8

256.0755

-41834.6

84

ECONOMIC SUMMARY:
1

TOTAL PLANT AREA

4.13 ACRE.

2.

TOTAL EQUIPMENT COST.

1275.39 LAKHS

3.

ESTIMATED COST OF PROJECT.

3414.34 LAKHS

4.

ISSUE OF ORDINARY SHARE

853.585 LAKHS

5.

SECURED LONG TERM LOAN

2276.227 LAKHS

6.

YEARLY DEPRECIATION.

120.8428 lakhs

7.

PAY BACK PERIOD.

In the first year.

8.

BREAK EVEN POINT

27.97%

9.

AVERAGE DEBT-SERVICE CONVERGENCE RATIO.

Hence, from the above summary it can easily be expected that this project is
economically viable.

4.07

85

References
Perry, R.H.- green, Dow Window ed. Chemical engineers Hand Book; 7th
edition;McGraw Hill.
Ullmanns, Encyclopedia of industrial chemistry;vol. 34,6 th edition.
Brownell, L.E & YOUNG, E.H, Process equipment design, vessel design: Mechanical;
aspects, chemical engineering Education Development,1976.
Joshi,M.V. & Mahajani, V.V, process equipment design,Mc. India 1996.
H.J. Rehm & G. Ree, Biotechnology vol.3, 1991.
http://www.google.co.in/url?sa=t&rct=j&q=Kilpimaa_pp21-23.
www.sciencedirect.com
www.thefreelibrary.com
http://commerce.nic.in/edib
Engineers India Research In, Handbook Of Biotechnology, 2006.
Max Roehr,The Biotechnology of Ethanol,2001.
Kirk & Othmer: Encyclopedia of chemical technology, vol. 5,6,12,16, 3 rd edition.
http://www.wbagrimarketingboard.gov.in/Cold%20Storage/Hooghly-I.html
http://www.99acres.com/Industrial-Lands/Plots-in-DELHI-HIGH-ROAD-HOOGHLYKolkata%20Others-for-Sale-spid-O3202160
http://www.specequipment.com/
www.icmic.com/ethanol/production-process/
Arthur Harden.Alcoholic Fermentation,2005.