CHAPTER I

INTRODUCTION AND ITS BACKGROUND

Coconuts are known for their versatility of uses, ranging from food

to cosmetics. The inner flesh of the mature seed, as well as the coconut milk extracted

from it, forms a regular part of the diets of many people in the tropics and subtropics.

Coconuts are distinct from other fruits because their endosperm contains a large

quantity of clear liquid, called "coconut water" or "coconut juice" and coconut milk.

Mature, ripe coconuts can be used as edible seeds, or processed for oil and plant

milk from the flesh, charcoal from the hard shell, and coir from the fibrous husk. Dried

coconut flesh is called copra, and the oil and milk derived from it are commonly used in

cooking – frying in particular – as well as in soaps and cosmetics. The hard shells,

fibrous husks and long pinnate leaves can be used as material to make a variety of

products for furnishing and decorating. The coconut also has cultural and religious

significance in certain societies, particularly in India, where it is used in Hindu rituals.

Coconut water is a refreshing drinks which also hygienic and nutritive. The white

flesh is a calories rich extensively used for cookery in South India. From grated wet

coconut kernel good quality oil as well as protein and carbohydrate can be extracted to

prepare coconut honey. Undesirable flavour changes in desiccated coconut is due to

oxidative rancidity of the oil. The residual cake after the oil has been extracted is used

as cattle food.

The dried coconut meat is known as copra and is the source of coconut oil, which
is used in enormous quantities for making fats for baking and confectionery. An

important product used in the chocolate and confectionery industry is desiccated

coconut. The nut is removed from the hard shell and the thin brown rind pared off. This

must be very thorough or the finished coconut will be contaminated by flecks of brown.

The pared nuts are then washed free of milk and skin residues and put through

shredding machines, which give a milled product of varying degree of fineness. After

shredding, the ground meat is subjected to a steam or hot water treatment to

destroy salmonella and lipases and to reduce bacteria counts to low levels. The

pasteurized meat is then dried on wire mesh belts by means of hot air, which reduces

the moisture content to less than 4%. The critical moisture level of desiccated coconut

is 5% and the product should be well below this to ensure good shelf life.

After drying, the desiccated coconut is put through a multiple sieving operation to

produce the four main grades. Extra fine, macaroon (fine), medium and coarse. A

variety of other coconut products is available to the chocolate and confectionery trade

such as, moist white sweetened coconut, toasted coconut, creamed coconut and

tenderized coconut.

Top quality desiccated coconut should be white in color, free from foreign matter, and

uniform in granulation against standard, and the expressed oil should have a free fatty

acid content of less than 0.1%.

LOCATION

The location to where the plant will be established will be at Malabrigo Lobo, Batangas

as seen in Figure 1. The location of the plant was determined by considering different
factors, these factors were the availability of raw materials, road accessibility, the

availability of water supply, distance from residential houses, and climate.

Figure 1. Plant Location of Coconut Powder Milk Production Plant

Since the raw materials of the Coconut Powder Milk Production Plant is Coconut, the

Coconut deposits in Lobo, Batangas were considered.

Furthermore, the chosen location would mean that it would offer job

opportunities to those residents living in Malabrigo Lobo, Batangas. Since, the plant

location would be estimated 1500 meters to the nearest residential houses, those who

live from that specific area would be the priority in these job opportunities, taking

consideration to the capability of those individuals.

RAW MATERIALS
 Coconut will be the raw materials of the Coconut Powder Milk Production Plant.

These Coconut will be here in Lobo Batangas, coconut as raw materials for the plant.

PRODUCT

The product of the Coconut Powder Milk Production Plant will be done by means

of processing the Coconut. It has numerous applications to which are the following:

 Coconut oil

 Coconut Water based Products

 Coconut chips

 Coconut Cream

 Toothpaste making

Coconut powder milk is also used as a

 Flavoring ingredient for ice cream

 Yogurt

 Bakery products

 Packed food sauces and beverages.

PLANT CAPACITY

The Coconut Powder milk Production plant capacity will be based on the demand

for production of coconut in the [Link] is statistically stated that the global market
for Coconut powder milk is projected to reach 98.7 million tons by 2020. Moreover, 6.6%

CAGR of that global market comes from the Asia, to which 17% of it is at South East Asia

(SEA), the Philippines shares 5% of that statistic forecast. Furthermore, the calculated

market of Coconut Milk powder in the Philippines would be estimated at 110,741.4 tons

annually.

DEMAND

The demand for coconut is booming, statistically it is stated that the global coconut

powder milk is expected to reach an estimated $23.5 billion by 2022 with a CAGR of 4.6%

from 2017 to 2022. This growth owing to rising demand from end-use industries including

flavoring ingredient for ice cream yogurt bakery products packed food sauces and

beverages.

MARKET SHARE

The market share of the Coconut Powder Milk in the Philippine Market will be at

10% of the total annual market of the CPM in the local market.
 CHAPTER II

TECHINCAL ASPECTS

This chapter includes the complete equipment layouts planned taking into

considerations the process diagrams, operations of the equipment, the process units

under standard specifications, mass balances and energy balances for each unit, and the

provisions for the ancillary buildings and services needed for the plant operation.

DESIGN BASIS
 Figure 2. Simplified Block Flow Diagram of CPM Process

The basis for the process of the production of Coconut Powder Milk (CPM) is shown at

figure 2. Figure 2 shows the block flow diagram for processing CPM. The process shows

the general procedural processes to be used in the production of CPM, these processes

are Grinding,Double screw,Filtering,Pump transfering, Pre Heating, Evapoarating,

Drying, Powder sieving and Powder packing, to all which focuses on the production of

CPM.

A. Process Units and Their Functions Crusher

De-husking

The husk of matured coconut to be used is removed, exposing the hard shell.

Figure 2. De husking Unit

Source: Unitech

De Shelling

De shelling machine is used to remove the hard outer shell of coconut with
operator assistance. The machine consists of two set of revolving cutters which are
used to remove the shell. Motor and speed reduction system are integrated inside the
machine. The high speed steel tool-tips on the cutter wheel are adjustable for the wear
and tear and can be easily replaced. Machine is provided with stainless steel outer
cladding.

Figure 3. De shelling Unit

Source: Unitech

Paring

this is the scraping away of the brown skin attached to the coconut meat to give

white coconut meat.

Figure 4. Paring Unit

Source: Unitech

Washing Coconut Machine

Washing Coconut Machine is the important machine to removed the dirts from

coconut.

Figure 5. Washing Coconut Unit

Source: [Link]

Grinding

Grinding The grated coconut is pulverized/ground into smaller particles.

Source: [Link]

 De-Shelling: The shell of the coconut is removed using a de-shelling machine. This can also be done

manually by cracking the shell open with a knife or hitting it against a hard surface.

 Paring: this is the scraping away of the brown skin attached to the coconut meat to give white coconut meat.

 Washing: The paired coconut is rinsed with clean water to remove specks of dirt and impurities attached to

the coconut meat.

 Grating: The clean coconut meat is grated into smaller sizes with the use of a grater

 Grinding: The grated coconut is pulverized/ground into smaller particles. This stage can also be done at home

by using a blender to blend the grated coconut with water.

 Milk Extracting: Milk is extracted using a milk extractor. The milk extractor presses the grounded coconut to

extract the milk. A cheesecloth can be used at home to squeeze out milk from the blended coconut.

 Filtering: The extracted milk should be filtered to remove any form of sediments.