Market Survey Cum Detailed Techno Economic Feasibility Report

MARKET SURVEY CUM
DETAILED TECHNO ECONOMIC

FEASIBILITY REPORT
(PROJECT FEASIBILITY REPORT)

ON
AYURVEDIC MEDICINES
Published Date: 23 March 2014
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AYURVEDIC MEDICINES
[EIRI/EDPR/1638] (J.C. 442)
CONTENTS
 Introduction 5
 Uses and application 8
 B.I.S specifications 9
 Market survey 11
 Some present manufacturers of ayurvedic medicines for diabetes 18
 Formulation of liquid ayurvedic medicine for diabetes 19
 Formulation of ayurvedic granules for diabetes (madhuhari type) 20
 Formulation of ayurvedic capsules for diabetes (deebonil type) 21
 Formulation of ayurvedic tablets for diabetes
(dybit-32 type) 22
 Manufacturing process for liquid ayurvedic medicine for diabetes 24
 Process flow diagram for the manufacture of liquid ayurvedic
medicine for diabetes 28
 Plant layout for liquid ayurvedic medicine for diabetes 30
 General detailed aspects of liquid extract of ayurvedic medicine
production by distillation 31
 Manufacturing process of ayurvedic tablets for diabetes 45
 Process flow diagram for the manufacture of ayurvedic tablets
for diabetes 51
 Manufacturing process of ayurvedic capsules for diabetes 52
 Process flow diagram for the manufacture of ayurvedic capsules
for diabetes 55
 Manufacturing process of ayurvedic granules for diabetes 56
 Plant layout of ayurvedic medicine for diabetes
(granules, capasules and tablets) 58
 Suppliers of plant and machinery 59
 Suppliers of packaging materials 66
 Liquid ayurvedic medicine for diabetes 68
 Raw materials calculations for ayurvedic medicines for diabetes
(granules, capsules & tablets) 69

APPENDIX – A :
1. Cost Of Plant Economics

2. Land & Building
3. Plant And Machinery
4. Fixed Capital Investment
5. Raw Material
6. Salary And Wages
7. Utilities And Overheads
8. Total Working Capital
9. Cost Of Production
10. Profitability Analysis
11. Break Even Point
12. Resources Of Finance
13. Interest Chart
14. Depreciation Chart
15. Cash Flow Statment
16. Projected Balance Sheet

AYURVEDIC MEDICINES
INTRODUCTION
Ayurvedic system of medicine is as old as the Vedic age. Now–a–days people

give preference to the Ayurvedic medicines as the allopathic medicines are costlier
and have side effects. Ayurvedic medicines are based on plants, animals extract
and minerals both in single ingredient drugs and compound formulations,
however, Ayurveda does not rule out any substances from being used as a
potential source of medicine.
Ayurvedic compound formulations are mainly divided into two groups viz.
(1) Kasthausadhi (predominantly plant drugs) and (2). Rasausadhi (predominantly
metals and minerals).
There are several categories of Kasthausadhi formulations such as

Asavaristra, Avleha, Grafa Churena, Taila etc. and of Rasausadhis such as
Bhasma, Pisti, Lauha, Kapibadkva, Rasayana etc.
The Ayurvedic drugs are derived from vegetable sources from the various
parts of the plant like root, leaf, flower, fruit extrude or plant as a whole.
There are about 21 varieties of compound formulations in which some of the

single drugs of animal origin (52 Nos).
Mineral origin (55 Nos.) and plant origin (351 Nos.) are used. There details
of the single drugs and other particulars can be had from the Ayurvedic formulary
of India, published by Govt. of India, Ministry of Health and Family Welfare.
Ayurvedic system has its origin in antiquity in our country which has been
dedicated to the cure of innumerable ailments. It has been most indelible
system for treatment which invariably stood to the test of time.
India abounds in medicinal plants and more than 75% of the vegetable
drugs included in pharmacopias are available in the country.
Ayurvedic medicines have been derived from variegated medicinal

plants. Forests abound in various medical plants from which various herbs are
collected and herbal/ayurvedic medicines are made out of than Ayurveda, Unani,
Siddha, Emchi (Tibetan) and Prakrtika Cikitsa (Naturopathy) are the various
traditional systems of medicine still prevalent in India.
The word `Ayurveda' is composed of two Sanskrit terms, viz., `ayus' meaning
`life' and `veda' meaning the `knowledge' and taken together, it means the
"Science of Life". However, in a limited sense, it is always used to imply "the
Science of Medicine". Charaka has defined ayurveda as the "Science through the
help of which one can obtain knowledge about the useful and harmful types of life
(hita and ahita ayus), happy and miserable types of life, things which are useful
and harmful for such types of life, the span of life as well as the very nature of life.
There has been a tremendous work on Ayurveda viz. Astaga Hardaya which
deals with drugs, their intricate composition and pharmacologial action. This
system has a great efficacy in eradicating ailments from their root cause,
though the action of Ayurvedic medicines may be slower.
DIABETES MELLITUS
It is a chronic disorder of carbohydrate metabolism due to inadequate

endogenous production or utilization of insulin and characterized by
hyperglycemia, glycosuria, polyuria, polydipsia, polyphagia, pruritus debility and
loss of weight.
As for the etiological consideration, damage of the insulin-producing cells of

the islets of longer hour is responsible for most cases of diabeties mellitus.
Continued hyperglycemia may produce such permanent damage reducing the
endogenous output of insulin.
The Ayurveidc medicine for Diabetes in India is available in the form of

Granules, tablets and Capsules. Among the ones prevelant, mention may be made
of madhuhari granules, Deebonil capsules, Dybit-32 Tablets.

Though in the modern world of hurry and scurry where people have no
time to stand and stare. They look for such medication which shows prompt
action. This they find in allopathic medication. But, however, there are lot
of side effects of Allopatic medicines. That is precisely why people are reverting
back to Herbal/Ayurvedic system of treatment which has no side effects.
The basically accounts for the prominence of Ayurvedic system of medicines.
As a consequence the demand of Ayurvedic/Herbal products is increasing day

by day.
At present there exists a great demand supply gap, therefore in order to bridge
this gap this is imperative need for more new units come up the field.

USES AND APPLICATION
Ayurvedic medicine for Diabetes is used for the treatment of Diabetes, by

controlling the blood sugar level.

B.I.S. SPECIFICATIONS
There are no Indian Standard prescribed for manufacturing Ayurvedic

products viz. Ayurvedic medicine for Diabetes.
For more Information contact at:
Headquarters:
Manak Bhavan, 9 Bahadur Shah Zafar Marg,

New Delhi-110 002
91 11 23238821,23233375,23239402
91 23238821, 23239399 (Fax)
sales@bis.org.intandards Institution.
Sr.No. Sales Outlets Address Telephone No/Fax/e-mail

01. Director (Sales) 91-11-
Manak Bhawan, 23238821,23233375,23239402
9, Bahadur Shah Zafar Marg 91-23238821, 23239399(Fax)
New Delhi-110 002
02. Western Regional Office Phone 022-28329295
Manakalaya, Fax 28374231
Plot No. E-9, MIDC, Road No. Email: saleswro@bis.org.in
8, Behind Telephone
Exchange, Andheri (East),
Mumbai-400 093
03. Eastern Regional Office 033-232053243
5, Chowringhee Approach 91-33-23377459(Fax)
P.O. Princep Street, ero@bis.org.in
Kolkata-700 012
04. Northern Regional Office 91-0172 2665512
SCO 335-336, Sector 34-A 91-0172 2602025 (Fax)
Chandigarh-160 022 910172-2609285,
2664750,2624136(PBX)
nro@bis.org.in
05. Southern Regional Office 91-044-22542315,
C.I.T. Campus, IV Cross Road 22541584,22541470
Chennai-600 013 91-044-22541087 (Fax)
sro@bis.org.in

NOTE :- The use of the ISI Certification Mark is governed by the provisions of the Indian
Standards Institution (Certification Marks) Act and the Rules and Regulations made
thereunder. The ISI Mark on products covered by an Indian Standard conveys the
assurance that they have been produced to comply with the requirements of that
standard under a well-defined system of inspection, testing and quality control which is
devised and supervised by ISI and operated by the producer. ISI marked products are
also continuously checked by ISI for conformity to that standard as a further
safeguard. Details of conditions under which a licence for the use of the ISI Certification
Mark may be granted to manufacturers or processors, may be obtained from the Indian
Standards Institution.

MARKET SURVEY

Thirdly firms need to spend time on patient education, Letting both Indian
and global consumers know the benefits of using Ayurveda. I do feel that many
young Indians associate Ayurveda with the older vision of India and do not want
to adopt it. During a recent trip to a Natu Marandu (Traditional Ayurveda )Shop in
Chennai I saw that most customers were in the age group of 50 plus. As a matter
of fact many in my peer group found it funny that I was buying traditional
medicine despite being trained in Allopathy.
In conclusion I feel the future of Ayurveda is in our hands. Firms need to get
smart about branding, manufacturing and patient education for us to get our due
in the global market place.

SOME PRESENT MANUFACTURERS
OF AYURVEDIC MEDICINES FOR DIABETES
1) Madhuhari Granules (Net wt. 100 gms Granules per pack)
Shiv Herbal Research Lab Ltd.

Plot No. S-19
M.I.D.C. Hingna Road
Nagpur-26
2) Deebonil Capsules (40 Capsules per pack)

Manufactured by
Prabhat Ayurvedic Pharmacy ASR

2171/5, Tilak Bazar,
Khari Baoli,
Delhi
3) Dybit-32 Tablets (100 Tablets (wt. = 50 gms) per pack)
Shree Hans Ayurvedic Pharma

Shree Prem Nagar Ashram
P.O. Jwalapur,
Haridwar-249407
Phone: 7503, 6345

FORMULATION OF LIQUID AYURVEDIC MEDICINE FOR DIABETES
COMPOSITION
1. Gurmar 45%
2. Vijay Sar 25%
3. Bilva Patra 10%
4. Karela Seeds 10%
5. Jamun Guthi 10%
Bhavina, Karela Ras, Pan Ras, Methi Ras, etc.

FORMULATION OF AYURVEDIC GRANULES FOR DIABETES
(MADHUHARI TYPE)

FORMULATION OF AYURVEDIC CAPSULES FOR DIABETES
(DEEBONIL TYPE)

FORMULATION OF AYURVEDIC TABLETS FOR DIABETES
(DYBIT-32 TYPE)

Dosage of Ayurvedic Medicine for Diabetes
1) Madhuhari Granules
1/2 Tab Granules twice a day
2) Deebonil Capsules
1 Cap twice a day before meals with warm milk or as
directed.
3) Dybit-32 Tablets
2 Tablets two or three times a day
1 Tab twice a day

MANUFACTURING PROCESS
FOR LIQUID AYURVEDIC MEDICINE FOR DIABETES

The different ingredients are taken in requisite quantities.
Among these ingredients, however, those of primal signifacance are

Gumar available as leaves and Vijay Sar as wood. To prepere the liquid extract (in
concentrated form), the main methodology takes recourse to steam distillation
technique.
However, the process of extraction for essential constituents in liquid

form from these Ayurvedic herbs comprises the following steps (If herbs are
available already in cleaned form, that is well and good. In case of adhering
contaminents, cleaning, etc. is done)
1. Cleaning of the botanical herbs viz. leaves, wood, seeds, etc.

2. Washing
3. Drying
4. Disintegration into small chips
5. Steam distillation
6. Bottling of the liquid extract
1. CLEANING
These herbs, if accompanied with adhering contaminations, are subjected to

cleaning to remove the impurities.
2. WASHING
The herbs are then washed with water to wash off the adhering dust or
any other impurities.
3. DRYING
Then these herbs from which liquid is extracted is to be drawn, are

subjected to drying.

4. DISINTEGRATION (COMMINUTION)
Prior to distillation, the herbs must be disintegrated to some extent. This

disintegration process commonly terned `comminution' results in exposing
directly as many oil glands as is practically possible. It always reduces the
thickness of the material through which diffusion must occur, greatly increasing
the rate or speed of vaporization and distillation of essential oils as extract
Seeds must be thoroughly washed in order to rupture as many of the cell walls
as possible, to render the essential oil extract accessible to the passing steam.
Woody materials should be cut into short lengths in order to expose a great
number or oil glands.
Vijay Sar (wood) is disintegrated by sawing into small pieces (chips) or

chipped mechanically the woody material should be cut into short lengths in
order to expose a great number of glands.
Karela seeds can be best crushed by passing then through smooth rolls.
These rolls should be arranged so that the distance between then can be varied.
The width of this space will determine the extent of crushing obtained. Each
roll should also be equipped with a scraping device, called a "doctor blade",
which serves to keep it free of adhering crushed material.
In general, roots, stalks, guthi (viz. jamun guthi) can be best handled in a
hay or ensilage cutter, or similar device, However, leaves and thin and non-
fibrous parts of the plant viz. Gurmar leaves, silva patra can be distilled without
comminution. The cell walls in these parts are in most cases sufficiently thin and
permeable to permit rapid removal of the essential liquid extract.
5. STEAM DISTILLATION
Steam distillation process is carried out with steam. Cleaned Gurmar

leaves, Vijay Sar wood chips, Bilva patra, karela seeds and jamun guthi are
sepaartely charged (not-collectively) into the distillation still filled with water
and steam distillation operation is carried out for the purpose of collecting
the liquid Ayurvedic extract separate distillation process for each of these herbs
is based on the different vopor processes of the individual constituents which
are ultimately condensed to obtain the liquid extract.

The distillation stills employed in industry are of copper, tin-lined copper or
stainless steel and of capacity in accordance with the amount of material to be
handled. They are provided with condensers of various sorts, tubular one being
the aqueous one.
A better procedure is to constract the still with a perforated false plate

lying just above the bottom. Underneath this false bottom are steam coils, bath
closed and perforated.
In operating these stills, the charge is heated with steam in both the open
and closed pipes, thus affecting economical steam distillation. The individual
liquid extract collected by separately distilling the herbs viz. Gurmar, Vijay Sar,
Silva patra, Karela seeds & Jamun guthi in the condensing vessel being heavier
than water sinks to the bottom and the water cover prevents loss by
evaporation the aqueous layer in the condensate frequently carries in solution,
valuable constituents, and is consequently pumped back into the still to supply
some of the necessary water.
The indvidual condensate liquid extracts collected separately by distillation are

then mixed together to prepare the final liquid extract (concentrated) as liquid
Ayurvedic medicine.
QUALITY TESTING
Quality testing of the product i.e. liquid extract is done to ensure that it is of
requisite quality.
BOTTLING
Then, this is filled in suitable containers and dispatched for marketing.
NOTE The concentrated extract may be diluted to desire degree and accordingly
selling price will vary i.e. reduced.

PROCESS FLOW DIAGRAM FOR THE MANUFACTURE OF LIQUID
AYURVEDIC MEDICINE FOR DIABETES

PLANT LAYOUT FOR LIQUID AYURVEDIC MEDICINE
FOR DIABETES
TOTAL LAND AREA = 500 SQ.MT.

GENERAL DETAILED ASPECTS OF LIQUID EXTRACT OF
AYURVEDIC MEDICINE PRODUCTION BY DISTILLATION
In general, the term `distillation' applies to vaporization process in which the

vapour evolved is recovered, usually by condensation. The main purpose of
distillation is either the separation of volatile components from nonvolatile
materials or the separation of mixture of volatile components. The separation of
volatile components from non-volatile materials is carried out by simple
distillation in which material is placed in a still and heated and the vapour
removed and condensed. This process is frequently used for high boiling organic
compounds, to prevent thermal degradation of the product, with addition of
steam or water, termed as water, steam/water, steam distillation.
The quality of essential oil produced is, of course, dependent on the plant
material but also the general design and operation of distillation equipment. the
distillation unit plays important role in the production of essential oils. It is the
controlling link between these oils in their natural state within the tissues of the
plant and their liberated form which are utilized for many purposes. The
yields and qualities of commercial essential oils depend on the correct design
and operation of the still.
Principle
Steam distillation is a simple vaporization achieved by letting in live steam

directly through the charge. The relation between the quantity of steam and that
of volatile constituent is given by the equation:
Ps Ls
-------- = --------
P LT
Where Ps is the partial pressure of the steam.
P is total pressure of the system

Ls is moles of steam issuing from the charge
LT is total moles of vapour generated (i.e., steam + volatile oil).

In order to isolate and essential oil from an aromatic plant, the material is
packed into a still, a sufficient quantity of water is added and brought to a boil,
or live steam is injected into the plant charge. Due to the influence of hot water
and steam, the essential oil will be freed from the oil glands in the plant tissue.
The vapour mixture of water and oil is condensed by indirect cooling with
water. From the condenser, distillate flows into a separator, where oil separates
automatically from the distillate water.
Mechanism of Distillation
Hydrodistillation of plant involves following main physico-chemical process:
i) Hydrodiffusion
ii) Hydrolysis
iii) Decomposition by heat.
(i) Hydrodiffusion
Diffusion of essential oil and hot water through the plant membranes is
known as hydrodiffusion. In steam distillation, the steam does not actually
penetrate the dry cell membranes. Therefore, dry plant material can be
exhausted with dry steam only when all the volatile oil has been freed from
the oil bearing cells by first thorough comminution of the plants. But, when the
plant material is soaked with water, exchange of vapours within the tissue is
based on their permeability while in swollen condition. It has been studied that
volatile oils are almost impermeable through membranes of plant cells.
Therefore, in the actual process, at the temperature of boiling water a part of
volatile oil dissolves in the water present within the glands, and this oil in
water solution permeates, by osmosis, through swollen membranes and finally
reaches the outer surface, where the oil is vaporized by passing steam.
Another aspect of hydrodiffusion is that the speed of oil vaporization is not

influenced by the volatility of oil components but by their degree of solubility in
water. therefore, the higher boiling but more water soluble constituents of an oil
in the plant tissue, distill before the lower boiling but less water soluble
constituents. Since hydrodiffusion rates are slow, distillation of uncomminuted
material takes longer time than comminuted.

Hydrolysis

Besides, being a time dependent reaction, the extent to which hydrolysis
proceeds, depends upon the time of contact between oil and water. This is one
of the disadvantages of water distillation.
(iii) Effect of heat
Almost all constituents of essential oils are unstable at high temperatures.

To obtain best quality of oil, it is necessary that the distillation is resorted to
low temperatures. The temperature in steam distillation is determined entirely
by the operating pressure, whereas in case of water distillation and water
steam distillation operating pressure is usually atmospheric.
All the above described there effects, i.e. hydrodiffusion, hydrolysis and
thermal decomposition occur simultaneously and they affect one another. The
rate of diffusion usually increases by higher temperatures and so also the
solubility of essential oil in water. The same is true for rate and extent of
hydrolysis. However, it has been observed that by (1) maintaining of low
feasible temperature; (2) use of as little water as possible in case of steam
distillation; and (3) through comminution of plant material before distillation and
uniform packing, it is possible to obtain better yield and quality of oils.
Types of Distillation and Their Techniques
There are three types of hydrodistillation techniques for isolating essential oils
from plant materials.
(1) Water distillation

(2) Water and steam distillation
(3) Direct steam distillation
1) Water Distillation
In this method, the material is completely immersed in water and water is

boiled by applying heat either by direct fire or steam jacket or closed steam coil
or open steam coil. the main characteristic of this process is that there is direct
contact between boiling water and plant material.

Adequate precautions are necessary to prevent the charge from overheating
when the still is heated by direct fire. When a steam jacket or closed steam coils
are used, there is less danger of overheating and with open steam coils this danger
is avoided. But with open steam, care must be taken to prevent accumulation of
condensed water within the still. Therefore, still should be well insulated.
During water distillation, all parts of the plant charge must be kept in motion
by boiling water and this is possible when the distillation material is charged
loosely and remains loose in the boiling water. For this reason only, water
distillation possesses one distinct advantage that it permits processing of very
finely powdered material or plant parts which by contact with live steam would
easily form lumps through which the steam connot penetrate. other practical
advantages of water distillation still a5e that these are cheap and easy to
construct and suitable for field operation. These are still quite widely used with
portable equipment in may countries.
The main disadvantage of water distillation is that complete extraction of

material is not possible. Besides, certain esters are partly hydrolysed and
sensitive substances like aldehydes tend to polymerize. Water distillation
requires a greater number of still, more space and more fuel. It demands
considerable experience and familiarity with the method. The high boiling and
somewhat water soluble oil constituents cannot be completely vaporized or
they require large quantities of steam. Thus the process becomes
uneconomical. For these reasons, water distillation is used only in case where
the plant material by its very nature cannot be processed by water and steam
distillation or by direct steam distillation.
(2) Water and Steam Distillation
In this method, the plant material is supported on a perforated grid or

screen inserted some distance above the bottom of still. The lower part of the still
is filled with water, to a level somewhat below this grid. The water is heated either
by open fire, or by jacket steam, or steam coil or open steam. The saturated low
pressure steam rises through plant material. The typical characteristics of this
method are that the steam is always fully saturated, wet and never superheater
and that the plant material is in contact with steam only and not with boiling
water.
This method is generally employed by small producers using portable

distillation equipment that can be moved from field to field, following the harvest.
The smaller units are heated by direct fire and the larger ones by steam jacket or
coil or open steam. When using direct fire, care is taken to ensure that only

bottom of the still is heated, otherwise one one of the major advantage of this
method over water distillation (no overheating of charge) will be lost.
Preparation of the plant material is also important factor in this method. Since
steam contacts the material only by rising through it, the plant charge must be so
dispersed that all parts of it are uniformly contacted by steam for obtaining high
yields.
Compared with water distillation, water and steam distillation has many
advantages, i.e., the decomposition of the oil is less, it requires less fuel, less
time and yields more oil. If, however, a plant material (for instance, rose or
orange blossoms) forms lumps under the influence of steam, the steam cannot
penetrate the charge and reach every plant material. In such a case water
distillation is opted.
One great disadvantage of water and steam distillation is that as a result of

the low pressure of the rising steam, oils, of high boiling range require large
quantities of steam for complete vaporization-hence long hours of distillation.
Water beneath the grid is usually discarded after the distillation is complete
because water soluble materials of the plant charge accumulate in the water and
they decompose during subsequent distillation imparting an objectionable note to
the essential oil.
(3) Steam Distillation at Reduced Pressure
This method is used when volatile oil is likely to decompose at high pressure,
especially for oils containing esters. However, it should be noted that in case of
distillation at reduced pressure the ratio of oil to water in the distillate is less
than when some products are distilled at atmospheric pressure, because any
lowering in the external pressure reduces the vapour pressure of all high boiling
compounds relatively much more than that of water. Besides, at reduced
pressure, because of lowering in temperature, effective log mean temperature
between water and vapours will reduce and considerable oil losses may be
expected by evaporation.
In order to achieve high rage of distillation at reduced pressure the empty

space above the liquid in the vacuum still should be kept sufficiently large to
permit the still content to boil without foaming into the condenser (this is
particularly so in respect of hydrodistillation). Besides, the condenser surface
must be larger, estimated to be 4 to 5 times than that required fro distillation at
atmospheric pressure, because of high volumetric rates and low temperature
difference.
Distillation at high pressure
Pressure in the still can be increased by inserting a throttling valve in the

vapour line connecting the still and condenser. Steam distillation at high
pressure is useful for certain purposes, for instances, for the hydrolysis of ester
if so desired. There is another advantage, i.e., relative to steam pressure, the
vapour pressure of higher boiling oil constituents increases more as the
temperature rises resulting in better oil to water ratio in the distillate. However,
from this viewpoint distillation with superheated steam is better because it
vaporizes more oil without necessitating the high pressure of the former method,
but hydrodiffusion in this case has be maintained by injecting wet steam,
intermittently to obtain good yield.
Superheated steam distillation
In this method saturated steam may be superheated within the still by means
of closed coils or jacket or outside the still in boiler. Usually, the stills employed
for distillation by superheated steam are constructed high with small diameter,
well insulated and provided with jacket. this method is with mostly used for
distilling all high boiling and chemically stable compounds and with the plants
containing high moisture (60 -80%), because hydrodiffusion is automatically
maintained by the presence of water in the plant material.
The operation can be carried out with superheated steam at reduced pressure
as well. By this methods, it is possible to regulate the temperature of the oil
vapours at will. According to degree of superheat, rise in vapour temperature will
result which means a more favourable ratio of oil in the distillate than is the case
when oil is merely steam distilled at reduced pressure without superheating.
Injection of wet steam intermittently is necessary to maintain hydrodiffusion
conditions.

Equipment
The equipment required for carrying out distillation of plant materials

depends upon the size of the operation and the type of distillation to be used.
But, however, in industrial practice, the following items are necessary:
i) Still
ii) Condenser
iii) Separator
iv) Steam generator
v) Labour saving devices
(i) Still:- This serves primarily as a container for the plant material where
steam contacts the plant material and vaporizes the essential oil from the
plant material. It is usually cylindrical, vertical tank equipped with a
removable cover which can be clamped upon the cylindrical section. On or near
the top of the cylindrical section a pipe is attached for leading the vapours to the
condenser. Nearby the bottom, there is a grid or false bottom on which the
material rests and live steam is introduced through a steam line, usually a
perforated coil below false bottom.
The cylindrical section is slightly tapered to facilitate easy discharging of

material manually or mechanically. The bottom of the still is provided with a
drain valve so that any water condensing within the charge can be drawn off in
the course of distillation.
Insulation:- The still, including the top should be well insulated to conserve
heat. If insulation is neglected, excessive steam condensation occurs resulting in
bumping of particles, higher steam consumption, prolonged distillation and
inferior yield of oil. Usually all heated sections including steam lines are well
insultated.
(ii) Condenser:- This serves to convert the steam and accompanying oil
vapours into liquid. This requires the removal of an amount of heat equivalent to
the heat of vaporization of the vapours plus steam, and cooling the distillate
to near ambient temperatures. The rate which heat will be removed from the
vapours is expressed by:

Q = UA/_\tlm
Where Q is heat removed per unit time

U is over all heat transfer coefficient
A is area of heat transfer
/_\ tlm is long mean temperature difference between cooling medium
and vapours.
Condenser design is important, the most efficient type being the multi-tubular
condenser. It is compact, does not develop back pressure and permits higher
distillation rate than the single coil or pipe condenser as U valves are much
higher. Another point of importance in favour of shell and tube condenser is that
when a distillation is carried out by cohobation, the condenser being compact,
enables the distillates to be returned easily to the still from the oil separator
without recourse to a high still head connection to the condenser.
(iii) Oil Separator:- Its function is to achieve a quick and complete separation
of the oil from condensed water. Volatile oil and water are mutually insoluble.
Because of the difference in their specific gravities two liquids form two separate
layers. Since the total volume of water condensed is always greater than the
quantity of oil, water is removed continuously. Various types of designs for
separator area in practice and are designed on the basis of specific gravities and
average flow rates.
Some of the prominent types of oil separators that are commonly used are
discussed below:
(a) For oils lighter than water:- A smooth flow of condensate is assured
by inserting a long stemmed funnel, the end turning upward. The distillate
streaming from the condenser thus flows first through the funnel and oil
droplets rise slowly towards the oil layer where they merge. Water is
continuously removed through a siphon pipe.
(b) For oils heavier than water:- In this type also condensate is allowed to
flow through the funnel steam ending in the middle of the separator chamber but
there is no upward bend. The oil droplets which are heavier than water sink
slowly to the bottom and get collected there. Water is allowed to flow
continuously from the top.

When some of the essential oil fractions are lighter than water and some
heavier, the separator is then so designed that both the heavy and light parts
are collected separately. The general arrangement is shown in Fig 2.(a).
In such cases, a cylindrical or rectangular chamber is divided into two

parts by partition which ends a few inches from the bottom of the vessel. the
condensate flows into the first chamber, oil lighter than water collects in the
upper part of the first chamber and flows out from there, while oil heavier than
water sinks to the bottom of the two chambers and is drawn off from there.
In some cases when oil and water do not separate immediately in the oil
separator, especially when the difference between specific gravities of water and
oil is slight, one operational precaution must be taken into consideration that
the condensate does not flow too rapidly and disturb the oil water layer. In
such cases the chamber must be large enough to allow enough residence time
for oil droplets. The stems of the inlet funnel and water outlet are bent
upwards as shown in Fig 2(a). The performance of the separator can also be
improved by providing more compartments as shown in Fig. 2(b) and bottom of
the chamber partitions may be tapered to ensure quick and complete withdrawal
of heavy oil. The same arrangement can be obtained by connecting serially
several separators usually in the form of step like cascades.
The continuous withdrawal of oil is based on the difference in surface tensions

of oil and water. But this type is useful for small flow rates, therefore, not of much
use in industrial large scale stills.
The effect of condensate temperature:- When the oil specific gravity is slightly
less than water, condensate should be allowed to flow hot through the
separator, because with rising temperature the specific gravity of oil decreases
relatively more than that of water. The resulting greater differential in the
specific gravity between oil and water at elevated temperature causes the two
layers to separate more rapidly. But in case of the specific gravity f oil at room
temperature being slightly higher than water, the condensate should run as cold
as possible. Any increase in the temperature would further decrease the
already small differential between the specific gravity of the oil and water.
Steam generator:- Steam is most useful heating medium in process plant. In the
initial stages of steam generation, water is evaporated and is in equilibrium
with the boiling water at the pressure of generation. This water vapour is called
saturated steam and any lowering of temperature or increasing of pressure will
cause condensation to begin. High moisture in steam is undesirable, therefore,
saturated steam passes through a heat exchanger called super-heater, which is
located in a hot zone of the furnace. The steam is heated above its
saturation temperature, so that it will be sufficiently dry to provide moisture-
free steam.

Solid fuels such as coal are all fed to the furnace manually or by mechanical
means. These include the following:
a) Retort Stoker : Introduces fuel beneath the bed.

b) Spreader stoker : Distributes coal above burning bed.
c) Travelling grate
d) Pulverizer : Pulverized coal is mixed with air
and distributed vertically/ horizontally
into the combustion zone.
Liquid fuels must be atomized so that drops of fuel will burn as completely
as possible. A number of different types of burners can be obtained using
either steam or mechanical atomization. In the first type, stem flows through
nozzle with oil causing atomization. In the second type atomization is
produced by forcing oil at high pressure through a spray type nozzle.
Types of boilers:- Boilers consist of surfaces through which heat is transferred

and are designed for circulation and separation of water and steam. They may
be classified generally as fire tube or water tube types.
Fire tube boilers:- I fire tube boilers, water circulation, steam formation and
separation all take place in a large horizontal drum situated above the furnace
floor so that it will receive both radiant and convective heat. Hot gases pass over
the drum and then through the drum . Feed water is maintained above the top
row of tubes. Fire tube boilers are low in initial cost and because of the large
capacity of the drum operate will under fluctuating loads common to process
plants. They are, however, limited to low capacities and pressure.
Water tube boilers:- In water tube boilers, water and steam flow inside the
tubes and hot gases are directed across the tubes by baffles. They may be
classified as straight tube and bent tube boilers. All large high pressure boilers
are water tube types. Since the pressure is on the inside of the tubes instead
of outside, the given thickness and diameter of the tube can withstand a
higher pressure.

Standardized and packaged steam generators:- the boiler industry has
standardized construction of many boiler styles in recent past. Standardized
boilers are obtainable as packaged units which are completely assembled units
that are ready fro installation. Fire tube units are built for capacities from 200
to 8000 kg/hr of saturated steam and pressure form 10 to 600 psig. Water
tube units produce twice as much steam and upto 900 psig.
Packaged units are automatically controlled and are designed to operate

efficiently both at low and high capacities. The locomotive type (oil fed) boiler is
sometimes used for temporary installation in process plants.
(v) Labour saving devices:- In industrial large scale steam distillation practice,
large-sized distillation stills in series are common. Labour and time
requirement for charging and discharging the stills are very high if done
manually. Therefore, in order to save both time and labour, the methods, of
charging and discharging are mechanized. This is accomplished by
installing a EOT Crane with suitable devices for lifting the top of the still and
material. Automatic charging is done by placing the still sin such a position that
truck or cart can directly empty the material in the still.
The false bottom or grid supporting the plant material, is usually circular in
shape. Chains or heavy wires attached to three or four equally spaced points
around the circumference of the grid, serve as handles so that the plant charge
can be easily removed after distillation simply by lifting the grid. If charges in
excess of one quintal are to be distilled, it will be convenient to use more
than one such section, placing a new one on top of the first layer and continuing
the charge above this section. This arrangement prevents excessive packing,
assures better steam distribution, and facilitates discharging the spent material.
Coarse and specifically lighter material can be packed higher, whereas fine and
heavier material should not exceed a certain height.
Material of Construction
In the past copper was main choice for the still body, but mild steel and
aluminium are used in many cases. There is increasing use of stainless steel
as it offers many advantages, because it is non-reactive to the oils and has good
mechanical strength. When mild steel constructed still is used, the
condenser vapour lines and separator are constructed of aluminium for economy
and maintaining the quality of oil.

Wood and concrete have been used in some instances, but because of
their absorption characteristics, are suitable for distilling only one type of
material. The use of plastic materials for lining purposes is not allowed. Where
gaskets are necessary and come in contact with the oils, they should be
constructed from compressed asbestos fibre. Rubber should never be used as
packing material as it tends to be dissolved by essential oils.
Optimization
It is quite obvious that steam distillation parameters greatly influence the

total cost of production therefore, for economic production on large scale it is
always necessary to determine the optimum operating conditions so that the
total cost of production per unit weight or volume of essential oil is minimum.
The main parameters that should be considered before commercial scale
production of essential oil by steam distillation are:
(a) Batch size

(b) Comminution of plant materials and handling
(c) Steam pressure and its saturation
(d) Steam injection rate
(e) Time of distillation.
For any particular type of plant material, the optimum values of the
parameters can be determined only by experimentation and economic
considerations; in essence, series of experiments are to be conducted by keeping
all but one parameter constant and then studying the effect on overall cost of
production. Detailed investigations on optimization studies on steam distillation of
various plant materials like Mentha piperita, Eucalyptus citriodora, saussurea
lappa roots, Himalayan Cedrus deodara wood, are available in literature and are
discussed here in brief.
On pilot plant scale, studies were conducted by Narasimha et al. on steam

distillation of M.piperita and E.citriodora by keeping batch size and steam pressure
constant and it was found that at the steam injection rate of 1.2 kg/min for M.
p;iperita (80kg/batch) and 1.3 kg/min for E.citriodora (175 kg/batch) and operation
time of 45 minutes (which does not include charging, preheating and discharging
time, etc.), the cost of production per unit weight of oil was found to be minimum.
At this steam injection rate, cost of production for the total oil produced at the end
of each interval was calculated. We get optimum distillation time. Similarly, for
E. citriodora the percentage recovery vs time at different steam rates. At 1.3
kg/min percentage recovery is maximum. At this steam injection rate optimum
distillation time can be graphically evaluated.
OF AYURVEDIC TABLETS FOR DIABETES
As per the formulation specified under Ayurvedic Tablets for Diabetes, various
ingredients are taken in requisite quantities.
The process consists of the following operations :
1. Formulation
2. Mixing and milling the dry extracts
3. Granulation
4. Drying
5. Lubrication
6. Compression
7. Coating (if required)

1. FORMULATION

2. MIXING AND MILLING THE DRY INGREDIENTS

3. GRANULATION

GRANULATION BY SLUGGING
In this method the ingredients are thoroughly in the form of powder and then
they are compressed into crude tablets or slugs. Now these slugs are ground
down to the size of the granules desired, then these granules are recompressed
into the final product.
The machine known as 'Oscillating Granulator' is used for breaking the slugs
into uniform granulation, and the machine used for initial compression of a
powder is a rotary type tabulating machine.
Oscillating granulator machine has a rotor at the bottom of the hopper which
oscillates back and forth, breaking the slugs, and forcing them through a special
steel screen of the proper mesh. In tabulating machine the powder is fed
through a satisfactory feeding device into die cavities which pass beneath it by
means of a revolving table.
4. DRYING
This method, described above, requires no granulating agent, since the

materials are always available in granular form.
It is the result of a minor vacuum created in the pores of the tablets by the
evaporation of the moisture at the surface. The granulations should be
dehydrated before they are compressed into the tablet form or the moisture
imprisoned within melt cause the tablet to crack. The drying equipments must be
flexible to a cause idle conditions to suit the product, because of the foil, all
materials dry at deferent speeds, thus requiring that under ordinary factory
conditions where a variety of products will be made. Normally dryer used for
tablet making is designed to circulate dry air through the drying closet. Dry
extracts are prepared in granular form by manufacturers.
Dry extracts of cascarasa grade, for example, is used almost exclusively in

tablet form.

5. LUBRICATION

6. COMPRESSION

ADJUSTMENT OF THE MACHINE
For Capacity
1. The lower punch is set at a low position by moving the capacity regulating
screw upwards and turning the driving wheel until punch is at its lowest point.
2. A weighed quantity of granules is placed in the die.
3. The lower punch is then moved upwards by turning the driving wheel
until the surface of the granules is level with surface of die.
4. The lower punch is now in its correct chopped position and is fixed by
moving the capacity regulating screw downwards until it presses against the
base of the machine.

Following care should be taken while compressing of tablets is being carried out :
1. Ensure proper cohesion of the particles that are being compressed.
2. Regulate the pressure carefully.
3. Secure readily soluble or medicinally active tablets.
4. Prevent adhesion of the material to any part of the machine.
QUALITY CHECK-UP
The Tablets are checked for quality.
PACKING
Then they are packed in suitable plastic packs and despatched for
marketing.
PACKING: 100 Tablets (Weight = 50 gms.) per pack

(Each Tablet = 500 mg)

PROCESS FLOW DIAGRAM FOR THE MANUFACTURE OF
AYURVEDIC TABLETS FOR DIABETES
Ingredients
As per Formulation
Grinder
Granulator

OF AYURVEDIC CAPSULES FOR DIABETES
As per the formulation specified under Deebonil type Ayurvedic capsules

recipe.
Each capsule of 500 mg contains
% age
1. Abhrak Bhasm 35 mg 7.00
2. Gurmar Buti 50 mg 10.00
3. Haldi Shudh 10 mg 2.00
4. Jamun Seeds 100 mg 20.00
5. Jaiphal 40 mg 8.00
6. Kapit Phal 30 mg 6.00
7. Karela Seeds 50 mg 10.00
8. Makar Dhwaj 35 mg 7.00
9. Parwal Bhasm 35 mg 7.00
10. Shud Shilajit 40 mg 8.00
11. Trivang Bhasm 50 mg 10.00
12. Vijay Sar 25 mg 5.00
---------- ----------
500 mg 100.00
---------- -----------
Bhavina, Karela Ras, Pan Ras, Methi Ras, etc.

MIXING
Out of these, the ingredients viz. Abhrak Bhasm, Gurmar Buti, Haldi
shudh, jamun seeds, Jaiphal, kapit phol, Karela seeds, Trivang Bhasm & Vijay
sar are in requisite quantities and introduced into a mixer fitted with a double
or single spiral agitator and mixed well.
MILLING/GRINDING
Then the above mixture is subjected to milling operation, which comprises

crushing and grinding, crushing is conducted in jaw tooth crusher. Then it is fed
to the grinder and the contents are ground well. Then, the remaining
ingredients viz. Makar Dhwaj, Pariwal Bhasm & Shud shilajit in requisite
quantities are mixed into the above staff and well ground.
CAPSULE FILLING
The powders or liquid are filled in soft and hard gelatine capsules. Hard filling
of capsules has been practiced for a long time in India. But now some semi
automatic and automatic machines are being used. The semi automatic machines
only fill the bottom of the capsules. The caps however are removed and
replaced manually. The complete automatic machines remove the caps and
clean the outside of capsules.
A semi automatic, hand operated capsules filling machine is capable of

opening and closing 200 hard gelatine capsules at a time in a single operation.
The unit is mainly fabricated out of steel and brass, chromium, with the all
contact parts made of stainless steel. The empty capsules are first loaded in
the sockers, provided in the loading keys which are then fed in the machine
where the capsules are opened, filled with the powder, pressed bad closed.
The powder to be filled is made by mixing the ingredients thoroughly with a

suitable diluent. The next step after filling the capsules, this is usually
accomplished, with held of a motorized capsules sealing machine. It can seal
30,000 to 40,000 capsules, or more in a day. All contact parts are made of
stainless steel with motor, heaters and panel lights. This machine can
process all sizes of capsules.

Soft gelatine capsules are usually employed for filling of liquids, ointments
and a modern die, capsules machine, is employed for the purposes. It is a self
contained unit capable of continuously and automatically producing finished,
capsules from a supply of gelatine mass and filling materials.
Two continuous gelatine ribbons formed by the machine, it self are brought
into vonveragence between a pair of revolging dies and an injection wedge.
Accurate filling under pressure and sealing of the capsule occurs, as dual
and coidicent in operations perfectly times against each other. Subsequent
sealing the capsules is also achieved by the same machine, this machine also
has the advantage that the contents of each capsule are accurately measured
or weighes individually by the single store of a pump. The machine contains a
back of pump so arranged that many capsules may be formed and filled
simultaneously. A provision is also made to encapsulate the products such
as vitamin A under an inert atmosphere so as to avoid oxidation of the vitamin.
After the process of filling and sealing the capsules are ready for packing
and shipments. Specially designed capsules counters for quick and accurate
counting of the capsule are available to be used as an laternate to manual
counterting, the later being a tedious and time consuming job. However, the
mechanical counting, of capsules also provide a means of producing a
product completely untouched by hand right from the manufacturing to
packaging stage provided the mechanical packaging is employed. A capsule
counter is a simple mechanism. A typical counter can count upto 2,00,000
capsules per day. These are available in various sizes.
QUALITY CHECKUP
There are checked for quality.
PACKING
Then they are packed in plastic packs and despatched for marketing.
PACKING 40 Capsules (500 mg each Capsule) per pack.

PROCESS FLOW DIAGRAM FOR THE MANUFACTURE OF
AYURVEDIC CAPSULES FOR DIABETES

MANUFACTURING PROCESS OF AYURVEDIC GRANULES
FOR DIABETES
As per the formulation for Madhukari type granules.
Composition:

MILLING/GRINDING
Then the above mixture is subjected to milling operation which comprises

crushing and grinding, crushing is conducted in jaw tooth crusher. Then it is fed
to the grinder and the contents are ground well. Then, the remaining ingredient
shilajeet in requisite quantity is taken and mixed into the above stuf and well
ground.
GRANULATION
Then the above stuff is subjected to granulation in a granulator, where

granules are formed. Though the methods of granulation in corporate Dry
granulation, moist-granulation, Granulation by preliminary compression, the
general method of granulation is to cause it rubbing through a screen or
buffer plate having a suitable mesh for producing desired size granules.
In the method of granulation by slugging, the ingredients which are

thoroughly in the form of powder, are compressed into crude tablets or slugs.
These slugs are ground down to the size of the granules desired. Subsequently
these granules are recompressed into the final product.
The machine oscillating granulator breaks the slugs into uniform granules.
In the oscillating granulator machine has a rotor at the bottom of the hopper
which oscillates back and forth, breaking the slugs and forcing them through
a special steel screen of proper mesh.
QUALITY CHECK-UP
After the granules are formed. They are checked for quality.
PACKING
Then these granules are packed in suitable plastic packs and despatched for
marketing.

PLANT LAYOUT OF AYURVEDIC MEDICINE FOR DIABETES
(GRANULES, CAPASULES AND TABLETS)
Tablet Capsule Granules

Raw Material Making Making Making
Storage 50 sq. mt. Section Section Section
Production Shed
400 sq. mt.
Finished Goods
Storage 50 sq. mt.
Adm. Building Lab.
50 sq.mt. 25 sq.mt.
vvvvvvvvvvvvvv
vvvvvvvvvvvvvv
PARKING
vvvvvvvvvvvvvv
vvvvvvvvvvvvvv
vv Security Guard
GATE Room 10 sq.mt.
TOTAL LAND AREA = 700 SQ.MT.

SUPPLIERS OF PLANT AND MACHINERY

Mixer/Blenders

Storage Tanks

Stirrers

Pulverizers

Paste Filling Equipments

Bottle Filling Machine

SUPPLIERS OF PACKAGING MATERIALS
Aluminium Caps

Pharma Bottles

Ayurvedic Herbs

LIQUID AYURVEDIC MEDICINE FOR DIABETES
Raw Materials Calculations
Basis = 1 Month
Plant Capacity = 25 Kgs/day
= 625 Kgs/Month Liquid Ayurvedic

For Diabetes
As per the Formulation of Liquid Ayurvedic medicine
Composition %Content % age Extract Recovery
(Average Recovery = 1.72%)
Considering average recovery = 1.72%
625
Total Raw Materials required/month = 100 x --------- Kg. = 36,337 kgs.
1.72
1) Gurmar (leaves) reqd. = 0.45 x 36,337 = 16,351.65 kgs.
2) Vijay Sar (Wood) reqd. = 0.25 x 36,337 = 9,084.25 kgs.
3) Bilva Patra reqd. = 0.10 x 36,337 = 3,633.70 kgs.
4) Karela Seeds reqd. = 0.10 x 36,337 = 3,633.70 kgs.
5) Jamun Guthi reqd. = 0.10 x 36,337 = 3,633.70 kgs.
RAW MATERIALS CALCULATIONS FOR AYURVEDIC MEDICINES

FOR DIABETES (GRANULES, CAPSULES & TABLETS)
1. AYURVEDIC GRANULES FOR DIABETES (MADHUHARI TYPE)
Capacity = 50 kgs/day (500 packs/day)

(1 pack = 100 gms) Granules
= 1250 kgs/month Ayurvedic Granules for Diabetes

(Madhuhari Type)
As per Formulation For Granules (Madhuhari Type)
2. AYURVEDIC CAPSULES FOR DIABETES (DEEBONIL TYPE)

Capacity = 25 kgs/day (1250 packs/day)
(1 pack = 40 capsules, Each capsule = 500 mg.)
= 625 kgs/month Ayurvedic Capsules For Diabetes

(Deebonil Type)
As per Formulation For Capsules (Deebonil Type)

3. AYURVEDIC TABLETS FOR DIABETES (DYBIT-32 TYPE)
Capacity = 25 Kgs/Day (500 packs/day)

(1 pack wt. = 50 gms. = 100 Tablets, Each Tablet = 500 mg)
= 625 Kgs/Month
1. Vang Bhasm = 0.01 x 625 = 6.25 Kgs

2. Yashad Bhasm = 0.01 x 625 = 6.25 Kgs
3. Loha Bhasm = 0.0165 x 625 = 10.31 Kgs
4. Tej Patra = 0.1365 x 625 = 85.31 Kgs
5. Triphala Churn = 0.53 x 625
---------------- = 3.31 Kgs
100
6. Vijay Sar = 0.0652 x 625 = 40.75 Kgs
7. Saptarangi = 0.0435 x 625 = 27.19 Kgs
8. Gudmar = 0.0435 x 625 = 27.19 Kgs
9. Jamun Beej = 0.0435 x 625 = 27.19 Kgs
10. Tulsi Patra = 0.0218 x 625 = 27.19 Kgs
11. Bel Patra = 0.0218 x 625 = 27.19 Kgs
12. Kali Mirch = 0.0218 x 625 = 27.19 Kgs
13. Aam Beej = 0.0218 x 625 = 27.19 Kgs
14. Neem Beej = 0.0218 x 625 = 27.19 Kgs
15. Neem Patra = 0.0218 x 625 = 27.19 Kgs
16. Kundru = 0.0218 x 625 = 27.19 Kgs
17. Amla = 0.0218 x 625 = 27.19 Kgs
18. Haldi = 0.0218 x 625 = 27.19 Kgs
19. Methi Beej = 0.0218 x 625 = 27.19 Kgs
20. Gilay = 0.0218 x 625 = 27.19 Kgs

21. Patol Patra = 0.0218 x 625 = 27.19 Kgs
22. Pitta Papdc = 0.0218 x 625 = 27.19 Kgs
23. Chirayata = 0.0218 x 625 = 27.19 Kgs
24. Surphonkha = 0.0218 x 625 = 27.19 Kgs
25. Makoy = 0.0218 x 625 = 27.19 Kgs
26. Kutki = 0.0218 x 625 = 27.19 Kgs
27. Kalmegh = 0.0218 x 625 = 27.19 Kgs
28. Karela = 0.0218 x 625 = 27.19 Kgs
29. Pokher Mool = 0.0218 x 625 = 27.19 Kgs
30. Shilajeet = 0.0218 x 625 = 27.19 Kgs

AYURVEDIC MEDICINES [EIRI/EDPR/1638] J.C. 442
J.C. 442 Page A- 1
PLANT ECONOMICS
Rated Plant capacity = 100.00 Kgs./day

= 30000.00 Kgs./annum
AYURVEDIC MEDICINES
Basis
No. of working days = 25 days/month

= 300 days/annum
No. of shifts = 1 per day
One shift = 8 hours
50 Kgs/Day (500 Packs/Day) Gra

nules, 25 Kgs/Day (1250 Packs/
Day) Capsules, 25 Kgs/Day (500
Packs/Day Tablets.
Currency - Rs.

J.C. 442 Page A- 2
LAND & BUILDING
1. Total land required

700 sq.mts.
@ Rs. 5000/-per sq.mtr. Rs. 35,00,000.00
2. Production shed
400 sq.mts.
@ Rs. 10,000/-per sq.mtr. Rs. 40,00,000.00
3. Raw material storage

50 sq.mts.
@ Rs. 10,000/-per sq.mtr. Rs. 5,00,000.00
4. Finished Goods Storage

50 sq.mts.
@ Rs. 10,000/-per sq.mtr. Rs. 5,00,000.00
5. Laboratory
25 sq.mts.
@ Rs. 12,000/-per sq.mtr. Rs. 3,00,000.00
6. Administration Building
50 sq.mts.
@ Rs. 12,000/-per sq.mtr. Rs. 6,00,000.00
7. Boundary wall, gate, etc Rs. 3,00,000.00
------------------------
TOTAL Rs. 97,00,000.00
------------------------

J.C. 442 Page A- 3
PLANT & MACHINERY

J.C. 442 Page A- 4
OTHER FIXED ASSETS
1. Office equipment, furniture plus

other equipment & accessories Rs. 1,50,000.00
2. Installation costs for water,

electricity, fuel etc. Rs. 5,00,000.00
3. Pre-operative & preliminary expenses Rs. 1,00,000.00
4. Technical Know-How & consultancy Rs. 50,000.00
5. Miscellaneous Rs. 30,000.00
------------------------
TOTAL Rs. 8,30,000.00
------------------------

J.C. 442 Page A- 5
FIXED CAPITAL
1. LAND & BUILDING Rs. 97,00,000.00
2. PLANT & MACHINERY Rs. 55,57,000.00
3. OTHER FIXED ASSETS Rs. 8,30,000.00
------------------------
TOTAL Rs. 1,60,87,000.00
------------------------

J.C. 442 Page A- 6
WORKING CAPITAL REQUIREMENT/MONTH
RAW MATERIALS

------------------------
TOTAL Rs. 22,85,316.72
------------------------

J.C. 442 Page A- 11
SALARY & WAGES / MONTH
1. Manager/Technologist 1 No. Rs. 35,000.00
2. Shift Supervisor 1 No. Rs. 25,000.00
3. Chemist 1 No. Rs. 22,000.00
4. Skilled workers 5 No. Rs. 60,000.00
5. Semi skilled workers 6 No. Rs. 60,000.00
6. Unskiiled workers 8 No. Rs. 72,000.00
7. Marketing personnel 2 No. Rs. 32,000.00
8. Accountant 1 No. Rs. 14,000.00
9. Typist/Clerk 1 No. Rs. 10,000.00
10. B. Pharmacist 1 No. Rs. 20,000.00
11. Peon/Chowkidar 2 No. Rs. 18,000.00
------------------------
TOTAL Rs. 3,68,000.00
------------------------
Plus perks @ 33% p.a.

Rs. 1,21,440.00
------------------------
TOTAL Rs. 4,89,440.00
------------------------

J.C. 442 Page A- 12
UTILITIES AND OVERHEADS
------------------------
TOTAL Rs. 4,90,500.00
------------------------
Total load is 33 Kwatts

J.C. 442 Page A- 13
TOTAL WORKING CAPITAL/MONTH
1. RAW MATERIAL Rs. 22,85,316.72
2. SALARY & WAGES Rs. 4,89,440.00
3. UTILITIES & OVERHEADS Rs. 4,90,500.00
------------------------
TOTAL Rs. 32,65,256.72
------------------------
1. WORKING CAPITAL FOR 2 MONTHS Rs. 65,30,513.44
2. MARGIN MONEY FOR W/C LOAN Rs. 16,32,628.36
COST OF PROJECT
TOTAL FIXED CAPITAL Rs. 1,60,87,000.00
MARGIN MONEY
Rs. 16,32,628.36
------------------------
TOTAL Rs. 1,77,19,628.36
------------------------

J.C. 442 Page A- 14
TOTAL CAPITAL INVESTMENT
TOTAL FIXED CAPITAL Rs. 1,60,87,000.00
TOTAL WORKING CAPITAL FOR 2 MONTHS

Rs. 65,30,513.44
------------------------
TOTAL Rs. 2,26,17,513.44
------------------------

J.C. 442 Page A- 15
COST OF PRODUCTION/ANNUM
------------------------
TOTAL Rs. 4,39,97,844.95
------------------------

J.C. 442 Page A- 16
TURN OVER/ANNUM
------------------------
TOTAL Rs. 5,39,25,000.00
------------------------

PROFIT = RECEIPTS - COST OF PRODUCTION
PROFIT SALES RATIO = Profit / Sales x 100
99,27,155.05
= ------------------------------ X 100
5,39,25,000.00
= 18.41 %
RATE OF RETURN = Operating profit / T.C.I x 100
99,27,155.05
= ------------------------------ X 100
2,26,17,513.44
= 43.89 %

J.C. 442 Page A- 17
BREAK EVEN POINT (B.E.P)
Fixed Costs of the plant are as under -
1. Interests Rs. 30,53,364.31
2. Depreciation Rs. 17,61,400.00
3. 40.00% of salaries Rs. 23,49,312.00
4. 40.00% of overheads Rs. 23,54,400.00

------------------------
TOTAL Rs. 95,18,476.31
------------------------
FIXED COSTS
B.E.P. = ------------------------------ X 100
FIXED COSTS + PROFIT
95,18,476.31
= ------------------------------ X 100
95,18,476.31 + 99,27,155.05
= 48.95 %
LAND MAN RATIO = Total land / Manpower
700 : 29 :: 24 : 1

J.C. 442 Page A- 18
RESOURCES FOR FINANCE
1. Term loans from Financial institutions

( 65.00 % of fixed capital )
at @13.50% p.a rate of interest Rs. 1,04,56,550.00
2. Bank loans for 3 months

( 65.00 % of working capital )
at @ 13.50% p.a rate of interest Rs. 42,44,833.74
3. Self raised capital from even

funds & loans from close ones to
meet the margin money needs at a
@ 13.50% p.a rate of interest Rs. 79,16,129.70
--------------------------
TOTAL Rs. 2,26,17,513.44
--------------------------

J.C. 442 Page A- 19
INSTALMENT PAYABLE IN 5 YEARS
================================================================================
Year To Financial To Commercial To others Total
institutions banks
(Rs. 10456550) (Rs. 4244834) (Rs. 7916130)
================================================================================
================================================================================

INTEREST PAYABLE IN 5 YEARS
================================================================================
Year On term loans On bank loans On self loans Total
(Rs. 10456550) (Rs. 4244834) (Rs. 7916130)
@ 13.50 % P.A. @ 13.50 % P.A. @ 13.50 % P.A.
================================================================================
================================================================================

TOTAL REPAYMENT SCHEDULE FOR 5 YEARS
================================================================================
Year Interest Instalments Total
================================================================================
================================================================================

J.C. 442 Page A- 20
DEPRECIATION CHART FOR 5 YEARS
================================================================================
Year Building costs Plant & Machinery fur. & office equip. Total
( Rs. 6200000.00 )
( Rs. 5557000.00 ) ( Rs. 150000.00 )
@ 10.00 % P.A. @ 20.00 % P.A. @ 20.00 % P.A.
================================================================================
================================================================================

J.C. 442 Page A- 21
PROFIT ANALYSIS FOR 5 YEARS
================================================================================================
YR CAP. Sales Mfg. Gross Depre- Interest Net profit Net profit
UTIL Expenses Profit ciation before tax after tax
@ 35.00%
================================================================================================
================================================================================================

CASH FLOW STATEMENT FOR 5 YEARS
================================================================================
YR CAP. Net profit Depre- Cash Repayment of Net surplus
UTIL (after tax) ciation in hand Instalment
================================================================================
================================================================================

PROJECTED BALANCE SHEET FOR ( 5 YEARS)
LIABILITIES ASSETS
1. Promoters Capital 79,16,129 1. Fixed Assets 1,19,07,000

2. Term loans 1,04,56,550 2. Interest during Construction
period @ 13.50 p.a. 11,96,074
3. W/C loan 42,44,833 3. Surplus funds 95,14,438
-------------------- --------------------
2,26,17,512 2,26,17,512
-------------------- --------------------
1 Year 70 % Capacity
1. Promoters capital 79,16,129 1. Depreciated value

2. Net Surplus 23,99,101 of Fixed Assets 1,01,45,600
3. Term loans 83,65,240 2. Working Capital 45,71,359
4. W/C loans 33,95,867 3. Surplus funds 73,59,378
-------------------- --------------------
2,20,76,337 2,20,76,337
-------------------- --------------------
1. Promoters capital 1,03,15,230 1. Depreciated value

2. Net Surplus 36,52,666 of Fixed Assets 86,74,480
4. W/C loans 25,46,901 3. Surplus funds 88,89,837
-------------------- --------------------
2,27,88,727 2,27,88,727
-------------------- --------------------

4. W/C loans 16,97,935 3. Surplus funds 1,11,48,411
-------------------- --------------------
2,38,14,605 2,38,14,605
-------------------- --------------------


4. W/C loans 8,48,969 3. Surplus funds 1,38,44,064
-------------------- --------------------
2,61,26,934 2,61,26,934
-------------------- --------------------

3. Term loans 0 2. Working Capital 65,30,513
4. W/C loans 0 3. Surplus funds 1,76,76,076
-------------------- --------------------
2,97,37,698 2,97,37,698
-------------------- --------------------

We hope MARKET SURVEY CUM DETAILED TECHNO ECONOMIC FEASIBILITY REPORT in
your possession at the time, must have conveyed you the elementary idea on process data, market
and economics. We feel you must have now taken a decision to finalize your project plan for
ultimate implementation in a successful manner. Before you go ahead, we suggest you to take our
PRACTICAL PROJECT EXECUTION KNOW HOW REPORT.
"EIRI" offer you PRACTICAL PROJECT EXECUTION KNOW HOW REPORT on this project.
Brief contents of PRACTICAL PROJECT EXECUTION KNOW HOW REPORT are as under :
THIS REPORT SHALL BE FULLY BASE DON CLIENT’S REQUIREMENTS WITH THEIR
PROJECT COST, CAPACITY, PROJECT LOCATION WITH DETAILED MARKET SURVEY,
DELIVERY SHALL BE MADE WITHIN 20 DAYS ON RECEIPT OF 60% AS ADVANCE- EIRI
• Introduction
• Properties
• BIS (Bureau of Indian Standard) Specifications & Requirements
• Uses & Applications
• Present Indian Market Position
• Expected Future Demand
• Export & Import Statistics Data
• Names and Addresses of Existing Units (Present Manufactures)
• List of Plant & Machineries
• Miscellaneous Items and Accessories
• Instruments, Laboratory Equipments and Accessories
• Electrification, Electric Load and Water
• Maintenance, Suppliers/Manufacturers of Plant and Machineries
• Process of Manufacture with formulae if applicable
• Flow Sheet Diagram
• List of Raw Materials
• Availability of Raw Materials
• Requirement of Staff & Labour
• Personnel Management
• Skilled & Unskilled Labour
• Requirement of Land Area
• Built up Area
• Plant Layout.
along with financial details as under:
Summary of Capital Cost of Project

Land & Side Development Exp.
Buildings
Plant & Machineries
Misc. Fixed Assets
Technical Know how Fees & Exp.
Preliminary Expenses
Pre-operative Expenses
Provision for Contingencies
below mentioned financial statements (Annexure) will be for 5 to 10 Years

Annexure :: Cost of Project and Means of Finance
Annexure :: Output, Profitability and Cash Flow Chart
Annexure :: Assessment of Working Capital requirements
Annexure :: Sources of Finance
Annexure :: Balance Sheets
Annexure :: Break-Even Analysis and profitability analysis.
Annexure :: Quantitative Details-Output/Sales/Stocks
Annexure :: Sales Realisation
Annexure :: Raw Material Cost
Annexure :: Other Raw Material Cost
Annexure :: Packing Material Cost
Annexure :: Consumables, Store etc.,
Annexure :: Employees Expenses
Annexure :: Fuel Expenses
Annexure :: Power/Electricity Expenses
Annexure :: Repairs & Maintenance Exp.
Annexure :: Other Mfg. Expenses
Annexure :: Administration Expenses
Annexure :: Selling Expenses
Annexure :: Depreciation Charges - Profitability
Annexure :: Depreciation Charges
Annexure :: Interest and Repayment - Term Loans
Annexure :: Tax on Profit
Annexure :: Assumptions for Profitability workings
Annexure :: Assessment of Working Capital
Engineers India Research Institute (EIRI) is a renowned name in the industrial world for
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MARKET SURVEY CUM

DETAILED TECHNO ECONOMIC

(PROJECT FEASIBILITY REPORT)

INDENTIFICATION & EVALUATION DIVISION FOR HI-TECH PROJECTS

EIRI CONSULTANTS & ENGINEERS

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ENGINEERS INDIA RESEARCH INSTITUTE, 4449 NAI SARAK, DELHI-110006

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1. Cost Of Plant Economics

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Ayurvedic system of medicine is as old as the Vedic age. Now–a–days people

There are several categories of Kasthausadhi formulations such as

There are about 21 varieties of compound formulations in which some of the

Ayurvedic medicines have been derived from variegated medicinal

It is a chronic disorder of carbohydrate metabolism due to inadequate

As for the etiological consideration, damage of the insulin-producing cells of

The Ayurveidc medicine for Diabetes in India is available in the form of

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The basically accounts for the prominence of Ayurvedic system of medicines.

As a consequence the demand of Ayurvedic/Herbal products is increasing day

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Ayurvedic medicine for Diabetes is used for the treatment of Diabetes, by

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There are no Indian Standard prescribed for manufacturing Ayurvedic

For more Information contact at:

Manak Bhavan, 9 Bahadur Shah Zafar Marg,

Sr.No. Sales Outlets Address Telephone No/Fax/e-mail

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1) Madhuhari Granules (Net wt. 100 gms Granules per pack)

Shiv Herbal Research Lab Ltd.

2) Deebonil Capsules (40 Capsules per pack)

Prabhat Ayurvedic Pharmacy ASR

3) Dybit-32 Tablets (100 Tablets (wt. = 50 gms) per pack)

Shree Hans Ayurvedic Pharma

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Bhavina, Karela Ras, Pan Ras, Methi Ras, etc.

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Among these ingredients, however, those of primal signifacance are

However, the process of extraction for essential constituents in liquid

1. Cleaning of the botanical herbs viz. leaves, wood, seeds, etc.

These herbs, if accompanied with adhering contaminations, are subjected to

Then these herbs from which liquid is extracted is to be drawn, are

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Prior to distillation, the herbs must be disintegrated to some extent. This

Vijay Sar (wood) is disintegrated by sawing into small pieces (chips) or

Steam distillation process is carried out with steam. Cleaned Gurmar

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A better procedure is to constract the still with a perforated false plate

The indvidual condensate liquid extracts collected separately by distillation are

Then, this is filled in suitable containers and dispatched for marketing.

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TOTAL LAND AREA = 500 SQ.MT.

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