COCONUT BASED INDUSTRIAL PLANT AT SELVAPURAM,PERIYANAICKEN PALAYAM, COIMBATORE, TAMIL NADU, INDIA MAN.SE.F MANAGEMENT SENZA FROTIERE, MILAN, ITALY.

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1 COCONUT BASED INDUSTRIAL PLANT AT SELVAPURAM,PERIYANAICKEN PALAYAM, COIMBATORE, TAMIL NADU, INDIA PROJECT PRESENT TO MAN.SE.F MANAGEMENT SENZA FROTIERE, MILAN, ITALY. Dr. NIRMALA RANI New No.11C, 129/A3, Brindavan Nagar, Kasturipalayam Road, Jothipuram, Coimbatore , Tamil Nadu, South India Tell: e.mail: wepindia@gmail.com,

2 Date : The President MAN.SE.F Milan Italy. Greetings from Rani secretary Welfare and education for the Poor (WEP) Coimbatore, Tamilnadu, India. I am very grateful to you and thanking you all.it was very great, and pleasure to collaborate with you. This Project will support many women and education for the poor children. I submit this project for your kind consideration. Thanking you Yours Sincerely DR. NIRMALARANI Hear I enclose 1. Eng certificate, Plan, Estimate 2. Quotation from kovai classic industrial 3. Oil machine Performa invoice 4. Powerica Limited quotation

3 INTRODUCTION WELFARE AND EDUCATION FOR THE POOR (WEP) is a non governmental organization established in the year 2006 with an intention of serving the Rural Community, especially the depressed class of the society and to support the poor people. WEP for the benefit of the mankind to improving the social, economic, political and living status of and Backward class people of Tamil Nadu, (South) India. We continuously council children and parents and guardians on the importance of welfare and education. CURRENT ISSUES Our target area is considered as underdeveloped both socially and economically. Since people are illiterate and from lower caste, they are not given any access to proper health care, clean water and other basic human needs etc. People are living in most miserable conditions and they work mostly for less income in agricultural sectors, spinning mills and other hard manual works. Their income is very less and not enough for their family basic needs and for their children education. As the result, Children's are at a very young age start helping their parents to rearing domestic animals, domestic work, agricultural work etc. Young children work for a low wage and bonded manual labors such as brick making, mill companies and retains them from basic schooling. WEP emphasis the importance of education and now the children are regular to the school and slowly the youth have started to take interest in Education and go ahead according to their capacities and aware of the studies.

4 MAIN PROJECT ACTIVITIES These training can easily motivate the young adults to fulfill their basic economical condition and help them to pursue higher education that will eventually lead them to get good jobs and other opportunities in society. Education is the way to make their condition better and these training will definitely pave a way for their future dreams and goals. If the girls are properly educated they will be able to bring about a social change in the family and in the society to which they belong. The Socio-Economic and Political situation of the Periyanayackanpalayam area SOCIAL LEVEL In all of our villages, the social status of the people is very poor, most of them to SC and BC community for the people whom we are working. The people of these villages do not possess lands. They are also agricultural coolies at the field of others. But that too not all through months they have works due to failure of monsoon.

5 EDUCATION LEVEL Most of the people are illiterates and only 50 % of them are able to read, write to some extend. The parents with their children who have completed 8th std. go for work rather than to schools. As some of their parents are nomads in search of works for some months they are forced to take their children along with them. The need of the family is going on increasing and so they are not able to pay attention to their children s education. The elder ones are usually kept as the care takers of the younger children. EMPLOYMENT STATUS As stated above there is no permanent employment for them. The people in these villages go for construction work now and then and fieldwork during the cultivation time. The rest of the months they are unemployed. Since they do not have a regular employment, they also do not have a regular income. The wages they get also very minimum.

6 Kernel Based Units COCONUT OIL PLANT

7 PROJECT PROFILE COCONUT BASED INDUSTRIAL PLANT AT SELVAPURAM PERIYANAICKEN PALAYAM, COIMBATORE, TAMIL NADU, INDIA AIM OF THE PROJECT WELFARE AND EDUCATION FOR THE POOR (WEP) has planned to start a new project on Coconut Based Industrial Plant in a motive of providing employment and the profit is utilized for the welfare of the poor children for their Education. WEP has one acre of land and oil mill project will be implemented in Selvapuram,Periyanaickenpalayam, Coimbatore. COCONUT OIL PROJECT OBJECTIVE OF THE COCONUT OIL PLANT To set up units with high standards of safety and hygiene. Units to cater to export & domestic markets. Fully developed plots to accommodate units. Supporting infrastructure to facilitate growth of coconut based industries in the State. Area - 1 Acre COCONUT PLANT DETAILS Location Selvapuram, Periyanaicken Palayam, Coimbatore District Nearest Airport Coimbatore - 25 Kms. Nearest Railway Station - Coimbatore - 20 Kms. Locational Advantage Heartland of coconut cultivation in the state

8 FACILITIES PROPOSED The Plant will be divided into 2 Zones Zoning proposed as follows: - Area for Kernel based units - Area for Coconut Husk Technology Demonstration & Common Facility Centre Power & Water Supply arrangements. ADVANTAGES OF THE PLANT Attract processing units Enhance income level of people Employment generation Enhance utilization of different parts of coconut tree in scientific manner Export revenue for the country. PRODUCT LINES Kernel based product - Coconut Oil, Coconut Oil Cake Coconut Shell Coconut husk Coconut Fiber & Coco Peat

9 PROJECT IDEAS Coconut Oil Virgin Coconut Oil is extracted from fresh coconut meat without chemical process It is rich in medium chain fatty acids, particularly lauric acid and also rich in minerals, vitamins, antioxidants etc. BASIS AND PRESUMPTION: 1. Eight hours per day and 295 days per annum has been considered as the working period. 2. Oil can be collected from the coconuts available from outside. 3. The unit will be set up in own premises and will adopt technical process to collect oil.

10 COCONUT PRODUCTION IN INDIA Coconut plays a significant role in the agrarian economy of India. Apart from the importance of copra and coconut oil which is widely used in the manufacture of soaps, hair oil, cosmetics and other industrial products, the husk is a source of fibre which supports a sizable coir industry. The tender nut supplies coconut water, a popular thirst quencher of health and hygienic value. Phil- 90% of world coconut product is from Asia Pacific region (mainly ippines, Indonesia, India and Sri Lanka). Indian Production 1572 Cr. Nuts/year. India ranks second in production productivity of coconut is 8300 nuts/hectare. Present utilization: - Raw nut - 50% - Copra - 35% - Tender nut - 11% - Seed purpose - 2% - Industrial Application - 2%

11 Global & National scenario Coconut is grown in more than 93 countries of the world in an area of million ha with a total production in terms of copra equivalent of million MT. Indonesia (25.63%), Philippines (23.91%), India (19.20%) are the major coconut producing countries of the world. India occupies a predominant position in respect of production of coconut in the world. Coconut is grown in 1.94 million ha in 19 states and 3 Union Territories of the country producing million nuts with an average productivity of 8303 nuts per ha or nuts/palm/year. Traditional areas of coconut in India are the states of Kerala, Tamil Nadu, Karnataka, Andhra Pradesh, Orissa, Goa, West Bengal, Pondicherry, Maharashtra and Islands of Lakshadweep and Andaman and Nicobar. Non-traditional areas are the states of Assam, Gujarat, Madhya Pradesh, Bihar, Tripura, Manipur, Nagaland and Arunachal Pradesh. The four southern states put together account for more than 90% of the total production in the country (Kerala 36.88%, Tamil Nadu 34.11%, Karnataka 13.83%, Andhra Pradesh 6.16% and other states 9.0%). Four southern states put together account for 92% of the total production in the country (Kerala 45.22%, Tamil Nadu 26.56%, Karnataka 10.85%, Andhra Pradesh 8.93% and other states 8.44%). Coconut is a crop of small and marginal farmers since 98% of about five million coconut holdings in the country are less than two hectares. In the west coast of India, the palm is an essential component in the homestead system of farming.

12 Coconut in Tamil Nadu Coconut is cultivated in all the 31 Districts in Tamil Nadu. Coconut occupies 4.19 lakh ha Coconut production in Tamil Nadu is 6200 million nuts The productivity per palm is 14,785 nuts per ha (as per state govt data ) Tamil Nadu is the second largest producer and a growing coconut market in the country. 12 Districts occupies more than 10,000 ha and contributes about 80 % towards the state's area and production.

13 Coconut in Coimbatore District Coconut occupies 0.82 lakh ha Coimbatore districts top in coconut production in the country Proper scientific management practices are adopted in coconut gardens in Coimbatore District More tender coconut variety is cultivated in Coimbatore District. Coimbatore District is the hub of tender Coconut trade

14 COCONUT BASED INDUSTRIAL PLANT, PERIYANAICKENPALAYAM (MAP) PROJECT ARE A IN SELVAPURAM LAND, COIMBATORE, INDIA

15 LAND/WORKING AREA/BUILDING Coconut Oil Mill Plant Diagram

16 MACHINERIES AND THEIR USES IN COCONUT OIL PLANT Coconut dehusking co- A coconut dehusking machine is used to detach the conut husk from the coconut fruit. Coconut deshelling A coconut deshelling machine is used to crack the hard coconut shell from the dehusked coconut fruit. Copra grinding cop- A copra grinding machine is used to grind the dried ra pieces into fine copra flakes. Copra oil extracting A copra oil press is used to squeeze the copra oil from dried copra flakes. Coconut defibaring Coconut fiber screening co- A coconut defibring machine is used to break the conut husk into coconut fiber and cocopeat. A rotating screener is used to screen the coconut fiber.

17 COCONUT PRODUCTS

18 By-products Flow and Main Products Equipment Required Coconuts Dehusking Dehusker Coco Husk > Fiber Splitting Machete Drying Mechanical Scooping Metal Scooper Coco Shell Copra Size Reduction Hammer Mill Copra Meal > Feeds Oil Extraction Setting of Oil Extraction of the Oil Settling Tank Filtering of Oil Filtering Tanks Filtered Oil Storage Tanks The process flowchart of producing filtered crude oil showing the main products, byproducts, and the equipment requirement for each step

19 Oil Plant View Visited by Project Manager COCONUT OIL CAKE USEFULNESS OF Coconut Oil cake is the byproduct of Oil Extraction. It constitutes mainly fibres and about 10% Oil. Mechanical extraction of oil cannot recover oil in full. This oil cake can be used for further oil recovery with a solvent extraction process.

20 Coconut oil cake is also sometimes called coconut meal. It is cattle feed, these have rich mineral content. coconut cake which is mainly used as feed for livestock.once the oil is extracted, the remaining coconut cake is 18-25% protein but contains so much dietary fiber it cannot be eaten in large quantities by humans. Instead it is normally fed to ruminants. [4] Its high oil and protein levels are fattening for stock.the protein in copra meal has been heat treated and provides a source of high-quality protein for cattle, sheep and deer, because it does not break down in the rumen. high-quality copra meal contains 12% non structural carbohydrate which makes this product well suited for feeding. UTILIZATION OF COCONUT HUSK Coconut husks are generally removed from whole coconuts at the farmsite in close proximity to the trees from which they are harvested. After dehusking, the husks are piled and left to rot in the fields or normally burned as waste. A greater portion however, is used as fuel in farmsite copra making. To a certain extent, husks are utilized in handicrafts, floor polishers and other minor applications. Coir dust/husk burial is the one of options available for moisture conservation in drought susceptible coconut lands which is presently recommended by the Coconut Research Institute. Coir dust which is a major by-product in coconut fibre industry could b e used to maintain and improve the organic matter content of depleted soils.also coir dust is a spongy material which can absorb ample quantity of water compared to its weight Nevertheless, the coir dust is not used in large quantities as a mulch or incorporation into soil as it could act as a breeding ground for black beetle due to its slow decomposition.

21 MANPOWER 1. Key Persons. Name and Surname Education Age Role in the New.Co. Rs/ Month Bonus Yearly Compensation (Rs) Dr. Nirmala Rani (Ms) Phd 42 yrs Chair of the Board Dr. Muthukumar Phd 47 yrs Mr. Bose Ebenezer FCA 72 yrs Plant Manager Commercial Manager Mr. A James jamestirunelveli@gmail.com M.Co m 33 yrs Technical Assistant Total Mr. Mathi BA 60 yrs Advocate nil nil nil Employees Designation No. of Employees Male/ Female Rs/Month Salary Bonus Per Annum Salary + Bonus Machine Operator - 1 M Men Machine Operator - 1 F Helper Watchman 1 M Driver 1 M Helper - Collecting Coco 4 M/F Dehusking 2 F

22 Coconut Cutting 2 F Total MALE -5, FEMALE - 7 Assumptions used in the financial analysis of oil processing centers General parameter data Quantity Unit Days per year 295 days/year Days per month 25 days/month Hours per day 8 hrs/day PRODUCT RECOVERIES - PER DAY 2000 COCONUT PRODUCTS PER DAY COST/ LTRS PER MONTH PER YEAR COCONUT OIL 280 Ltrs RS Ltrs Ltrs OIL CAKE 110 Kg Rs Kg Kg HUSK 2000 Kg Rs Kg Kg COCONUT SHELL 200 Kg Rs Kg Kg

23 2. Inputs for the Profit & Loss Account: Revenues (in RS). Items Unit Calculation Main potential Costumers Coconut Oil production 1.Ltrs 295 Days x 280 Ltrs Oil Ganana Sekaran Teena Oil group Coimbatore 2. RS/Ltr Coconut Oil sales Coconut Oil Cake Coconut Shell Sales 3= 1x2 in RS 4. KGs 295 Days x 110 Kg/Day x Rs KGs 295 Days x 200 Kg/Day x Rs Antony Store PeriyanayaganPalayam Coimbatore Ravi Kumar Karur Tamilnadu HUSK production & finished products sales 6. KGs 295 Days x 2000 Kg/Day x Rs Mohan Arul Ottakamandalam Tamilnadu Total Revenues RS= Note : Cost increased every year (Approx)

24 3. Inputs for the Profit & Loss Account: Variable Costs (in RS). Items Unit Calculation Comments, Notes Raw materials (green coconouts) Consumables (oils for machineries, other) RS/KG 295 Days x 2000 Coco x Rs.8.5/Coco Electric Power? KWH KWH/RS Total Cost in RS Water? Other costs related to the production? Packaging costs Total Packaging Cost Total costs related to the production Load (Lorry) Load/RS Total Cost in RS In RS Which Unit - 25Ltrs Tin In RS In RS In RS (sum of the previous lines) Inputs for the Profit & Loss Account: Industrial Margin (in RS). Items Unit Comments, Notes 2-3 In RS

25 4. Investment Analysis (in RS) Items Value in RS 2016 Comments, Notes Fixed Investment: Land As equity contribution to the New.Co. Building Krishnana Engineer Coconut Bio shredder Machine Coconut Dehusker machine with 5 HP Electric Motor Coconut Cutting Machine Periyanayakanpalayam Kovai Classic Industries 411, ,600 Kovai Classic Industries 100, ,150 Kovai Classic Industries Oil Machine 1,417,500 1,417,500 Sri Aaanoor Amman Engineerings Commercial Vehicles (how many? What for?) No needs of Warehouse? Other-20 KW / 25 KVA, SILENT Diesel Generating Set No No 310, ,000 Powerica Limited Quotation Coimbatore TOTAL 4,905,500 49,05,500

26 Investments and maintenance cost for the coconut oil production Investments Amount Lifespan (yrs) Depreciation Maintenance cost (2% on investment) Coconut Bio Shredder Coconut Dehusker Machine Coconut Cutting Machine Coconut Dryer Copra Cutter Copra Cooker & Boiler Cutting Copra Loading Screw Conveyor Copra Storage Bin Oil Expeller Cutting Copra Storage Bin Filter Press Oil Unfiltered Storage Tank, Oil Storage Tank, Cooker And Tank Platform Total

27 Salary to the Employees Per Annum Designation No. of Employees Rs/Month Salary Bonus Salary + Bonus Chair of the Board Plant Manager Commercial Manager Technical Assistant Machine Operator - Men Machine Operator - Helper Watchman Driver Helper - Collecting Coco Dehusking Coconut Cutting Total

28 COST OF THE PROJECT CAPITAL EXPENDITURE WEP AMOUNT MAN.SE.F IN RS. Land 2,500,000 Building (As per estimate) 500,000 RC Building & Electrical Fitting 2,500,000 Machinery Coconut Bio Shredder 166,250 Coconut Dehusker machine with 5 HP Electric Motor 411,600 Coconut Cutting Machine 100,150 (Coconut Dryer, Copra Cutter, Copra Cooker & Boiler, Cutting Copra Loading Screw Conveyor, Oil Expeller, Filter Press, Oil Unfilter Storage Tank, Cooker & Tank Platform) 1,417, KW / 25 KVA, SILENT Diesel Generating Set 310,000 TOTAL (Rupees Forty Nine Lakhs Five Thousand Five Hundred Only) RS- 4,905,500

29 IN - 41,666 IN 68,131

30 Financial analysis of coconut oil production and WEP Charitable Activity Expenses Benefits Year 1 Year 2 Year 3 Year 4 Year 5 Year 6 Year Gross sales from crude oil 9,086,000 9,994,600 10,994,060 12,093,466 13,302,813 14,633,094 16,096,403 Gross sales from by-product a. Copra cake 649, , , , ,201 1,045,221 1,149,743 b. Husk 590, , , , , ,201 1,045,221 c. Shell 413, , , , , , ,655 Total Income 10,738,000 11,811,800 12,992,980 14,292,278 15,721,506 17,293,656 19,023,022 Costs Raw Material cost/coconuts 5,015,000 5,516,500 6,068,150 6,674,965 7,342,462 8,076,708 8,884,378 Labor cost 1,489,000 1,637,900 1,801,690 1,981,859 2,180,045 2,398,049 2,637,854 Maintenance cost 100, , , , , , ,156 Marketing cost 60,000 66,000 72,600 79,860 87,846 96, ,294 Transportation cost 200, , , , , , ,312 Electricity cost 420, , , , , , ,056 Administrative cost 975,000 1,072,500 1,179,750 1,297,725 1,427,498 1,570,247 1,727,272 Water and garbage cost 240, , , , , , ,175 Depreciations 307, , , , , , ,224 Redn. With Sales Tax & Legal Exp. 50,000 55,000 60,500 66,550 73,205 80,526 88,578

31 Total Costs 8,856,200 9,741,820 10,716,002 11,787,602 12,966,362 14,262,999 15,689,299 Net Benefit 1,881,800 2,069,980 2,276,978 2,504,676 2,755,143 3,030,658 3,333,723 Educational Help for the Poor 752, , ,791 1,001,870 1,102,057 1,212,263 1,333,489 Medical Help for the Poor 564, , , , , ,197 1,000,117 Welfare of the Poor Family Health 376, , , , , , ,745 & Awarness WEP Administrative Expenses 188, , , , , , ,372 Total Expenses 10,738,000 11,811,800 12,992,980 14,292,278 15,721,506 17,293,656 19,023,022

32 From Net Profit WEP Charity Activity Expenses 20% 10% 40% Educational Help for the Poor Medical Help for the Poor 30% Welfare of the Poor Family Health & Awarness WEP Administrative Expenses

33 Gross Income from Coconut Oil Business 6% 5% 4% Gross sales from crude oil Gross sales from byproduct a. Copra cake 85% b. Husk c. Shell Gross Expenses to Coconut Oil Business 5% 11% 2% 1% 1% 17% 3% 3% 0% 57% Raw Material cost/coconuts Labor cost Maintenance cost Marketing cost Transportation cost Electricity cost Administrative cost Water and garbage cost

34 PROJECT TIME 7 MONTH Serie1 1 0

35 DAILY STOCK RECORD Date coconut Number Oil Processed kg Presscake Produced kg Oil cake kg Husk kg Coco shell kg TOTAL DAILY FINACIAL RECOD Date Details Expense Income Total

36 OUTCOMES OF THE PROJECT:- This project help the WEP sustainability, Improving 200 poor children Education and health status of the children, and their family There will be work for 5 men and 7 women and many people will get good training can cum training centre Every year 100 to 150 farmers would be trained up on sustainable organic farming and awareness traning Increase production of Vermi/compost organic manure production per year in the neighbor villages families will be adapted sustainable methods of agriculture practices every year Reduction of cost of cultivation for the farmers and improvement of crop yield in coco by giving training Increase of organic food productions by coconut Bee keeping as subsidiary occupation provide additional income to the families Reduction of Chemical Fertilizers usage coconut trees. There would development of Human resource of farming communities on various, Sustainable agriculture skills CONCLUSION: WEP idea of running a Sustainable Farming to run self sustained evening school, health, awareness activities and other community development activities which will be help us to reach the maximum number of children and school drop outs deprived their childhood and who will be brought in to the main stream of education. This Coconut based industrial plant infrastructure will be helpful for us to sustainability WEP and welfare and education children and people. Totally this area Farms will be get benefit and support various means initiate development activities for needy children and people. DR. NIRMALARANI WEP secretary Project Manager *************

37 PROFORMA INVOICE Perfect Machineries Fabricators No: 376, Selva Nagar, Elumathur, Erode , Tamil Nadu, India TIN No: , CST No: / Phone: , Mobile: W.O.NO: CO/M/009 DT 19/02/2015 PROFORMA INVOICE OF:INDIAN MAKE COCONUT OIL MILL MACHINERIES To, Mr.JAMES 3 KK Thottam Irugar Road, ondipudur, Coimbatore jamescbe@yahoo.com You re Ref. : Your Delivery : In 30/35 days from the date of Order. Terms of Payment : 40% Adv, Balance at the time of Delivery Website: M/s. SRI AANOOR AMMAN ENGI- NEERINGS, ERODE, A/C No with STATE BANK OF INDIA, MODAKU- RICHI BRANCH IFS CODE :SBIN DU NO / PART NO DESCRIPTION QTY PRICE IN RS. PER UNIT AMOUNT IN RS. 001 / ( 01 To 04 ) 002/ ( 01) 003/ 01 Coconut Dryer Size : 10*4*6 H.P.Required:03 & 960RPM CAP. 01 To 05 TON PER DAY Copra Cutter H.P.Required:05 & 1440 RPM CAP. 01 To 05 TON PER DAY Copra Cooker & Boiler H.P.Required:15 & 960 RPM CAP. 01 To 3TPD 1 UNIT 1 UNIT 1 UNIT 2,00,000/- 60,000/- 5,00,000/- 2,00,000/- 60,000/- 5,00,000/-

38 DU NO / PART NO DESCRIPTION QTY PRICE IN RS. PER UNIT AMOUNT IN RS / 005/ / / / / 1 Cutting Copra Loading Screw Conveyor H.P.Required:03 & 960 RPM CAP. 01 To 05 TON PER DAY Oil Expeller Complete with All accessories Without Electricals, H.P.Required:10 & 960 RPM CAP. 01 To 05 TON PER DAY Filter Press H.P.Required:2& 960 RPM CAP. 01 To 05 TON PER DAY Oil Un Flitter Storage Tank Size:4*6*4 CAP: 2500 Littre Oil storage Tank Size:6*11*6 CAP: 5000 Littre Cooker &Tank platform Size:16*10*18 1 UNIT 1 UNIT 1 UNIT 1 UNIT 1 UNIT 1,00,000/- 1,80,000/- 1,50,000/- 20,000/- 40,000/- 1,00,000/- 1,00,000 /- 1,80,000/- 1,50,000/- 20,000/- 40,000/- 1,00,000/- Ex-Works Price : 13,50,000/- 13,50,000/-. C.S.T. 5% : 67,500/- 67,500/- TOTAL RS. : (In Words: Fourteen Lakes One Seven Thousand Five Hundred Only) VALIDITY: THIS OFFER IS VALID FOR 30 DAYS FROM THE DATE GIVEN ABOVE 14,17,500/- 14,17,500/-

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