Production of pectin

Pectin is a high molecular organic compound presenting in all plant tissues and used to support the turgor in plant cells. Pectin got it's unique profit due to it's typical features: jellying ability complexing ability

Jellying is formation in a mix with sugar of strength thick jelatinous jellies. Complexing is an ability of a pectin to interact in human organism with salts of heavy and radioactive metals, binding and removing them from the gastrointestinal tract.

Those two features are unique for pectin only and no other matters, which gave a powerful insective to it's production and made it irreplaceable in public economy.

Due to international classification pectin is food supplement marked with index E-440. Molecular mass of pectin is up to 200,000 with linear size of up to 1600 angstrems.

The main point of project is establishing the first production plant of E-440-PECTIN. For realizing of this project the purchase and assembly of contemporary highly productive equipment with technology of production and software is assumed. The equipment of pectin plant, built into the united technological line, represents in the essence the universal extract plant, capable of producing not only more than 200 types of quality pectin with the predetermined properties, but also more than 300 types of different medical and food ingredients, or many forms of different extracts, utilized in the pharmaceutical, perfume and food industry for the production of medicines, creams, ointments, lotions, colognes, perfumes and aromatizers. Today's production assortment of aromatizers includes more than 1000 types.

The estimate cost of the project is evaluated tentatively at 5 million Euro. Assuming the fact that the production of pectin in the world is considered as the highly remunerative business, which gives to its owners the possibility to obtain up to 180% of profit, the turnaround time of this plant, on the basis of the net profit, will be 0.9 years.

Most optimum by our calculations is the unit type scheme of building with the initial production capacity of 400 tons of pectin per year with the subsequent increasing in the capacity of plant.

Pectin production is the field of high technologies in the deep and complex processing of agricultural production exceptionally on the recycling of waste of production - citrus refuse, which at present nowhere and in no way is used, but is dropping to the dumps and rotting, soiling environment.

On the world market for a period of decades the steady trend of increasing in the consumption of pectin is observed in an annual level of the average 3-3.5% at the price of $14 for 1 kg. After reaching the design capacity of the plant it will manufacture only 4% of the world volume of pectin consumption, which is equal to the annual need for pectin of 2-3 large confectionery factories.

Pectin is used in 14 branches of the industry:

1. in the canning industry.
2. in the confectioner's shop.
3. in the oil-and-fat.
4. in the food-concentrate.
5. in the baking.
6. in milk industry.
7. in beverage industry.
8. in cosmetics industry.
9. in pharmaceutical industry.
10. in geology.
11. in textile production.
12. in casting industry.
13. in polygraph industry

1. Confectionery products - fruit candy, a fruit candy, sweets, jams, jams, creams, confitures, halvah, pies, a zephyr,
2. Ice-cream.
3. Mayonnaise and liquid margarines,
4. Canned food - meat, vegetable and fruit,
5. Breads and bakery products for a dietary feed(meal),
6. Lactic products - yoghurts, fermented baked milk,
7. Cheeses,
8. Medicines of a huge spectrum,
9. The dietary and preventive feed(meal) connected with a conclusion from an organism of salts of heavy metals and радионуклидов, collecting in an organism of the person at residing in the territory infected by Chernobyl, or contacting to them at work in mining and other branches,
10. Cosmetic preparations,
11. In the polygraphic industry,
12. In the textile industry,
13. In geological prospecting at drilling of chinks,
14. In foundry manufacture

In manufacture of the majority of the listed products practically there is no replacement to pectin. Alongside with manufacturing of pectin it is necessary to establish the manufacturing of wide assortment:

1. Pectin products, extracts and concentrates.
2. Pectin powders
3. Pectin pastes.
4. Pectin of medical purpose
5. An ascorbic acid
6. Dry vegetable and fruit powders
7. Various extracts
8. Food components.
9. Aromatizers.

Construction and commissioning of a factory with automated management and use of modern European technologies of extraction of pectin will be an incitement to creation of other hi-tech manufactures with the profound processing agricultural raw material, such as manufacturing of native starch, that undoubtedly will be reflected in transformation of manufacturers and on saturation of the market by a modern domestic production. This variant will create a significant competition to suppliers not only fresh oranges, tangerines and lemons for the Russian market, but also will transform pectine manufacturing plant into the large corporation.

Authors of the project have analyzed more than 20 variants of "know-how" of pectin and as a result compared analysis by such criteria, as:

1. Novelty of technology
2. Quality of released production
3. Cost of a factory
4. A designed production capacity of a factory
5. The price of released production
6. Power saving
7. Ecological safety and cleanliness
8. An opportunity of expansion and perfection of manufacture
9. Universality of work with various raw material
10. An opportunity of manufacturing of the wide nomenclature of released production
11. Image of firm
12. A time of recovery of outlay of the project
13. Technical support of the project
14. A degree of automation and comfort of working conditions, etc.

Authors have come to a choice of one firm and its technological process. The hardware-process scheme of a factory consisting of the following units is chosen:

1. Grinder
2. Calibrating machine
3. Washer
4. Centrifuge
5. An ultrasonic hydroex-tractor
6. separator
7. Neutralizer
8. Cleaner with the vibrator
9. Heater-heat exchanger
10. Vacuum evaporating device
11. Spraying dryer
12. The equipment of the first stage of clearing
13. The equipment of the second stage of clearing
14. The modifier of pectin's structure
15. The equipment of the third stage of clearing
16. Coagulator continuous action
17. Drying chamber
18. Crusher
19. Blender
20. The packing equipment
21. The local area network
22. The Control panel
23. Presscake drying equipment
24. Plant for producing of ethyl spirit

The main industrial building of a factory is the module in which all equipment included in the chosen hardware-process scheme will be located. The equipment is located in three levels and includes all workplaces, beginning with loading of raw material ending with packing finished goods. Production is completely automated and controlled by computer. Workers in a shop are operators and servicemen. With the purpose of economy partial replacement of the western equipment by domestic is supposed, but only in a case of their ability to work in an automatic mode under control of a computer. Manufacturers of such equipment are known to us. Manufacturing is all-the-year-round, in two changes every day.

Number of workers within the limits of 50 person, including:

1. Workers - 30.
2. Engineers - 6.
3. Employees - 6.
4. Logistics - 3.
5. Administration - 5.

Total investments - 4 million Euro.

Cost of the "know-how" - 0.5 million Euro.

The part of the process equipment will work in aggressive environments, under big pressure and temperature that will demand for its full restoration the accelerated rate of amortization.

Definition of the cost price of the released pectin

Article of the cost price:

1. Expenses for power resources.
2. Wages with charges.
3. Amortization of buildings, constructions and the equipment.
4. Expenses for operating repair.
5. An overhead charge.

Raw material and materials.

Prospective volume of manufacture of pectin a year - 400 tons. Initial raw material are citrus extracts.

Expenses for power resources and water.

The annual charge on the technological purposes will make:

The electric power: 2200000 kw hour

Gas: 2500000 cube M

Water: 50000 cube M

Sewer waters: 30000 cube M

Wages with the additions.

General staff includes 50 persons.

Depreciation charges and expenditure for routine repair.

The depreciation rate for complete restoration is accepted in size of 5.6% V. The depreciation rate for routine repair of equipment is accepted in size of 3%.
Overhead expenses.
Overhead expenses are accepted in size of 1.5% of total expenditures.
The structure of pectin production prime cost.
Raw material and other materials: 54.5%
Expenditures for energy resources and water: 4.6%
Wages with additions: 20.7%
Depreciation rates and expenditures for current expenditures: 18.7%
Overhead expenses: 1.5%
Total prime cost: 100%

It is necessary for the building of plant:

1. territory of 3-4 GA
2. production building with an area of 800 square meters.
3. the warehouse accomodations
4. boiler room with the hot water and the vapor, that operates on gas
5. the water pumping plant
6. substation with the power of 950 kW
7. the railroad and automobile siding tracks

Production is ecologically clean; effluents are harmless and can be used in the closed cycle.

Analyzing the hardware-process diagram of pectin plant and the contemporary methods of processing the agricultural production, project authors arrived at the following conclusion.

It is more than half of the most expensive, most unique and complex aggregates, begun to operate in the production of pectin, which can be used without any readjustment and modernization in the production of such necessary products as the native and modified starch, which Russian domestic industry is produced on the obsolete technology and on the obsolete equipment, and which today is in the great demand. In the case of installation into the general flow chart of auxiliary equipment pectin plant can simultaneously with the production of starch, produce the whole range of such highly technological products as:

1. D- glucose
2. Maltose syrup, which is a raw material for 72% of maltose, 18% of glucose and 10% of isomaltose.
3. High-molecular sugar.
4. Maltodextrine.
5. Isoglucose syrup, which is the raw material for 53% of D- glucose, 42% of D- fructose and 5% of oligosaccharides.
6. D -sorbitol.
7. D- mannitol.

All these enumerated products, being the associated substances in the production of starch, have the enormous sphere of application and are extremely necessary in Russian pulp and paper and food industries and are in a great demand on the Russian market. One pulp and paper industry alone consumes thousands of tons of starch per year. This is the entire branch of production, which does not have the competitors today.

During the year pectin plant will be able to produce pectin and starch simultaneously, which will enlarge the assortment of production and will liquidate idle times of equipment in the case of the shortage of pectin raw material before beginning the collection of the new harvest.