CHITIN & CHITOSAN (TECHNICAL & MEDICAL GRADE)

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Chitin is a white, hard, inelastic, nitrogenous, polysaccharide found in the outer skeleton of insects, crabs, shrimps and lobsters and in the internal structures of invertebrates. It is the second most abundant organic compound next to cellulose. It is a macro molecular linear polymer of_ (1-4) N acetyl D glucosamine and is insoluble in water and many organic solvents. Chitin itself has only a few applications; it acts more as a precursor of Chitosan, its most familiar derivative.

Chitosan is deacetylated chitin, and is polymer of _(1-4) acetyl – D glucosamine. It has multifarious uses in the cosmetic, pharmaceutical and medical industries. It is even considered as a wonder drug of the twenty-first century due to its versatile utility.

Chitin is a chemical compound belong to glucosamine polysaccharide group categories. It contains about 7% nitrogen, and is structurally similar to cellulose.

It is the principal constituent of the shells of prawn fish, shrimps, crabs, lobsters, beetles and other sea fishes. It is also found in some fungi, algal, and yeasts.

Fish is a valuable and easily accessible source of food, rich in proteins. India has abundant marine and inland fish resources. It has a coast-line c. 4,667 km. long and a continental shelf 2,59,000 sq. km. or more in area, offering considerable scope for the establishment of fisheries. The Bay of Bengal and the Arabian Sea abound in fishing grounds; gulfs and bays all along the coast and a large number of islands with their mangrove swamps and coral reefs, are rich sources of marine fish.

Tidal estuarine waters in the mouths of large and perennial rivers, large brackish water lakes, backwaters, lagoons and swamps scattered along the entire coast-line, afford lucrative estuarine fisheries. Vast stretches of fresh water consisting of rivers, streams, lakes, reservoirs, tanks, ponds and paddy fields offer scope for inland fisheries. The principal rivers of India, including their main tributaries, have a total length of c. 27,360 km. and the length of canals and irrigation channels is c. 1,12,650 km. When added to other freshwater resources, the total surface would run to several million acres of which not more than a million acres are under fish culture. Most of these freshwater resources, though culturable, are at present lying fallow.

In order to study the distribution and bionomics of marine fishes inhabiting Indian waters and to assess the topographic conditions for the establishment of fisheries, the Indian coast has been divided into the following 12 bio-geographical zones:

Zone 1: West Bengal and Orissa
Zone 2: Andhra coast (south of Gopalpur to north of Visakhapatnam)
Zone 3: Andhra coast (Visakhapatanam to Masulipatham)
Zone 4: Andhra coast (south of Masulipatnam to north of Pulicat lake)
Zone 5: Coromandel coast (Pulicat lake to Cuddalore)
Zone 6: Coromandel coast (south of Cuddalore to Devipatnam)
Zone 7: Palk Bay and Gulf of Manaar (south of Devipatnam to north of Cape Comorin)

Zone 8: Kerala and South Malabar (Cape Comorin to Ponnani River)
Zone 9: Malabar and South Kanara (north of Ponnani River to Mangalore)
Zone 10: Konkan coast (north of Mangalore to south of Ratnagiri)
Zone 11: Mumbai and Gujarat coast (Ratnagiri to Broach)
Zone 12: Kathiawar coast

Fishing in Indian seas is generally contained to a narrow coastal belt, 11-16 km. in width and the richer offshore and deep sea waters are practically unexploited. This is largely due to the inadequacy of fishing craft and gear in use. Over 49% of the total fish landings are sun-dried, salted or pickled for future consumption, but the curing processes are by and large unscientific and the product is inferior. A good part of the landings in different parts of the country gets spoiled owing to lack of adequate transport and preservation facilities and is used as manure or otherwise disposed.

Chitin is a polysaccharide that is widely spread among marine and terrestrial invertebrates and lower forms of the plant Kingdom. Chitin is a promizing natural raw material for industrial use. It is biodegradable and non-toxic. Its biological production is about 2,00,000 tons/Annum all over the World.

Chitosan is a deacetylated derivative of chitin. It is polysaccharide found in nature with an amino group, contained in the shells of Crustacea such as crab, shrimp etc. Chitosan is a white to light red solid powder, insoluble in water, soluble in organic acid, but indigestible by human digestive enzymes. Therefore, it is used as one of the so called dietary fibers.

Chitin is one of the three most abundant polysaccharides in nature, in addition to cellulose and starch. It ranks second to cellulose as the most plentiful organic compound on earth. Chitin and its derivatives have many properties that make them attractive for a wide variety of applications, from food, nutrition and cosmetics to biomedicine, agriculture and the environment.

Their antibacterial, anti-fungal and anti viral properties make them particularly useful for biomedical applications, such as wound dressings, surgical sufures and as aids in cataract surgery and periodontal disease treatment.

Chitin/Chitosan is the most important additive and product from marine bio sources beside Calcium, Astaxanthin, Glucosamine. The middle extraction value of chitosan is 5%. It is strongly depend on process and knowhow which kind of extraction grade the production will reach.

Chitosan/ka?t?sæn/is a linear polysaccharide composed of randomly distributed ß-(1-4)-linked D-glucosamine (deacetylated unit) and N-acetyl-D-glucosamine (acetylated unit). It is made by treating shrimp and other crustacean shells with the alkali sodium hydroxide.

Chitosan has a number of commercial and possible biomedical uses. It can be used in agriculture as a seed treatment and biopesticide, helping plants to fight off fungal infections. In winemaking it can be used as a fining agent, also helping to prevent spoilage. In industry, it can be used in a self-healing polyurethane paint coating. In medicine, it may be useful in bandages to reduce bleeding and as an antibacterial agent; it can also be used to help deliver drugs through the skin.

More controversially, chitosan has been asserted to have use in limiting fat absorption, which would make it useful for dieting, but there is evidence against this.

Other uses of chitosan that have been researched include use as a soluble dietary fiber.

Chitosan is produced commercially by deacetylation of chitin, which is the structural element in the exoskeleton of crustaceans (such as crabs and shrimp) and cell walls of fungi. The degree of deacetylation (%DD) can be determined by NMR spectroscopy, and the %DD in commercial chitosans ranges from 60 to 100%. On average, the molecular weight of commercially produced chitosan is between 3800 and 20,000 Daltons. A common method for the synthesis of chitosan is the deacetylation of chitin using sodium hydroxide in excess as a reagent and water as a solvent. This reaction pathway, when allowed to go to completion (complete deacetylation) yields up to 98% product.

The amino group in chitosan has a pKa value of ~6.5, which leads to a protonation in acidic to neutral solution with a charge density dependent on pH and the %DA-value. This makes chitosan water-soluble and a bioadhesive which readily binds to negatively charged surfaces such as mucosal membranes. Chitosan enhances the transport of polar drugs across epithelial surfaces, and is biocompatible and biodegradable. It is not approved by FDA for drug delivery though. Purified quantities of chitosans are available for biomedical applications.

Chitosan and its derivatives, such as trimethylchitosan (where the amino group has been trimethylated), have been used in nonviral gene delivery. Trimethylchitosan, or quaternised chitosan, has been shown to transfect breast cancer cells, with increased degree of trimethylation increasing the cytotoxicity; at approximately 50% trimethylation, the derivative is the most efficient at gene delivery. Oligomeric derivatives (3-6 kDa) are relatively nontoxic and have good gene delivery properties.

Description

INTRODUCTION
PROPERTIES & CHARACTERISTICS
STRUCTURE OF CHITIN & CHITOSAN:
CHITIN [1398-61-4]:
ITS EMPIRICAL FORMULA = (C8H13NO5)N,
EMPERICAL FORMULA = (C6H11NO4)N
IMPORTANT PROPERTIES OF CHITOSAN ARE AS FOLLOWS:
DEGREE OF DEACE ELATION
AVERAGE MOLECULAR WEIGHT
VISCOSITIES AND BEHAVIOR IN SOLUTION
SOLUBILITY
CATIONIC PROPERTIES
CHEMISTRY OF CHITIN AND CHITOSAN
USES AND APPLICATIONS
INDUSTRIAL USES:
APPLICATION OF CHITOSAN
CHITOSAN
MEDICAL AND PHARMACEUTICAL USES
BIOMEDICAL USES
PRELIMINARY RESEARCH AND FDA REVIEW
AGRICULTURAL & NUTRITIONAL USES:-
CHITIN SYNTHESIS INHIBITORS
USES OF CHITOSAN
I) CLARIFICATION AND PURIFICATION
II) CHROMATOGRAPHY
III) PAPER AND TEXTILES
IV) PHOTOGRAPHY
V) FOOD AND NUTRITION
VI) AGRICULTURE
II) MEDICAL AND PHARMACEUTICAL
TECHNICAL PARAMETERS
LOCATION OF THE PROJECT
BORROWER’S PROFILE
B.I.S. SPECIFICATION
MARKET OVERVIEW OF CHITIN
CHITIN MARKET DIVIDED BY DERIVATIVE TYPE AS:
CHITIN MARKET DIVIDED BY END-USE AS:
CHITIN MARKET DIVIDED BY GEOGRAPHY AS:
MARKET OVERVIEW OF CHITOSAN
PRESENT MANUFACTURERS OF CHITIN AND CHITOSAN
FOREIGN PRODUCERS OF CHITIN & CHITOSAN
SPECIFICATION AND TEST FOR MEDICAL GRADE CHITOSAN
ANALYZE REPORT OF CHITOSAN (MEDICAL GRADE)
RAW MATERIALS
CHITIN CONTENTS OF SOME ORGANISMS
CRUSTACEA:-
INSECTS:-
MOLLUSKS:-
FUNGI:-
MANUFACTURING PROCESS
BASIC CONCEPT:
CHITIN:
CHITOSAN:
CHITIN:-
DETAILS OF PROCESSING STEPS:-
CHITOSAN MANUFACTURING PROCESS:-
PROCESS FLOWSHEET FOR MANUFACTURING OF CHITIN-FROM
PRAWN FISH SHELL WASTES
MANUFACTURING PROCESS OF CHITOSAN (MEDICAL GRADE)
PRETREATMENT STEP
DEMINERALIZATION
DEPROTEINATION
CHITOSAN MANUFACTURING FROM CHITIN (MEDICAL GRADE)
TECHNOLOGY
RAW MATERIAL
DEPROTEINISATION
DEMINERALISATION
REMOVAL OF WATER
DEACETYLATION OF CHITIN
REMOVAL OF WATER
DRYING
POWDERING AND PACKING
YIELD
ILLUSTRATION OF THE PROCESS
PROCESS IN DETAILED
AT THE SAME TIME, ENZYMES
TWO EXPLANATIONS OF THIS PHENOMENON HAVE BEEN PROPOSED.
TABIE: CHEMICAL COMPOSITION OF VARIOUS CRUSTACEAN WASTES
AND OF INSECT’S LARVES OF CALLEHORA ERYTHROCEPHALA
CHITIN AND CHITOSAN EXTRACTION FROM CHITINOUS MARINE WASTE
CHEMICAL EXTRACTION
CHEMICAL DEPROTEINATION
CHEMICAL DEMINERALIZATION
BIOLOGICAL EXTRACTION
ENZYMATIC DEPROTEINATION
FERMENTATION
LACTIC ACID FERMENTATION
DEPROTEINIZATION OF CHITIN FROM SHRIMP HEAD WASTE
MATERIALS & METHODS
PREPARATION OF RAW MATERIAL
CHITIN EXTRACTION PROCEDURE
CHEMICAL ANALYSIS
FIGURE: THE TWO- STAGE METHOD FOR CHITIN PRODUCTION
TABLE: CHEMICAL COMPOSITION OF SHW1
TABLE: PROTEIN RECOVERY (%) OBTAINED BY USING DIFFERENT DEPROTEINIZATION PROCESSES
TABLE: NITROGENOUS COMPOSITION OF PRECIPITATE AFTER DEPROTEINIZATION PROCESSES
TABLE: EFFECT OF NAOH CONCENTRATION ON THE RESIDUAL PROTEIN CONTENT AND DEGREE OF ACETYLATION OF CHITIN PRODUCED BY THE TWO-STAGE METHOD)
TABLE: SPECIFICATION OF PRODUCED CHITIN COMPARED TO FOOD
GRADE PRODUCT
PRODUCTION METHOD OF CHITIN AND CHITOSAN FROM SHRIMP
SHELL IN BATCH CULTURE OF LACTOBACILLUS PLANTARUM
MATERIALS AND METHODS
SHRIMP SHELL
DATE SYRUP
TABLE – CHEMICAL CHARACTERISTICS OF DATE SYRUP
FERMENTATION
PREPARATION OF CHITIN
PREPARATION OF CHITOSAN
ANALYTICAL PROCEDURE
EFFLUENT TREATMENT PROCESS
EFFLUENT TREATMENT SYSTEM
PROTEIN PASTE FROM THE SHELL/PROTEIN SEPARATION
NAOH DE-PROTEINIZATION WASH WATER
HCL DE-MINERALIZATION WASH WATER
SEA AND FRESH WASH WATER
PLANT LAYOUT
SUPPLIERS OF PLANT AND MACHINERY
SUPPLIERS OF CONVEYOR BELT
SUPPLIERS OF PULVERISER
SUPPLIERS OF WASHING TANKS
SUPPLIERS OF TRAY DRYER
SUPPLIERS OF PVC TANKS
SUPPLIERS OF LIQUID TANKS
SUPPLIERS OF EVAPORATION UNIT
SUPPLIERS OF DRYING CHAMBER
SUPPLIERS OF BOILERS
SUPPLIERS OF WATER CHILLER
SUPPLIERS OF FILTER PRESS
SUPPLIERS OF LABORATORY TESTING EQUIPMENTS
SUPPLIERS OF CHEMICALS
SUPPLIERS OF RAW MATERIAL
RAW MATERIAL SUPPLIERS FOR CHITIN AND CHITOSAN
SUPPLIERS OF HYDROCHLORIC ACID
SUPPLIERS OF CAUSTIC SODA
SUPPLIERS OF LABORATORY CHEMICALS
ADDRESSES FOR CONSULTANT & TURNKEY PLANT

APPENDIX – A:

01. PLANT ECONOMICS
02. LAND & BUILDING
03. PLANT AND MACHINERY
04. OTHER FIXED ASSESTS
05. FIXED CAPITAL
06. RAW MATERIAL
07. SALARY AND WAGES
08. UTILITIES AND OVERHEADS
09. TOTAL WORKING CAPITAL
10. TOTAL CAPITAL INVESTMENT
11. COST OF PRODUCTION
12. TURN OVER/ANNUM
13. BREAK EVEN POINT
14. RESOURCES FOR FINANCE
15. INSTALMENT PAYABLE IN 5 YEARS
16. DEPRECIATION CHART FOR 5 YEARS
17. PROFIT ANALYSIS FOR 5 YEARS
18. PROJECTED BALANCE SHEET FOR (5 YEARS)

Additional information

Plant Capacity

1500 Kg./Day

Land & Building

(4000 sq.mt.)

Plant & Machinery

US$.814285

Rate of Return

35%

Break Even Point

54%