Casein from Milk

Uploaded on : May 2019

Introduction

 

Casein is the major protein in cows' and buffalo' milk, and comprises about 80 % of the total protein content of which the rest, some 20 %, are the whey or serum proteins. Casein is a mixture of phospho-proteins found in milk to the extent of about 3%. It contains all of the common amino acids and is high in the essential ones. The caseins are of Alpha, beta, gamma and K are in the order of decreasing mobility at pH 7.0.

 

Commercial casein is made from skim milk by one of two general methods – precipitation by acid or coagulation by rennet. As much of the fat, whey proteins, lactose and minerals as possible must be removed by multistage washing in water, as they reduce the quality of the casein as well as its keeping quality. Dried, properly produced casein has a relatively good keeping quality and is used mainly in the food and chemical industries.

 

Products and Its Application

 

Casein can be produced in various grades for different applications by precipitation from the skimmed milk with dilute Sulphuric acid, Hydrochloric acid or Lactic acid. Lactic Casein or Lactic acid Casein is the product of natural self-souring, although this is normally promoted by inoculating skin milk lactobacillus. It is used in paints, paper coating, paper cones, adhesives, rubber chemicals, leather, textile auxiliaries and pharmaceuticals. Rennet Casein is produced by Rennet process that is precipitated by the enzyme Rennet.

Rennet Casein is Calcium Caseinate, which has high ash content and is primarily used

by the food industries and is not used in adhesives

 

Product Mix & Product Capacity 1 ton/day
SRN	Produ ct	Cap. Kg/Day	Wkg Days	TPA
1	Rennet Casein	1,000.00	150.00	150.00
2	Lactic Acid Casein	1,000.00	90.00	90.00
3	Sulphuric Acid Casein	1,000.00	45.00	45.00
4	Fat Free Casein	1,000.00	15.00	15.00
			300.00	300.00

 

Desired Qualification for Promoter

 

The entrepreneur must be aware of processing and marketing of casein. Besides that he must be able to judge the quality of all inputs and finished products.

 

Industry Outlook/ Trend

 

India is world largest producer of milk. Production of milk is growing at the rate of 4% per annum. However, government has plan to double the milk production by 2022 by applying scientific methods in animal husbandry, improved cattle feed and batter veterinary services. This will result in increased availability of milk which can be converted in to products like casein. The application and demand for casein are growing at faster rate due to higher growth of food processing industries and specialty chemicals.

 

Market Potential

 

The market for casein is very wide and potential. It is estimated for period of 2016-2026 has projected that the global market for casein will surpass US$ 1 Billion in revenues by 2026. Global Micellar Casein Market to Grow at a 5.9% CAGR Through 2026

 

Raw Material Requirements

 

Sr. No.	Raw Material	Qty. in MT
1	Skimmed Milk	8,400.00
2	Rennet	3.00
3	Lactic Acid	1.80
4	Sulphuric Acid	0.90
5	Misc. Additives	1.30
	Total	8407.00

 

Manufacturing Process

 

Skim milk, normally pasteurized at 72 °C for 15 – 20 seconds, is used for the production of rennet casein, as well as other types of casein. Small amounts of fat are detrimental to the quality. It is therefore important that the milk has been separated efficiently. Renneting takes place with the help of the enzyme chymosin in the rennet. The milk is heated for a short period of time and then cooled to about 30 °C. Then the rennet is added. A gel forms after 15 – 20 minutes. It is cut and the coagulum is stirred while being heated to about 60 °C. The high temperature is needed to deactivate the enzyme. Cooking time is around 30 minutes.

 

Manpower Requirement

 

Sr. No.	Category	Persons
1	Technical Staff	5
2	Adm. Staff	4
3	Marketing Staff	4
4	Labour	16
	Total	29

 

Implementation Schedule

 

Project Stages	MONTHS
	1	2	3	4	5	6	7	8	9	10
Purchase of Land
Completion of Building
Ordering of Machinery
Delivery of Machinery
Term/ Wkg. Loan Sanction
Installation of Machinery
Commissioning of Plant
RM/Inputs Procurement
Manpower Appointments
Commercial Production

 

Cost of Project

 

Sr. No.	Costing Heads	Qty.	Rate/Unit	Rs. Lakh
1	Land in Sq. M. + Expn.	1,000.00	1,000.00	10.00
2	Building in sq. m.	700.00	9,000.00	63.00
3	Plant & Machinery			103.98
	Total			176.98

 

Means of Finance

 

Sr. No.	Means Heads	Rs. Lakhs
1	Promoters Capital	44.25
2	Term Loan	82.74
3	MFPI Subsidy	50.00
	Total	176.98

 

Working Capital Calculation

 

Particulars	Total Amount	Stock Period Days	Value of Stock Period	Promoter Margin	Promoter Share	Bank Borrowings
Raw Material	847.00	15	42.35	0.60	25.41	16.94
Packing Material	25.00	30	2.50	0.75	1.88	0.63
Work in Process	969.19	3	9.69	0.40	3.88	5.82
FP Stock	1,071.00	15	53.55	0.40	21.42	32.13
Bills Receivable	1,071.00	15	53.55	0.40	21.42	32.13
Working Expense	25.00	30	2.50	1.00	2.50	0.00
Total:	4,008.19		164.14		76.50	87.64
Loan + Promoter	164.14					13.15

 

Machinery Required

 

Sr. No.	Equipments	Qty.
	Preparatory Section
1	Skimmed Milk Storage Tanks	2
2	Skimmed Milk Pasteurizer	1
3	Casein Making Vats	2
4	pH Control	1
5	Washing Tanks	2
6	Decanters	2
7	Casein Collection Tanks	1
8	Tray Dryers	4
9	Pulveriser	1
10	Vibro Sifter	1
11	Packing & Bagging Machine
	Utility & Other Equipments
12	Steam Boiler & Pipelines/Fittings	1 Lot
13	Effluent Treatment Plant	1 Lot
14	Electrification, DG Set, Transformer	1 Lot
15	Material Handling Equipments	1 Lot
16	Laboratory Equipments	1 Lot
17	RO Plant	1 Lot
18	Working Platform	1 Lot
19	SS Pipeline and Fittings	1 Lot

 

IDMC Limited

Plot no. 124-128,

GIDC Estate, GIDC,

Vitthal Udyognagar INA,

Gujarat

YSM Biotech International

UL 30, EF3 Mall, Plot No. 12, Sector 20 A
Sector - 20 A
Faridabad - 121001 Haryana,

 

Profitability Calculations

 

Sr. No.	Particulars	Year 1	Year 2	Year 3	Year 4	Year 5
A	Gross Sales	749.7	856.8	963.9	963.9	963.9
	Less:
1	Raw Materials, Rs. 1/lit	592.9	677.6	762.3	762.3	762.3
2	Packing Material	17.5	20	22.5	22.5	22.5
3	Fuel	4.41	5.04	5.67	5.67	5.67
4	Power	0.84	0.96	1.08	1.08	1.08
5	Manpower	39.8424	44.9504	50.0584	50.0584	50.0584
6	Sundry Expenses	4.2	4.8	5.4	5.4	5.4
7	Interest on Term Loan	6.951	7.944	8.937	8.937	8.937
8	Interest on WC Loan	9.205	10.52	11.835	11.835	11.835
9	Repairs & Maintenance	7	8	9	9	9
B	Production Cost	682.8484	779.8144	876.7804	876.7804	876.7804
C	Gross Profit (A-B):	66.8516	76.9856	87.1196	87.1196	87.1196
	Taxes @ 30%	20.05548	23.09568	26.13588	26.13588	26.13588
	Net Profit	46.79612	53.88992	60.98372	60.98372	60.98372

 

The proposed unit will have the production capacity of one MT per day. The unit cost of power is taken at Rs. 8. The depreciation on building is taken at the rate of 5% whereas for plant and machinery it is at 10%.

 

The average sales price of casein is taken at the rate of Rs.357 per kg for proposed project.

 

Breakeven Analysis

 

Particulars	Rs in Lakhs
Break Even Point
Annual Fixed Cost x100/	46.44
Annual Fixed Cost + Profit

 

Statutory/ Government Approvals

 

There is statutory requirement of FSSAI license for setting up of food processing industry. Moreover, MSME & GST registration, IEC Code for Export of end products and local authority clearance may be required for Shops and Establishment, for Fire and Safety requirement and registration for ESI, PF and Labour laws may be required if applicable. Entrepreneur may contact State Pollution Control Board for consent and permission to treat and dispose of the liquid effluent. Casein production is highly polluting activity and therefore while selecting location utmost care must be taken by the promoter.

 

Backward and Forward Integration

 

As part of backward integration promoter may think of creating facilities for milk processing to make milk products such as butter, cream, cheese, yogurt etc. there is no possibility of forward integration.

 

Training Centers/Courses

 

For food processing industry training and short term courses are available at Indian Institute of Food Processing Technology, Thanjavur, Tamil Nadu and Central Food Technological Institute, Mysore, Karnataka, National Dairy Research Institute, Haryana and National Dairy Development Board, Anand.

Udyamimitra portal  ( link :  www.udyamimitra.in  ) can also be accessed for handholding services viz. application filling / project report preparation, EDP, financial Training, Skill Development,  mentoring etc.

Entrepreneurship program helps to run business successfully is also available from Institutes like Entrepreneurship Development Institute of India (EDII) and its affiliates all over India.

 

Source

SIDBI Tower, 15, Ashok Marg, Lucknow- 226001, Uttar Pradesh

Phone No. - 0522-2288546, 0522-2288547, 0522-2288548

Fax no. – 0522-2288459

 

For further information please contact

Information Manager
TIMEIS Project
E-mail: timeis@ficci.com