Although the cocoa tree is indigenous to Latin America, Africa today accounts for 70% of the world’s cocoa bean production. Cocoa farming is mostly manual, requiring significant expertise and most cocoa in Africa is grown on small family farms of 2-5 hectares. Next to the Ivory Coast and Ghana, other major cocoa producing countries are Nigeria, Cameroon, Indonesia, Papua New Guinea, Malaysia, Ecuador, Brazil and Colombia.

The cocoa is a very unusual looking tree, with yellow, green and red coloured fleshy fruit pods, about 25 cm long, hanging directly from its trunk and branches. The cocoa beans are embedded within a sticky, white, sweet tasting pulp. At harvest, the cocoa bean has to have reached the proper level of ripeness as under-ripe or over-ripe pods will have a negative impact on the bean’s cocoa flavour.

Raw cocoa beans are bitter and quite inedible. Two processes are required to turn the raw bean into the raw material for chocolate: fermentation and drying. Once the beans have been removed from the pods they are stacked, covered and left to ferment for 3-9 days. The process generates high temperatures of about 50ºC activating enzymes in the beans to form compounds that produce the chocolate flavour when the beans are roasted. The fermentation process must have been concluded properly. Too little fermentation and the desired cocoa taste does not develop fully, too much fermentation and undesirable “off tastes” develop.

African countries such as the ivory Coast, Ghana, Nigeria and Cameroon today account for over 70% of the world’s cocoa bean production.

ocoa Powder (Cocoa) is the food prepared by pulverizing the material remaining after the part of fat (Cocoa Powder) is removed from chocolate liquor. The V.S.chocolate standards define three types of cocoa based on their fat content. These are

• Breakfast or high fat cocoa containing not less than 22% fat.

• Cocoa, or medium fat cocoa containing less than 22% but more than 10%

• Low fat cocoa, containing less than 10% fat.

Cocoa powder production today is an important part of the cocoa and chocolate industry, because of increased consumption of chocolate - flavoured products.

Cocoa powder is the basic flavouring ingredient in most chocolate flavoured cookies, biscuits, cakes and ice cream. It is also used extensively in the production of confectionary coating for candy bars.

Commercial cocoa powder is produced for various specific uses and many cocos are alkali treated or "Dutched” to produce distinctive colors and flavour. The alkali process can involve the treatment of nibs, chocolate liquor or cocoa with a wide variety of alkalizing agents.

Cocoa powders not treated with alkali are known as cocoa, natural cocoa. Natural cocoa has as ph at about 5.4 to 5.8 depending upon the type of cocoa beans used alkali processed cocoa ranges in ph from 6 to as high as 8.5.

Cocoa Powder and Cocoa Butter

The pleasant and sometimes addictive experience of eating chocolate is mainly due to the unique qualities of cocoa butter, which is extracted from cocoa beans along with cocoa powder. This pleasant experience, enjoyed by millions of chocolate eater has ensured that the cocoa crop has achieved major economic importance in many tropical countries. In fact, its value exceeds that of tea.

Cacao or cocoa beans were probably commercially exploited first by the Aztecs when the Spanish Colonized part of America in the 15th and 16th centuries, they brought back the beans from Mexico to Europe for use in drinks. But it was not until the 19th century that chocolate was developed.

The cocoa plant is an evergreen tree growing 5 to 10m. (16 to 33ft.) in height, originating from tropical rain forests. Flowers and fruit (Pods) are produced continuously at eyes located on the trunk or the heavier branches.

The industrially important products from cocoa pods - cocoa liquor, cocoa powder and cocoa butter are both used to make chocolate such as chocolate Spread , chocolate syrup.

The principal ingredient of cocoa butter is triacylglycerol, which has a very special fatty acid composition. Unlike other plant edible fats, which are usually oil, cocoa butter is enriched in saturated fatty acids so that it is solid under normal condition. The sensation beloved of chocolate addicts, when they bite into a chocolate bar is largely caused by heat adsorption from the tongue as the fat melts.

The unique characteristics of melting behaviour and stability exhibited by cocoa, butter are due to its high stearate content in addition to the usual palmitate, the most common saturated fatty acid in plants.

Complex Factor

There are a number of the complex factors controlling the production of cocoa butter. The identification of these factor will allow existing suppliers of cocoa-butter to better define those environmental condition that have a major effect on cocoa butter quality, Also it should be possible to identify cultivars with particularly useful properties and which can be used preferentially for higher quality cocoa butter production.

The global cocoa products market size was valued at $24.5 billion in 2019 and is projected to grow at a CAGR of 3.1% to reach a value of $30.2 billion in 2026.

It is intended to manufacture various cocoa products from Cocoa Beans with processing capacity 600 Tons/Year as a Green Field Project. The products proposed to be manufactured are

a. Cocoa Couverture (Cocoa Liquor)
b. Cocoa Butter
c. Cocoa Powder
d. Chocolate Spread
e. Chocolate Syrup

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Carbon is probably the most widely distributed element in nature. It occurs in two allotropic crystalline forms viz. graphite (hexagonal system) and diamond (isomeric system), the former is soft and black while diamond is hard and transparent. Charcoal, coke and carbon black, classified as amorphous carbon; are considered by some to represent a third allotropic form. They are said to be composed of very minute crystals of graphite by others. Carbon is an essential constituent of all vegetable and animal matter in which it occurs in combination with hydrogen, nitrogen, oxygen and other elements in immense variety of compounds. In combination with hydrogen it occurs as hydrocarbons in petroleum. It is also found in carbon dioxide in air (0.03% as sodium bicarbonate in sea water, and as calcium and magnesium carbonate in sedimentary rocks such as chalk and dolomite.

Many carbons of industrial value are prepared from coal and from organic vegetable and animal matter. The resulting amorphous products include charcoal, coke and petroleum coke. Several carbon products are prepared and used in the electrical and electro-chemical industry.

Carbon 13, a stable isotope of carbon (At wt 13) has recently come into prominence as a tracer element employed in the study of biological process. It is obtained from carbon compounds by concentrating the minute quantity of the heavier isotope, normally present in them, by thermal diffusion methods. Carbon 14 or radioactive carbon, a product of the uranium atomic pile, is used also as a tracer element in the study of plant and animal metabolism.

The term Activated carbon, active carbon, or active charcoal is usually applied to amorphous carbons possessing higher absorption capacities than wood or animal charcoal. Many processes were developed during world war for the production of effective absorbents for use in gas masks. Industrial activated carbons in the form of pellets, granules or fine powders, and with many industrial applications, are now available in the market under different trade names.

Commercial absorbent carbons may be grouped into decolorizing, gas absorbant, metal absorbant, and medicinal carbons according to their physical structure, properties, and applications. No one type of carbon can be used for all purposes. A large variety of raw materials are available for the manufacture of these products. Coal, petroleum coke, and wood charcoal are activated by gas activation. Industrial waste e.g. raw dust, bagasse, molasses, straw, coconut pericarp and shell, corn cobs, paddy and ground nut husk, corn bean shell, distillery slop, waste Mahua flowers, waste wood pulp laquor, and mud from sugar factories have been utilized for the production of active carbons by chemical activation.

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Coconut water is the clear liquid inside young green coconuts (fruits of the coconut palm). In early development, it serves as a suspension for the endosperm of the coconut during the nuclear phase of development. As growth continues, the endosperm matures into its cellular phase and deposits into the rind of the coconut meat. Coconuts for drinking are served fresh, chilled or packaged in many places. They are often sold by street vendors who cut them open with machetes or similar implements in front of customers. Processed coconut water for retail can be found in ordinary cans, tetra packs, or plastic bottles, sometimes with coconut pulp or coconut jelly included.

In recent years, coconut water has been marketed as a natural energy or sports drink having low levels of fat, carbohydrates, and calories, and significant electrolyte content. However, the contents of primary electrolytes per 100 ml serving, sodium, potassium, magnesium and calcium, are negligible (table of nutritional values) unless fortified in manufacturing. Further, marketing claims attributing health benefits to coconut water are not based on science and are disallowed by regulatory agencies, such as the United States Food and Drug Administration.

Unless the coconut has been damaged, it is likely sterile. Coconut water has been used rarely as an intravenous rehydration fluid when medical saline was unavailable. Although this is not recommended by physicians today, it was a common practice during the Khmer Rouge regime in Cambodia from 1975 to 1979

Tender Coconut Water

The water of tender coconut, technically the liquid endosperm, is the most nutritious wholesome beverage that the nature has provided for the people of the tropics to fight the sultry heat. It has caloric value of 17.4 per 100gm. "It is unctuous, sweet, increasing semen, promoting digestion and clearing the urinary path," says Ayurveda on tender coconut water (TWC).

"It’s a natural isotonic beverage with the same level of electrolytic balance as we have in our blood. It’s the fluid of life, so to speak," says Mr. Morton Satin, Chief of FAO’s Agricultural Industries and Post Harvest Management Service. The major chemical constituents of coconut water are sugars and minerals and minor ones are fat and nitrogenous substances.

Analysis of Mature and Tender Coconut Water

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Many carbons of industrial value are prepared from coal and from organic vegetable and animal matter. The resulting amorphous products include charcoal, coke and protroleum coke. Several carbon products are prepared and used in the electrical and electro-chemical industry.

Carbon 13, a stable isotope of carbon (At wt 13) has recently come into prominence as a tracer element employed in the study of biological process. It is obtained from carbon compounds by concentrating the minute quantity of the heavier isotope, normally present in them, by thermal diffusion methods. Carbon 14 or Radioactive carbon, a product of the uranium atomic pile, is used also as a tracer element in the study of plant and animal metabolism.

The term Activated carbon, active carbon, or active charcoal is usually applied to amorphous carbons possessing higher absorption capacities than wood or animal charcoal. Many processes were developed during world war for the production of effective absorbents for use in gas masks. Industrial activated carbons in the form of pellets, granules or fine powders, and with many industrial applications, are now available in the market under different trade names.

Commercial absorbent carbons may be grouped into decolorizing, gas absorbant, metal absorbant, and medicinal carbons according to their physical structure, properties, and applications. No one type of carbon can be used for all purposes. A large variety of raw materials are available for the manufacture of these products. Coal, petroleum coke, and wood charcoal are activated by gas activation. Industrial waste e.g. raw dust, bagasse, molasses, straw, coconut pericarp and shell, corn cobs, paddy and ground nut husk, corn bean shell, distillery slop, waste Mahua flowers, waste wood pulp laquor, and mud from sugar factories have been utilized for the production of active carbons by chemical activation.

• INTRODUCTION
• USES & APPLICATIONS
• END-USER INDUSTRIES OF ACTIVATED CARBON
• BUYERS IN OVERSEAS COUNTRIES
• PROPERTIES
• B.I.S. SPECIFICATIONS
• STRUCTURE OF ACTIVATED CARBON
• ADSORPTION MECHANISM OF ACTIVATED CARBON
• MARKET SURVEY
• BUYERS ADDRESSES OF ACTIVATED CARBON
• MANUFACTURERS/SUPPLIERS OF ACTIVATED CARBON
• DIFFERENT TYPES OF ACTIVATED CARBON
• MANUFACTURING PROCESS OF ACTIVATED CARBON (BY STEAM ACTIVATION)
• PROCESS FLOW DIAGRAM FOR THE MANUFACTURE OF ACTIVATED
• CARBON FROM RICE HUSK (BY STEAM ACTIVATION)
• MANUFACTURING PROCESS OF ACTIVATED CARBON FROM COCONUT SHELL (BY STEAM ACTIVATION)
• PROCESS FLOW DIAGRAM FOR THE MANUFACTURE OF ACTIVATED
CARBON FROM COCONUT SHELL
• MANUFACTURING PROCESS OF ACTIVATED CARBON FROM SAW DUST
• PROCESS FLOW SHEET FOR MANUFACTURE OF ACTIVATED
CARBON FROM SAW DUST
• MANUFACTURING PROCESS OF ACTIVATED CARBON FROM LIGNITE
• TIME FOR COMPLETION OF PROJECT
• PROCESS IN DETAILS
• QUALITY CONTROL TESTING OF ACTIVATED CARBON
• PLANT LAYOUT
• STATE AND CONTROL SUBSIDY SCHEME FOR ACTIVATED CARBON PROJECT
• COMPLETE PLANT SUPPLIERS FOR ACTIVATED CARBON
• ADDRESSES OF RAW MATERIAL SUPPLIERS
• ADDRESSES OF PLANT & MACHINERY SUPPLIERS

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 STATEMENT
16. PROJECTED BALANCE SHEET

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