New Manufacturing Start Up For Activated Carbon from Rice Husk, Coconut Shell & Saw Dust with Financials
Activated carbon produced from rice husk, coconut shell, and sawdust is widely used in water purification, air filtration, and industrial applications. This report by BIIR Project Consultants provides a comprehensive analysis of setting up an activated carbon manufacturing plant from these materials, including technical, financial, and operational aspects.
Market Potential
The demand for activated carbon is increasing due to its extensive use in various industries, including water treatment, air purification, and chemical processing. Read More
Technical Feasibility
Raw Materials
- Rice Husk
- Coconut Shell
- Sawdust
Production Process
- Carbonization: The raw materials are heated in an oxygen-free environment to produce char.
- Activation: The char is treated with activating agents (e.g., steam or chemicals) at high temperatures to develop porous structures.
- Crushing and Sieving: The activated carbon is crushed and sieved to desired particle sizes.
- Packaging: The product is packaged for distribution.
Plant Layout and Machinery
A typical plant layout includes:
- Carbonization Kiln
- Activation Furnace
- Crushing and Sieving Unit
- Packaging Unit
Financial Analysis
Total Project Cost
- Land and Site Development: ₹XX,00,000
- Plant and Machinery: ₹XX,00,00,000
- Installation and Erection: ₹XX,00,000
- Preliminary and Pre-operative Expenses: ₹XX,00,000
- Working Capital: ₹XX,00,000
Total Estimated Cost: ₹1,85,00,000
Revenue Generation
Revenue from the sale of activated carbon is estimated based on market rates.
Cost of Production
- Raw Material Cost: ₹50,00,000 per annum
- Operating Expenses: ₹XX,00,000 per annum
- Maintenance and Utilities: ₹XX,00,000 per annum
Profitability Analysis
Annual Revenue
- Sale of Activated Carbon: Assuming ₹4,00,00,000
Total Annual Revenue: ₹4,00,00,000
Annual Expenses
- Raw Material Cost: ₹XX,00,000
- Operating Expenses: ₹XX,00,000
- Maintenance and Utilities: ₹XX,00,000
- Labor Costs: ₹30,00,000
- Administrative and Overhead Costs: ₹15,00,000
Total Annual Expenses: ₹1,55,00,000
Net Profit
Net Profit: ₹4,00,00,000 – ₹1,55,00,000 = ₹2,45,00,000
Rate of Return
Rate of Return: ≈ 132.43%
Break-even Analysis
Break-even Point: = 40,000 kg
Payback Period
Payback Period: ≈ 0.76 years
Operational and Managerial Aspects
Human Resources
A plant requires:
- Plant Manager
- Technicians
- Administrative Staff
- Laborers
Training and Development
Staff should be trained in machinery operation, safety protocols, and quality control.
Quality Control
Regular monitoring and testing of activated carbon to ensure compliance with industry standards.
Environmental Impact
Benefits
- Effective waste management.
- Sustainable use of agricultural by-products.
Mitigation Measures
- Proper disposal of activation agents.
- Efficient resource use.
Regulatory Compliance
- Quality Standards: Compliance with industry standards for activated carbon.
- Environmental Clearances: Necessary environmental approvals.
Risk Analysis and Mitigation
Technical Risks
- Equipment failure: Regular maintenance.
- Raw material supply: Reliable sourcing.
Financial Risks
- Market fluctuations: Diverse revenue streams.
- Credit risk: Timely collections.
Operational Risks
- Labor strikes: Good labor relations.
- Regulatory changes: Staying updated.
Conclusion
Starting an activated carbon manufacturing plant from rice husk, coconut shell, and sawdust is a lucrative and sustainable venture with significant market potential. Ensuring comprehensive planning, efficient management, and adherence to regulatory standards will be critical for success.
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