Abhay Cotex - FOOD 360

hollandmarigoldOil and Offshore

Nov 8, 2013 (3 years and 5 months ago)

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Very Good
morning to
all the

Hon’ble team Members
of

FICCI


AP State Council

By


ASHISH O MANTRI & D A PRASAD Team

ABHAY COTEX PVT LTD


JALNA, MS INDIA

Introduction


Abhay Cotex Private Limited


promoted by
ASHISH O
MANTRI
a young entrepreneur, Chemical Engineering
graduate from UDCT Mumbai.



OTA
-

New Delhi honored him as “
Young Entrepreneur award
for establishing New Innovative process technology




Project developed & conceived by
D.A.PRASAD

as CEO,

Concept to Commercialization of Saleable Products
” one of
the senior most & experienced Oil Technologists in India
exclusively in Cotton Seed Processing .




Core Team


Ashish Mantri B.Tech ChemEngg UDCT,Mumbai
-
M.D.


D.A.Prasad B.Sc. ,B.Tech Oil Tech. ,PGDBM
-

C.E.O.,


Venkat B.Sc. ,B.Tech Oil Tech.


P.M.


Team of Animal Nutritionists


Blend of Expert & talented Management team


Professional expertise comprises of M.Sc.(Oil technology /
Chemistry), Engineering & Quality controls core groups.


Total Manpower of > 600



Current Status


BIPP

supported 600 TPD Cotton Seed Processing with
Proven

Single Step Extraction with on
-
line Miscella Refining Project

at
Dhule
, Maharashtra ,will be
commissioned by end April 2012.


Received an
Equity Investment
of Rs 2600
Lakhs

from
SEAF

Agribusiness group for the above Project


Commercially,
products were launched
within India & overseas
markets since 2010 with this technology installed at
Jalna

Maharashtra in 2010


Received
good market feed back


Processed
> 132,000 Metric Ton of Cotton seed
since its
inception.


Achieved a
Turn Over of

USD 23
Mn

in FY 2011
-
12


Process Route


Cleaning Raw Cotton Seed.


Delinting the Raw Seed


Dehulling the Delinted Seed and Cotton Kernel separation.


Cotton
Kernel (meat) admixing with cotton hulls


Cotton
Kernel (meat) preparation to ooze out the oil cells to
ease
-
out
the
extraction.


Direct Extraction with n
-

Hexane as solvent to produce Cotton Crude


Miscella (crude oil + hexane)


On
-
line
direct Refining of Crude Miscella to remove both physical &
chemical impurities from the extracted
Miscella.


No involvement of High pressure Expeller crushing


Process Route

Cotton
-
seed
Warehousing

De
-
Hulling

Conditioner

with Solvent

Extraction

Seed Cleaning

Cotton Seeds

De
-
Linting

Cotton Lint
(Yield 5
-
6%)

De
-
linted
Cotton Seed

Cotton Hull
(Yield 28%)

Kernel
Flakers

Cotton Meal
Cooking

Crude Miscella

Refining &
Distillation

Neutral Oil
(14.75
-
15%)

Cotton
-
meal DOC
(49
-
50%)

Bleaching &

Oil Filtration

Deodorization

Refined Oil
(14
-
14.5%)

Cottonseed
Meal

Process Principle

Liquid Particulars

Specific

Gravity

Diff in Specific

Gravity
with Soap


Water

1

Oil

0.91

0.07 ( Conventional
Process)

Soap

0.98

Miscella

0.77

0.21 ( Our Process )

Hexane

0.65

Products and Markets




Institutional sales:
Strong demand pull from players like NDDB dairies,
Godrej group, Baramati Agro etc


Retail:

Currently the fastest growing segment with high margins and
volumes.


Exports:

Product well established in China, Thailand, Iran, South Africa. &
expected to contribute 40% of the sales.

Cottonseed Meal

(35% of revenue)


Domestic


At present all cottonseed neutral oil is sold locally.


Gujarat is the leading consumer market where cottonseed is preferred over
groundnut oil due to its characteristic taste, odour and longer shelf life.

Cottonseed Oil

(45% of revenue)



Exports


Exported to China where it is used as a fertilizer for mushroom cultivation
and has strong demand.

Cottonseed Hulls

(7% of revenue)

Cottonseed Linters

(12% of revenue)


Exports


Currently sold to China


currency note and paper industry


Process Benefits


Very less Usage of Water
with
Zero discharge
of effluents

from the
Miscella Refining Plant.
-

Eco friendly process design


No Color Fixation in Oil & Minimizes growth of Free Gossypol in D.O.C
.
unlike Expelling Technology.


Our Process facilitates
Higher content of Bye
-
Pass protein
in De Oiled Cake.


Unique & Consistent Oil Quality
of PBSY grade


30


40% Reduction
in foot print of the plant
.


20%
-
25% Cost Reduction

in CAPEX both on equipment & civil construction.


Enhanced recovery of cotton neutral oil
(Washed oil)


Due to uniqueness in neutralization,
No need of multi stage Centrifugal
Separators (4) ,N
o water wash & No vacuum drying.

Possible National Savings by adoption of New Technology


DESCRIPTION

QTY IN LAKH
TONS

IN %

VALUE IN Rs. CRORES

COTTON SEED PRODUCTION #

93.24

COTTON SEED PROCESSED IN PARTIALLY

SCIENTIFIC METHOD

3.5


3.754

OIL

LOSS DUE TO TRADITIONAL PROCESS

6.28

7

2601


LINTERS

LOSS DUE TO TRADITIONAL PROCESS

3.59

4

1224

HULLS LOSS DUE TO TRADITIONAL PROCESS

24.23

27

1524

SOAP

STOCK LOSSDUE TO TRADITIONAL PROCESS

0.724

0.8

31

TOTAL LOSS DUE TO TRADITIONAL PROCESS

34.824

38.8

5380

SAVINGS BY ACPL’S TECHNOLGY

ADDITIONALLY WITH RESPECT
TO PARTIALLY SCIENTIFIC PROCESS

1557Rs/TO
N

TOTAL

SAVINGS BY OUR TECHNOLOGY

1452

NATIONAL SAVINGS IF WE ADOPT OUR
PROCESS TECHNOLOGY

Rs
CRORES

6838

# Source AICOSCA

Key Cost Advantages


No additional cost
-

on E T P chemicals & its
operations.



No
recurring expenses on maintenance of processing equipments like
Expellers
&
separators
.



20
-
22% Reduction in consumption of Power Units



10
-
12% Reduction in consumption of Steam & Utilities



50 to 60% Reduction in Handling of No. of process equipments.



Reduction of RED color unit is excellent with less consumption of lye.



9
-
10 times reduction in consumption of process water


Sr no

PARTICULARS


Addnl. Financial
Benefit

in the proposed
process technology
(Rs
/ T of seed)

compared
to existing process

1

Savings
-

on Additional revenue due to higher recovery of (1.5% on seed basis) PBSY grade
Neutral oil (Washed oil price @ 41,800/
-

per MT):

627

2

Savings on
-

Additional premium on DOC (@ Rs 800 per ton due to higher quality specs., @
49.65% yield @ Rs 11200/
-

per MT)

397

3

Additional recovery of DOC: (16.5 kg / t of seed @ Rs 11.2/kg)

185

4

Savings on Power unit consumption (Rs 5/
-

per Unit including MD charges)
-

Rs / T of seed

175

5

Savings
-

Due to very less maintenance repair, spare parts cost
-

Rs / T of seed

59

6

Additional premium on Neutral oil (@ Rs 900 per ton due to exceeded quality specs., i.e.,
currently Ex Washed oil is @ Rs 41800/
-

Per MT, SEO Washed oil is @ Rs 40900/
-

Per MT, where
as the oil produced with this technology will be sold @ Rs 41800 / MT being single step process)
(@ 45% of 14% oil recovered will be sold at Rs 41.80/kg equal to exp washed oil)

56

7

Cost reduction on
-

Manpower expenses
-

cost reduction:

16

8

Steam cost reduction: [55 kg of husk @ Rs 1.80/kg per ton of seed] (40kg of coal @Rs 2.20/kg
per ton of seed)

11

9

Savings on E T P Operations (chemicals + power + labor + mnt)

9

10

Process water & Cooling tower water reduction & its cost saving

9

11

Savings on internal material handling:

7

12

Savings on less consumption of Caustic

6

Additional process benefit over conventional process: Rs / T of seed :



1,557

COST BENIFT ANALYSIS ON PER TON OF SEED BASIS WITH
ACPL’S
NEW PROCESS TECHNOLOGY
:

Comparison between Traditional & ACPL’S Technology

Requirement

Particulars

UOM

Traditional

Technology

ACPLs Unique

Miscella
R
efining
Technology







No of Expellers required for
600 TPD

Nos

12

0

No of Expanders required
for 600 TPD

Nos

0

2

No of Separators required
for 600 TPD

Nos

4

1

Water quantity required

LTR/HR

800

75

Power units consumption

KWH

120

75

Aflatoxin in

DOC

PPB

>15

<5

Strength of Technology



Single step Extraction Integrated with
Miscella

Refining


“Zero discharge” concept process


Unique process & avoids traditional /cumbersome steps.


ECO
-
FRIENDLY Process design


30% Reduction of Footprint & CAPEX against traditional


Enhanced Yields with Consistent QUALITY products


Hi Pro ABHAY PROTEIN (AP
-
CSM)
product suitable for Poultry
& Aqua
-

FEED formulations / rations.


Deactivated Anti
-
Nutritional factors & Low or Undetectable
level of
Aflatoxin

products


Enhanced YIELDS with SUPERIOR in QUALITY Product


Strength of Abhay Protein with


De activated Anti
-
Nutritional factors.


High
Metabolizable

Energy levels .


Alternative protein to high cost Soybean Meal (SBM).


Low or undetectable level of
Aflatoxin

(B1,B2, G1,G2) .


Easily adaptable for formulation of Poultry & Aqua feed.


Proven
80% replacement of SBM in Layers feed

formulation
& benefits the farming community.


Proven
25% replacement of SBM in Broiler feed

formulation
& benefits the farming community.


Better
Feed Conversion Ratio
(FCR),
-

Body Weight Gain

&
Feed Efficiency
.




National Scalability of
ACPL innovative process technology



Cotton seed raw material availability in India.


2009
-
10
10.5
Mn

MT


2010
-
11
11.09
Mn

MT


2011
-
12

12.50
Mn

MT




96.4 % of seeds are processed inefficient traditional
methods



3.4 % follows Scientific process with 2
-
Step Extraction
followed by Multi
-
step Refining & produces huge Effluents.


0.2 % are only follows the
Novel Advanced Scientific process
SSEIMR of ZERO
-
DISCHARGE
, Innovated & Implemented by
ABHAY COTEX

, protects naturally occurred Amino acid
profile in
-
tact & aptly suitable as
Poultry & Aqua feed
ingredient,

Huge potential to install min. 100 plants of this
scale.



International Scalability


International cottonseed resources


China
-


12.0
Mn

M Tons


Pakisthan
-


6.0
Mn

M Tons


African Countries
-

3.5
Mn

M Tons


Uzebikisthan

-
1.5
Mn

M Tons



Globally potential to install min 250 plants.


National Savings
By following ACPL novel process
India
alone could save USD 1.2
Bn






Patent rights on “Process” & “Product”




ACPL registered 10 PATENTS on Process (8) & Product (2)
within INDIA.



ACPL has also registered 2 PROCESS PATENTS
Pakisthan
.



ACPL has
registered PATENT rights on “Abhay
-
Cotton Pro” (
Patent Pending ) .






CSR Award


“Best Innovative Zero Discharge Process
Technology (Agribusiness)” by
Hon’ble

Minister of Industries
Maharashtra state
Sri
Narayan

RANE
Ji

for 2011
-
’12 of

Dainik’s

Divya

Marathi”

Maharashtra INDIA.



Agricultural Innovation

of INDIA
ACPL’s success story was
published in “
KRISHI SUTRA
’’
by

SFAC (Small Farmers
Agribusiness Consortium) for 2011
-
12.



GMP Certification;

Abhay Cotex Private Limited has been
acknowledged for

Good Manufacturing Practice by SGS


India (Food Certification Services)




RECOGNITION & AWARDS


ACPL
-

ACHIEVEMENTS


OTAI
-

New Delhi’s AWARD



SFAC


New Delhi’s Article




EXPORT HOUSE
-

Recognition




GMP
SGS India
(Food Certification Services)


R& D facility’s Recognition by DSIR by,
Ministry of Science & Technology,
Government of India
.

ACPL
-

ACHIEVEMENTS


Vision & Mission

Vision



“A

globally

competitive

INDIA

focused

company,

with

Leadership

in

Cottonseed

processing

business,

providing

VALUE

ADDED

QUALITY

COTTON

PRODUCTS

(Cotton

Oil,

De
-
Oiled

Meal,

Hulls

&

Linters)

to

the

delight

of

our

customer

&

share

holders”
.


Mission


To develop
LOW VALUE


HIGH QUALITY AGRO BASED
PRODUCTS
”.


GETTING MORE


OUT OF LESS


FOR MORE(
PEOPLE
)



Future
-

Secondary Agricultural Projects:





International Products


Krishi

Gold
BPC

(Broiler Protein Concentrate)


Krishi

Gold
LPC

(Layer Protein Concentrate)



To set up 100 TPD
I
-
DAL (
Dal

Analogue)
manufacturing facility made out of
Soya & Rice Flour, This has 50% more Protein than regular DAL & price 60%
lower than regular DAL.



To set up multi
locational

proven process
ACPL s existing Zero Discharge
technology based PROJECTS.



To set up
POULTY & CATTLE Feed Manufacturing

units across the Nation at
strategic locations.



To set up 50 TPD
SOYA PROTEIN CONCENTRATE (SPC)

project for BABY FOOD (a
milk grade Protein)

To Conclude




The Company has successfully implemented Single Stage Cotton Extraction (SSCE)
Integrated with Miscella refinery each of 600 TPD capacity at JALNA (2010) &
DHULE (2012) MS India successfully.



ACPL has been successful in
Replacing SOYABEAN MEAL by ABHAY PROTEINS in
POULTRY Feed Industry,

thus adding significant cost advantage to the entire
sector; Similarly for CATTLE Feed Industry.




ACPL has awarded with
MEGA PROJECT STATUS

by Maharashtra State
Government, enjoying various “ Package Scheme of Incentives (PSI)”
-

2007



The project is of
National importance
as the successful replication of the
technology can lead to
Large Environmental Benefits
, Reduction in
imports of
Edible oil
and can generate significant
value addition to the POULTRY & CATTLE
FEED
Industry.

THANKS & CONGRATULATIONS FROM

JALNA, Maharashtra, INDIA.

Presented By

ASHISH O MANTRI

6
th

Nov. 2012