1

UNIVERSITAS INDONESIA

ALPHA AMYLASE ENZYME PRODUCTION FOR TEXTILE

INDUSTRY
Report Assignment 5
GROUP 25
GROUP PERSONNEL:
Anggoro Wiseso
Dwini Normayulisa Putri
Firnanda Rizki Riasta
Khansa Zahrani
Muhammad Fahmi Zaenal Abidin
Rizka Margi Astuty

(1206212514)
(1206238482)
(1206212464)
(1206239724)
(1206212520)
(1206212470)

CHEMICAL ENGINEERING DEPARTMENT

ENGINEERING FACULTY
UNIVERSITAS INDONESIA
DEPOK 2015
EXECUTIVE SUMMARY
As we know the current fashion world is undergoing rapid development.
This also had an impact on fashion in Indonesia. At this time the textile industry
and Textile Products (TPT) Indonesia still play a pretty big role against the
national economy. In 2006, the industry contributes 11.7% amounting to the total
national exports, 20.2% against the national trade surplus, and 3.8% against the
formation of the gross domestic product (GDP). While the absorption of labor in
this industry is also big enough reach 1.84 million workforce. Until 2006, the
number of textile industry Indonesia achieve 2.699 company, with a total

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investment of Rp 135,7 trillion. This amount is only experienced a slight increase

over the previous year which amounted to 2,656 company. Location of TPT
concentrated industry in West Java (57 percent), Central Java (14 percent), and
Jakarta (17 percent). The rest are scattered in East Java, Bali, Sumatra and
Yogyakarta.
Textile industry needs alpha amylases for desizing agent for removing
starch from the grey cloth before its further processing in bleaching and dying.
Alpha amylase enzyme is enzyme that catalyses the hydrolysis of internal -1, 4glycosidic linkages in starch in low moleculer weight products, such as flucose,
maltose, and maltotriose units. The alpha amylase can be found in microorganism,
plants, and also another higher organism. The enzyme acts on starches, glycogen,
and oligosaccharides in a random manner, liberating reducing groups.
Alpha amylases needed by the textile industry are generally produced by a
microorganism is Bacillus sp. the species most often used is the Bacillus
licheniformis, Bacillus stearothermophilus and Bacillus amyloliquefaciens,. The
substrate is used to production alpha amylase in this design is molasses, molasses
was chosen because of its availability in Indonesia. Additionally, on this design
we add wheat bran to increase its activities. According to the research that has
been done before the addition of wheat bran on the process production of alpha
amylases with the microorganisms Bacillus sp produced enzyme activity units/g
464.000.

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TABLE OF CONTENT
TABLE OF CONTENT..........................................................................................iii
LIST OF TABLES...................................................................................................v
LIST OF FIGURE...................................................................................................vi
CHAPTER 1 CAPITAL ESTIMATE.......................................................................1
1.1 Cost Index.......................................................................................................1
1.2 Capital Expenditure........................................................................................3
1.2.1
Total Equipment Cost.........................................................................3
1.2.2
Site Developmet Cost.........................................................................5
1.2.3
Offsite Facilities Cost.........................................................................5
1.2.4
Supporting Facilities Cost..................................................................6
1.2.5
Contingency Cost and Contractor Fee...............................................7
1.2.6
Piping Cost.........................................................................................7
1.2.7
Controller Cost...................................................................................8
1.2.8
Electrical Equipment Cost.................................................................8
1.2.9
Land and Building Cost.....................................................................9
1.2.10 Additional Cost................................................................................11
1.2.11 Working Capital...............................................................................12
1.2.12 Calculation of TCI............................................................................12
CHAPTER 2 OPERATING COST........................................................................14
2.1 Equity............................................................................................................14
2.2 Raw Material Cost........................................................................................14
2.3 Utility Cost...................................................................................................14
2.4 Labor Cost....................................................................................................14
2.4.1
Direct................................................................................................14
2.4.2
Indirect.............................................................................................14
2.5 Maintanance Cost.........................................................................................14
2.6 Insurance Cost..............................................................................................14
2.7 Depreciation..................................................................................................14
CHAPTER 3 MASS AND ENERGY BALANCE................................................15
3.1 Investment Feasibility Analysis....................................................................15
3.1.1
Income..............................................................................................15
3.1.2
Cash Flow........................................................................................15
3.2 Profitability Analysis....................................................................................15
3.2.1
IRR...................................................................................................15
3.2.2
NPV..................................................................................................15
3.2.3
Payback Period.................................................................................15
3.2.4
ROR/ROI.........................................................................................15
3.3 Cost Breakdown...........................................................................................15
3.4 Sensitivity Analysis......................................................................................15
3.4.1
IRR Analysis....................................................................................15
3.4.2
NPV Analysis...................................................................................15
3.4.3
Payback Period Analysis..................................................................16
CHAPTER 4 CONCLUSION................................................................................17
REFERENCES.......................................................................................................18

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LIST OF TABLES
Table 1.1 Chemical Engineerings Plant Cost Index.........................................................................1
Table 1.2 Projection of Chemical Engineerings Plant Cost Index...................................................2
Table 1.3 Total bare module cost equipment.....................................................................................3
Table 1.4 Site preparation costs.........................................................................................................5
Table 1.5 Offsite facilities calculation..............................................................................................5
Table 1.6 Supporting facilities costs..................................................................................................6
Table 1.7 Straight pipe cost................................................................................................................7
Table 1.8 Fitting and elbow pipe cost................................................................................................7
Table 1.9 Valve cost..........................................................................................................................8
Table 1.10 Controller cost..................................................................................................................8
Table 1.11 Controller cost..................................................................................................................8
Table 1.12 Building Area...................................................................................................................9
Table 1.13 Asphalt Area...................................................................................................................10
Table 1.14 Cost of Land, Building, and Asphalt..............................................................................10
Table 1.15 Additional Cost..............................................................................................................11
Table 1.16 TCI Calculation..............................................................................................................12

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LIST OF FIGURE
Figure 1.1 Starch structure..................................................................................... 3
Figure 1.2 Amylopectin model structure................................................................ 4
Figure 1.3 Amylopectin molecul............................................................................ 6
Figure 1.4 Alpha amylase structure....................................................................... 9
Figure 1.5 Alpha amylase growing...................................................................... 19
Figure 1.6 Textile Production Capacity in Indonesia........................................... 20
Figure 1.7 Alpha amylase production plant location........................................... 32
Figure 1.8 Location of Kediri district.................................................................. 32
Figure 1.9 Molasses produced by PG Pesantren Baru Kediri in 2004................. 33
Figure 2.1 Microbial Enzyme Production............................................................ 35
Figure 2.2 Schematic production process of industrial enzymes......................... 36
Figure 2.3 Blending tank for liquid phase (mixing and sterilization).................. 47
Figure 2.4 A typical submerged culture fermenter............................................... 48
Figure 2.5 Fermentation process scale up............................................................ 49
Figure 2.6 Enzyme storage tank........................................................................... 50
Figure 2.7 Microfiltration principle..................................................................... 51
Figure 2.8 Disk stack centrifugation process....................................................... 53
Figure 2.9 Ultrafiltration technology................................................................... 53
Figure 3.1 Simulation of alpha amylase plant...................................................... 68

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CHAPTER 1
CAPITAL ESTIMATE
In this chapter of economical evaluation, these following assumptions will
be used:
1. Plant lifetime is 20 year; start from 2020 (including the equipment purchase).
2. The building process will be conducted in 1 year and start to operate in the
beginning of 2021.
3. Plant total production for 1 year is 175 batch for 100% capacity (2461 kg per
batch) or approximately 430.675 ton of alpha amylase.
4. Each IDR 13,500 will be converted as USD 1.
5. Depreciation will be calculated using declining balance method.
1.1

Cost Index

The index used is the Chemical Engineering (CE) Plant Cost Index. The
table below shows the data for cost index from 2000 to 2020:
Table 1.1 Chemical Engineerings Plant Cost Index

Year
2000
2001
2002
2003
2004
2005
2006
2007
2008
2009
2010
2011
2012
2013

CEPCI
394.1
394.3
395.6
402
444.2
468.2
499.6
525.4
575.4
521.9
550.8
585.7
584.6
567.3

(Source: Chemical Engineering Online, 2014)

Using the data above, we can projected all the equipment to the purchasing
year of 2020. We plot the data above as the figure below:

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700
600

f(x)
- 34050.49
f(x) =
= 17.22x
- 0.64x^2
+ 2575.5x - 2600642.06
R = 0.92

500
400
300
200
100
0
1998

2000

2002

2004

2006

2008

2010

2012

2014

Figure 1.1 Chemical Engineering Plant Cost Index (CEPCI) Graphic

(Source: Chemical Engineering Online, 2014)

By extrapolating the data and graphic, we can get a cost index value of 726.3 on
2020, this is shown on the table below:
Table 1.2 Projection of Chemical Engineerings Plant Cost Index

Year
2014
2015
2016
2017
2018
2019
2020

CEPCI
623.0
640.2
657.5
674.7
691.9
709.1
726.3

(Source: Authors Personal Data, 2014)

To estimate the equipment cost, we assumed that all equipments are

bought in 2020. So, the projection of Chemical Engineerings Plant Cost Index
will be purchase in 2020 using 2000 or 2004 price.
1.2

Capital Expenditure

Capital expenditure (CAPEX) or total capital investment (TCI) of a plant

is a one-time expense for the design, construction, and start-up of a new plant or a
revamp of an existing plant.

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1.2.1 Total Equipment Cost

The calculation of equipment or total bare module cost is begun with the
calculation of FOB itself. FOB (Free On Board) is the bases cost of the
equipment. This is based on the parameter of each equipment. The parameters and
the formula we can see in Process and Product Design Principles by Seider
exactly in the Table 16.32 or based on the vendor (catalog) that we find at in the
internet.
To get an estimate of the purchase cost at a later date, we need to multiply
the cost from an earlier date by the ratio called cost index at that date to a base
cost index. From the planning, the equipment purchasing on this plant will be
done on 2020. So, we need to know the cost index on the year 2020 which is after
extrapolating about 726.3.
Using the design specification for all equipment, the purchase cost can be
determined, and later converted into 2020 purchase cost using the cost index.
Total bare module cost than will be depreciated.
Table 1.3 Total bare module cost equipment

N
o

Equipment
Code

Price/Unit
Qty.
(USD)

Total
Price
(USD)

Year
Basis

Cost Index
in Year
Basis

Bare
Module
Factor

CTbm in
2020
(USD)

Storage Tank
1 TK-101
2 TK-102
3 TK-103
B Mixing Tank
1

MT-101

1
1
1

16,000
2,000
24,000

16,000
2,000
24,000

2004
2004
2004

444.2
444.2
444.2

1.41
1.41
1.41

37,000
5,000
56,000

219,000

219,00
0

2,004

444.2

1.41

505,000

Table 1.3 Total bare module cost equipment (contd)

N
o
C

Equipment
Code

Price/Unit
Qty.
(USD)

Reactor
1 FT-101
2 FT-102

1
1

13,000
57,000

219,000

FT-103
Purification

Total
Price
(USD)
13,000
57,000
219,00
0

Year
Basis

Cost Index
in Year
Basis

Bare
Module
Factor

CTbm in
2020
(USD)

2,004
2,004

444.2
444.2

4.30
4.30

92,000
401,000

2,004

444.2

4.30

1,540,000

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1
2
3
4
E
1
2
3
4
5
6
7
8
9
10
11
12
13
F
1
2
3
G
1

MF-101
DS-101
UF-101
UF-102
Pump
P-101
P-102
P-103
P-104
P-105
P-106
P-107
P-108
P-109
P-110
P-111
P-112
P-113
Compressor
C-101
C-102
C-103
HE
(Autoklaf)
HE-101

1
1
1
1

17,200
12,000
96,000
2,500

17,200
12,000
96,000
2,500

2,000
2,000
2,000
2,000

394
394
394
394

3.20
3.20
2.03
3.20

102,000
71,000
360,000
15,000

1
1
1
1
1
1
1
1
1
1
1
1
1

6,000
12,000
12,000
12,000
5,000
5,000
20,000
6,000
5,000
5,000
4,000
7,000
9,000

6,000
12,000
12,000
12,000
5,000
5,000
20,000
6,000
5,000
5,000
4,000
7,000
9,000

2000
2000
2000
2000
2000
2000
2000
2000
2000
2000
2000
2000
2,000

394.1
394.1
394.1
394.1
394.1
394.1
394.1
394.1
394.1
394.1
394.1
394.1
394

3.4
3.4
3.4
3.4
3.4
3.4
3.4
3.4
3.4
3.4
3.4
3.4
3.40

37,000
74,000
74,000
74,000
31,000
31,000
123,000
37,000
31,000
31,000
25,000
43,000
56,000

20,000

2000

394

3.24

239,000

180,000

2000

394

3.24

2,151,000

320,000

40,000
360,00
0
640,00
0

2000

394

3.24

3,823,000

38,000

38,000
Total

2000

394.1

3.3

232,000
10,300,000

(Source: Private data, 2015)

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In addition, for operating the plant for 20 years or more, we should prepare
the spare parts in order to back up the first equipments work ability. We invest the
spare parts on the beginning, at the same time with the first equipment purchased.
Each of equipment will has 1 spare part. So, the cost for spare parts itself will be
the same as the total cost of equipment. We will be paying for $20,600,000 for all
of equipments and spare parts on 2020.
1.2.2 Site Developmet Cost

The calculation that are involves in site development cost are making land
surveys, land preparation (such as surface clearing, excavation, rock blasting),
fencing, roads and sidewalks, and fire protection facilities. Costs for site
preparation, Csite, can be quite substantial for grass-roots plants in the range of 1020% of total bare-module cost of the equipment. For our alpha amylase plant, we
take Csite as 15% of total bare-module cost of the equipment.
Table 1.4 Site preparation costs

No.
Component Needs
1.
Making land surveys
2.
Land preparation
3.
Fencing
4.
Roads and sidewalks
5.
Fire protection facilities
Total Site Preparation (15% of Total Bare-Module of
Equipment)

Price (USD)
154,200
616,800
231,300
308,400
231,300
1,542,000

(Source: Private data, 2015)

1.2.3 Offsite Facilities Cost

Offsites cost sites consist of some calculation which are including waste
treatment equipments, steam boiler, cooling tower, and the generator. The
summarize of Coffsite calculation is shown in the table below:

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Table 1.5 Offsite facilities calculation

No
1
2
3

Utility and Water

Waste Treatment
Facilites

Qty

W-101
CT-101
GR-101

1
1
2

Price/Unit
(USD)

Total
Price
(USD)

51,000
51,000
12,000
12,000
58,519
117,037
Total

Year
Basis

Cost Index
in Year
Basis

Bare
Module
Factor

Coffsite in
2020
(USD)

2000
2000
2014

394.1
394.1
623

1
0.67
0.73

94,000
15,000
99,700
208,700

(Source: Private data, 2015)

1.2.4 Supporting Facilities Cost

Supporting facilities equipment needed to accelerate production process

which is including in the entire area of plant building. Costs for supporting
facilities, Csupp, are costs for the equipment in the area of office, laboratory for
feed and product testing, medical facilities, and other service facilities such as
utility lines, control rooms, maintance and workshop, cafetarias, and mosque.
Below is the table of supporting facilities equipment.
Table 1.6 Supporting facilities costs

Cost/unit
(USD)

Total Cost
(USD)

Office
Faximile Machine
2
90
Telephone
10
56
Computer PC
12
259
LCD Projector
1
190
Printer + Scanner + Photocopy
2
150
Air Conditioner 2pk
4
678
Stand Dispenser
2
75
Attendance machine
2
241
Paper Shredder
1
59
Refrigerator
1
107
Office Desk (President)
1
148
Office Desk
20
74
Office Chair
20
37
Cabinet
5
74
Sofa
3
148
Table 1.6 Supporting facilities costs (contd)

180
556
3,111
190
300
2,711
150
481
59
107
148
1,481
741
370
444

Cost/unit
(USD)
370

Total Cost
(USD)
370

Equipment

Qty

Equipment

Qty

Meeting room set

1
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Receptionist desk
Whiteboard
CCTV
Truck
Forklift

1
111
2
15
10
148
4
40,741
6
11,500
Laboratory for Feed and Product Testing
Laboratory set (beaker glass, pipet, microscope,
1
2,222
quality analysis equipment, etc)
Medical Facilities
Medical set (stethoscope, tensimeter, medical
1
741
bed, first aid box, medicine, etc).
Other Service Facilities
Utility lines
741
Control rooms
1,111
Maintanance and workshop
556
Cafetarias
370
Mosque
222
Total of Supporting Facilities Equipment

111
30
1,481
162,963
69,000
2,222

741
741
1,111
556
370
222
250,950

(Source: Private data, 2015)

1.2.5 Contingency Cost and Contractor Fee

Contingency is unanticipated costs incurred during the construction of a

plant. To account for the cost of contingency, it is common to set aside 15% of the
direct permanent investment (CDPI). In addition, Guthrie adds a contractor fee of
3% of CDPI. The calculation of contingency and contractors fee will be shown in
the table of total capital investment.
1.2.6 Piping Cost

To determine the cost of piping, we should know first what kind of pipe
that we will use and how longer it is. The price for pipe is $3.4 per lb. below is the
result of piping cost.

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Table 1.7 Straight pipe cost

Requirements
Material

Nominal Pipe

Carbon Steel
Carbon Steel
Carbon Steel

3/4
1 1/4
2

Sc
ID
h
40
0.82
40
1.38
40
2.067
Total

Lengt
h (ft)

Weight
(lb/ft)

Total
Weight (lb)

131.17
85.38
234.32

1.13
2.28
3.66

148.22
194.67
857.61

Lengt
h (ft)

Weight
(lb/ft)

Total
Weight (lb)

36.18
24.12
60.3
8.61

1.13
2.28
3.66
3.66

41
55
221
32

Total Price
(USD)

500
660
2,920
4,100

(Source: Private data, 2015)

Table 1.8 Fitting and elbow pipe cost

Requirements
Material
Elbow 90
Elbow 90
Elbow 90
Tee

Nominal Pipe
3/4
1 1/4
2
2

Sc
h
40
40
40
40

ID

Total Price
(USD)

Qty

0.82
1.38
2.067
2.067
Total

6
4
10
1

(Source: Private data, 2015)

Table 1.9 Valve cost

Type
Globe Valve

Qty
28

Price/Unit (USD)
1,100

Total Price (USD)

30,800

(Source: Private data, 2015)

So, by adding all the straight pipe cost, fitting and elbow pipe cost, also
the valve cost that we have, then we will spent $36,090 for these piping system in
the plant.
1.2.7 Controller Cost

Controller is one of the very important equipment for the plant. So, we
also need the spare like the equipment. The amount of our controller are based on
the P&ID. The calculation are shown below.

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140
190
750
110
1,190

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Table 1.10 Controller cost

Type
Level Control
Flow Control
Pressure Control
Temperature Control
pH Control

Qty Spare Price/Unit (USD)

7
2
1,000
3
1
900
3
1
2,000
4
1
1,300
1
1
800
Total

Total Price (USD)

9,000
3,600
8,000
6,500
1,600
28,700

(Source: Private data, 2015)

1.2.8 Electrical Equipment Cost

For electrical installment, we need the equipment first. This consist of

lamp, stabilizer, socket outlet for manufacture, socket outlet for office, switch, and
electric panel. The amount of these equipment are adapted on the area needed.
The calculation of electrical equipment is shown in the table below:
Table 1.11 Controller cost

Component Needs

Qty

Price per Unit (USD)

Total Price (USD)

Lamp (PL-C 36 Watt)

Lamp (PL-C 24 Watt)
Stabilizer
Socket Outlet
Manufacture
Socket Outlet Office
Switch
Electric Panel

200
35
2

3
2
222

593
65
444

35

16

544

20
240
30
Total

7
1
1

148
160
17
1,971

(Source: Private data, 2015)

1.2.9 Land and Building Cost

Cost of land (Cland) is the cost to buy land as a place of plant building. The
land cost in Kediri (the place that our plant will be built) is predicting arround Rp
1,500,000/m2. Then, we will also calculate the cost of all building. This cost
included the steel and concrete that we use. We take 20% of C TBM for cost of
building (Cbuilding). There is also asphalt cost for the road and parking area. The
calculation of land and building are summarize in the table below.
Table 1.12 Building Area

Building

Size

Building Area (m2)

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Length
Laboratory
28
Office
43
Raw material storage
18
Control room
18
Product storage
18
Process area
74
Process area
92
Waste water treatment
20
Water utility
12
Electrical utility
12
Fuel utility
12
Workshop
18
Warehouse
18
Cafetaria
18
Clinic
18
Mosque
18
Total Building Area

Wide
12
12
9
6
9
24
16
15
16
16
12
4,5
4,5
12
9
12

336
516
162
108
162
1,776
1,472
300
192
192
144
81
81
216
162
216
5,900

(Source: Private data, 2015)

Table 1.13 Asphalt Area

Asphalt
Truck parking lot
Assembly point 1
Assembly point 2
Car parking lot
Motorcycle parking lot
Assembly point 3
Road 1
Road 2
Road 3
Road 4
Road 5

Size
Length
24
24
15
35
14
18
6
6
6
24
24

Wide
14
10
12
12
12
4.5
37.25
29
29
7
1.25

Asphalt Area (m2)

336
240
180
420
168
81
223.5
174
174
168
30

Table 1.13 Asphalt Area (contd)

Asphalt
Road 6
Road 7
Road 8
Road 9
Road 10
Road 11
Road 12
Road 13

Size
Length
100
25
69
71
18
7
5
7

Wide
5
6
2.5
2.5
12
37.25
22
46.5

Asphalt Area (m2)

500
150
172.5
177.5
216
260.75
110
325.5

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Road 14
Road 15
Road 16

13
25
2.5
Total Asphalt Area

12
1.25
16

156
31.25
40
4334

(Source: Private data, 2015)

Table 1.14 Cost of Land, Building, and Asphalt

Component
Land area (m)
Building Area (m)
Asphalt (m)

Qty
1023
4
5900
4334
Total

Price per qty (USD)

Total Price (USD)

111

1.137.111

348
33

2.056.000
144.467
3.337.578

(Source: Private data, 2015)

1.2.10Additional Cost

Additional costs include market research, industry design permission,

brand, water utility, electrical installment, communication line installment, and
internet network installment. Market research cost is used to make a research from
the consumer. The method to do the market research cost is consulting with some
consultant company. This method will be used to determine the production
capacity. Market research analysis is will be doing once before we begin the
production or maybe after some years of production we will do the market
research again.
Electrical installment is one of the utility installments that spend the
money so much. This cost is calculated by determining the electricity component
that we use for the plant. Because the main source of electrical utility in our plant
is from PLN, so we decide the electical installment to be done by PLN and we just
to pay it. This scenario is also conducted in communication line installment (be
done by Telkom) and internet network installment (be done by provider). The
summarize of the additional cost is shown below:
Table 1.15 Additional Cost

No.
1
2
3
5

Component
Market Research
Industry Design Permission
Brand
Water Utility

Price (USD)
370
111
741
370

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6
7
8

Electrical installment
Communication Line Installment
Internet Nework Installment
Total Additional Cost

630
33
52
2,307

(Source: Private data, 2015)

1.2.11Working Capital

Working capital is the 17.6% of C TPI (the things that we already mentioned
above from the equipment to the additional cost. The equation will be sums up on
the next sub-bab that will calculate the overall TCI.
1.2.12Calculation of TCI

The summarize of all the components of capital investment is all

calculated and shown in the tabe below:
Table 1.16 TCI Calculation

Capital Component
Total bare-module costs for equipment
Total bare-module costs for spares
Total bare-module investment (C-TBM)
Cost of site preparation (Csite)
Cost of supporting facilities (Csupp)
Cost of offsite facilities (Coff)

Ammount
(USD)
10,300,000
10,300,000
20,600,000
1,545,000
250,950
208,700

Parameter
Calculated
Calculated
Calculated
15% CTBM
Calculated
Calculated

Table 1.16 TCI Calculation (contd)

Capital Component
Total of direct permanent investment (C-DPI)
Cost of contingency
Cost of contractor's fee
Total depreciable capital (C-TDC)
Cost of piping and valve
Cost of controller
Cost of electrical equipment
Cost of land (Cland)
Cost of bulding (Cbuilding)
Cost of asphalt (for road)
Cost of market research
Cost of industry design permission
Cost of branding
Cost of water installment
Cost of electrical installment

Ammount
(USD)
22,604,650
3,090,000
618,000
26,312,650
36,090
28,700
1,971
1,137,111
2,060,000
144,467
370
111
741
370
630

Parameter
Calculated
15% CDPI
3% CDPI
Calculated
Calculated
Calculated
Calculated
Calculated
20% CTBM
Calculated
Calculated
Calculated
Calculated
Calculated
Calculated

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Cost of communication line installment

Cost of internet nework installment
Total Permanent Investment (C-TPI)
Working Capital (C-WC)

33
52
29,723,296
5,231,300

Total Capital Investment (Ctci)

34,955,000 Calculated

Calculated
Calculated
Calculated
17,6% CTPI

(Source: Private data, 2015)

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CHAPTER 2
OPERATING COST
2.1

Equity

2.2

Raw Material Cost

2.3

Utility Cost

2.4

Labor Cost

2.4.1 Direct
2.4.2 Indirect
2.5

Maintanance Cost

2.6

Insurance Cost

2.7

Depreciation

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CHAPTER 3
MASS AND ENERGY BALANCE
1.1

Investment Feasibility Analysis

This part will discuss about the mass and enegery balance for every stream
in every unit operation. The calculations are based on the production capacity and
some journals that explain about operating condition and the results, also the
electricity requirement.
1.1.1 Income
1.1.2 Cash Flow
1.2

Profitability Analysis

1.2.1 IRR
1.2.2 NPV
1.2.3 Payback Period
1.2.4 ROR/ROI
1.3

Cost Breakdown

1.4

Sensitivity Analysis

1.4.1 IRR Analysis

1.4.2 NPV Analysis
1.4.3 Payback Period Analysis

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CHAPTER 4
CONCLUSION
1. Alpha amylase enzyme is one of the needed enzyme in Indonesia. But
unfortunately, Indonesia do not have an alpha amylase plany yet.
2. One of the alpha amylase uses is in textile industry. It used in desizing process
when alpha amylase will hydrolyse the starch.
3. Bacillus licheniformis is used as our enzyme source in plant and the medium
of bacterial growth cosists of molasses, wheat bran, urea, and phosphoric acid
as the bacteria needs carbon and nitrogen.
4. Our plant is placed in Kediri, East Java, due to the availability of raw material
needed, unemployee amount, etc. The production capacity is 132 tons per year
(1 ton per batch).
5. The process that we selected are pre-treatment (wheat bran hydrolysis),
mixing

and

sterilization,

fermentation,

and

purification

(by

using

microfiltration, centrifuge, and ultrafiltration).

6. Overall mass balance of the process is shown below:
Compound
Biomass
Alpha-amylase
Glucose
Sucrose
Water
Ash
Urea
Phosporic Acid
Nitrogen
Oxygen
Carbon dioxyde
Total

Input
(kg/batch)
0
0
21397.40493
16523.80952
10963.50247
3680.892703
188.6666667
180.5555556
38559.52381
10250
0
101744.4

Output
(kg/batch)
10533.33333
776.5357667
441.6666667
1982.857143
15535.80247
3337.5
188.6666667
180.5555556
38559.52381
3925.1943
26282.72
101744.4

7. Our plant efficiency is 53% based on energy balance

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