Mr. Ashish Singh, Managing Director , Phyto Ingredients Biopharma Pvt Ltd Haridwar, Uttrakhand , explains how to set up ashwagandha extract processing unit and also provides consultancy for setting up any type of herbal extraction unit.
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The raw materials for extraction of ashwagandha come in two parts – panchang which contains stem and leaves, which are sundried and taken for extraction, and the other one is the root. The prices of the two raw materials vary a lot. While the panchang costs Rs. 25 to 30 per kg, the roots cost Rs. 300 to 350 per kg, and the price varies according to the seasonal demands. The output price from panchang costs Rs. 800 to 900 while the HPLC costs Rs. 1200 to 1300. Ashwagandha root extract costs Rs. 1900 to 2000 while the one through HPLC is selling at Rs. 7500.
Assuming we are setting up a plant for 1 ton input every day, that is raw materials, we need 3500 to 4000 sq. m of land, out of which, 400 to 500 sq. m for stores, 200 to 250 sq. m for utility are needed. In storing area, we can store the raw materials, stabiliser, and other products related to production unit for one or two months approximately 60 to 80 MT. Utility area is for boilers, cooling towers, chillers, air compressors, and other machineries. We have solvent storage which is being procured from tankers should be kept in the ground due to security reasons as per the government laws. So 400 sq. mt. are needed. For the boilers, solid fuel, and fuel required for boiler like firewood or rice husk or saw dust need to be kept for 2.5 months stock which needs 200 to 250 sq.mt. Extraction facility in which we are extracting the solution is tentatively 300 to 350 sq.mt. Processing and purification after extraction that we need to do to get pure product needs 300 to 350 sq.mt. After getting the solid form, we have to dry the product and make it into powder to pack. That needs to be done in a clean room as the pharma products should be packed in closed and controlled areas. the laboratory needs 200 to 250 sq.mt and the office 200 to 250 sq.mt. These are only standard requirements, and we can establish in smaller areas too. Bigger space will help in future expansion.
Based on the construction and planning, the plant equipment will cost Rs. 150 lakhs, lab equipment Rs. 40 lakh, utilities equipment Rs. 60 lakh, land and building Rs. 150 lakh, and the total expenditure will be approximately Rs. 4 crores which may vary from time to time.
The raw material, panchang, is ground into smaller particles, coarse one, and charged to extraction which is the basic procedure of extraction. Taking the raw material for extraction and extracting. The next step is solvent recovery, and the extract soluble in the solvent is collected from the extraction chamber and moved to solvent recovery plant. Here the solvent is removed and the extract collected which is in liquid form. Then in an evaporation process we try to remove complete solvent from the liquid. We further purify it by purification and settling, crystallisation process, and drying in the dryer. When we get the product from the dryer, it is dried cake forms. So this has to be powdered and packed in plastic drums which are polybags. Storage of raw materials can be done in units that are needed to store them in controlled environment. Raw materials need to be temperature resistant. So they are stored inside insulated chambers. We are using insulated tin sheds so that the temperature difference created in storage areas, and materials do not get degraded due to natural process. We usually consider one MT per one sq.mt. We can store more also by using other methods. Air handling unit is actually a humidifier used in the clean room and storage. Some industries use it in raw materials storage area, but in clean room area it is a mandatory requirement.
Processing part: The machineries like hammer, mill and pulveriser reduce the particle size of the products. The extractor can be of two to four types. It can be vertical, quadra. Ultrasonic or rotatory extractor. Based on the studies, we have to tune the rotary extractor in which the solvent and herbs are mixed in the correct ratio, which is why we choose this. In other machines there are a few drawbacks and are also expensive.
Evaporation of solvents: in the main hole from this the herbs are put into the vessel and the chamber where the herbs are charged, which means the material is put into the chamber manually or through the conveyor system, but it is done manually preferably because small quantities are handled every day. The solvent is then charged through the other side, we increase the temperature, and since it is a jacketed vessel it is filled with steam which increases the temperature. Once the required temperature is reached, the extraction occurs, and the solvent is drained through the filter which is not visible and taken to the evaporators. The liquid comes to the tank through the pump with the materials settling down in the bottom, and steam is circulated in the jacketed part. The material is heated for some time, taking care that it does not get burnt. The evaporator is used to evaporate solvent in a short duration, and we are circulated the product to evaporator and separating the solvent as the extract. First the extract is separated from the evaporator. However, we cannot remove the solvent completely, and so for the complete removal of solvent, we have to do more process. We get concentrated syrup of ashwagandha pure extract in liquid form and oleoresin. We have to supply to the manufacturers in dry powder form. For that we need to dry or filter the impurities and dry in driers.
The filtration equipment include nutch filter, and centrifuge is used to remove the unwanted parts. There are driers with vacuum trays which function on a basic oven system. We put the syrup in the trays, close the lid, and the material gets dried in the reduced temperature and pressure. We get it in the cake form, we put it in the grinding equipment. As this is our finished product, we cannot use the MS built structure but only SS structure. Once the material is received, they will be of different percentages. We have to mix them to get homogenous powder into huge quantity for supply. We can use the packing materials to get the powder packed.
The machinery used for the purpose are boiler for steam generation, water cooling towers, vacuum pumps, water chilling units, soft water plant with capacity of 200 litres per hour, electricity generator for power backup, air handling units for raw materials, final processing water cooling towers, chilling water system which may be of different designs, and cooling towers of various categories. The cooling towers reduce the temperature from 35 degrees to 22 degrees Celsius, but chilling towers reduce temperature from 15 degrees to 8 degrees or lower. The vacuum pump creates a negative pressure so that when we put the material in the reactor when the solvent is very less quantity, and if we use vacuum it creates a vacuum to lower volume material to be removed from the product. The product is categorised based on the HPLC method. For that we need basic set up of analysis of raw materials, to analyse intermediate solvents and compounds.
What is the ideal soil weather conditions for cultivating ashwagandha plants and to get good yield?
I am just an expert in extracting the active ingredients from the ashwagandha dried materials.
Can you let us know about market demand for ashwagandha product, and how can entrepreneurs tap into the market?
The business has scope in the pharmaceutical sector. The extract we get are in high demand in this industry. Companies like KSM 66 are using ashwagandha in capsules for applications.
What are the various stages involved in processing ashwagandha, and how can entrepreneurs ensure the quality of the final product?
The processing of ashwagandha is done with some basic steps. Collection of raw materials, grinding, further processing of extraction, solvent recovery, concentration, purification, drying, and crystallisation, and finished product testing. Ashwagandha is extracted using HPLC and … methods which have basic processing difference in concentration, purification, and crystallisation.
Are there any tools or equipment to set up ashwagandha processing unit and the cost?
The cost to set up one ton per day input raw material including plant, equipment, extraction, processing, evaporation, filtering, drying, and finished good processing are included in plant equipment. Laboratory equipment to analyse produce and raw materials are needed. We can get the third party to test the materials, but we need utilities, plant, equipment, land, and building. Land can be of 3500 to 4000 sq.mt. The size can vary too. It depends on the project. For one ton per day consumption basis 2000 1500 sq.mt is enough. For a solvent storage and utility more area is needed. If we organise these things properly we can reduce the area requirement.
What is the common mistake that entrepreneurs make when they set up ashwagandha processing unit, and how should they avoid them?
Entrepreneurs usually think they can do all things by themselves, but if somebody is an expert, they have to take their opinion. When they are investing huge money, they have to go for consultants to get the second opinion and optimised solutions.
Can you explain the regularity requirements and certification that entrepreneurs need to set up the ashwagandha processing unit?
We have to get clearance from pollution department to set up a project like this, submit application to DIC office, labour pollution department and some more. Once we get clearance from CET, we can set up the unit. CTO has to be obtained to start manufacturing. The CTO application is sent to DIC office, and they will approve it based on what is mentioned in the CTO after checking. Then we can start processing and manufacturing facility. Explosive license has to be obtained for solvents. all these can be done with guidance from consultants. Without these certifications, we cannot start manufacturing.
Can you mention some successful stories in this sector and what contributed to their success?
Cennet Biopharma have done a tremendous work with consultancy from the best people. They have not faced any hurdle in getting licenses.. They have a turnover of Rs. 35 to 40 crores. It is a 3-year old company.
What are the emerging trends in ashwagandha processing? What are the opportunities and challenges in exporting ashwagandha?
We are working on two products, and we can achieve 95% purity. The prices when exported are doubled. We can get good business when exporting. If we do not follow the government laws, we will face lot of hurdles.
Please let us know your career background and how you got into agriculture field.
I am a chemical engineer from Karnataka and go associated with an herbal extraction unit. I realised this has great potential, and so I wanted to invest and start the unit. The cost that I mentioned for the unit set up may vary based on the capacity and is tentative. By going into complete details and taking guidance we can reduce the cost of the project. Anyone in need of guidance to start and run the project, can contact us.
Those interested in setting up the projects can approach us. Apart from ashwaganth we also provide consultancy for setting up any type of herabal extraction unit.
Mr. Ashish Singh
Managing Director
Phyto Ingredients Biopharma Pvt Ltd
Haridwar, Uttrakhand
www.phytoingredients.com
E-Mail: phytoingredients@gmail.com
Telephone: 8840804180
.
The raw materials for extraction of ashwagandha come in two parts – panchang which contains stem and leaves, which are sundried and taken for extraction, and the other one is the root. The prices of the two raw materials vary a lot. While the panchang costs Rs. 25 to 30 per kg, the roots cost Rs. 300 to 350 per kg, and the price varies according to the seasonal demands. The output price from panchang costs Rs. 800 to 900 while the HPLC costs Rs. 1200 to 1300. Ashwagandha root extract costs Rs. 1900 to 2000 while the one through HPLC is selling at Rs. 7500.
Assuming we are setting up a plant for 1 ton input every day, that is raw materials, we need 3500 to 4000 sq. m of land, out of which, 400 to 500 sq. m for stores, 200 to 250 sq. m for utility are needed. In storing area, we can store the raw materials, stabiliser, and other products related to production unit for one or two months approximately 60 to 80 MT. Utility area is for boilers, cooling towers, chillers, air compressors, and other machineries. We have solvent storage which is being procured from tankers should be kept in the ground due to security reasons as per the government laws. So 400 sq. mt. are needed. For the boilers, solid fuel, and fuel required for boiler like firewood or rice husk or saw dust need to be kept for 2.5 months stock which needs 200 to 250 sq.mt. Extraction facility in which we are extracting the solution is tentatively 300 to 350 sq.mt. Processing and purification after extraction that we need to do to get pure product needs 300 to 350 sq.mt. After getting the solid form, we have to dry the product and make it into powder to pack. That needs to be done in a clean room as the pharma products should be packed in closed and controlled areas. the laboratory needs 200 to 250 sq.mt and the office 200 to 250 sq.mt. These are only standard requirements, and we can establish in smaller areas too. Bigger space will help in future expansion.
Based on the construction and planning, the plant equipment will cost Rs. 150 lakhs, lab equipment Rs. 40 lakh, utilities equipment Rs. 60 lakh, land and building Rs. 150 lakh, and the total expenditure will be approximately Rs. 4 crores which may vary from time to time.
The raw material, panchang, is ground into smaller particles, coarse one, and charged to extraction which is the basic procedure of extraction. Taking the raw material for extraction and extracting. The next step is solvent recovery, and the extract soluble in the solvent is collected from the extraction chamber and moved to solvent recovery plant. Here the solvent is removed and the extract collected which is in liquid form. Then in an evaporation process we try to remove complete solvent from the liquid. We further purify it by purification and settling, crystallisation process, and drying in the dryer. When we get the product from the dryer, it is dried cake forms. So this has to be powdered and packed in plastic drums which are polybags. Storage of raw materials can be done in units that are needed to store them in controlled environment. Raw materials need to be temperature resistant. So they are stored inside insulated chambers. We are using insulated tin sheds so that the temperature difference created in storage areas, and materials do not get degraded due to natural process. We usually consider one MT per one sq.mt. We can store more also by using other methods. Air handling unit is actually a humidifier used in the clean room and storage. Some industries use it in raw materials storage area, but in clean room area it is a mandatory requirement.
Processing part: The machineries like hammer, mill and pulveriser reduce the particle size of the products. The extractor can be of two to four types. It can be vertical, quadra. Ultrasonic or rotatory extractor. Based on the studies, we have to tune the rotary extractor in which the solvent and herbs are mixed in the correct ratio, which is why we choose this. In other machines there are a few drawbacks and are also expensive.
Evaporation of solvents: in the main hole from this the herbs are put into the vessel and the chamber where the herbs are charged, which means the material is put into the chamber manually or through the conveyor system, but it is done manually preferably because small quantities are handled every day. The solvent is then charged through the other side, we increase the temperature, and since it is a jacketed vessel it is filled with steam which increases the temperature. Once the required temperature is reached, the extraction occurs, and the solvent is drained through the filter which is not visible and taken to the evaporators. The liquid comes to the tank through the pump with the materials settling down in the bottom, and steam is circulated in the jacketed part. The material is heated for some time, taking care that it does not get burnt. The evaporator is used to evaporate solvent in a short duration, and we are circulated the product to evaporator and separating the solvent as the extract. First the extract is separated from the evaporator. However, we cannot remove the solvent completely, and so for the complete removal of solvent, we have to do more process. We get concentrated syrup of ashwagandha pure extract in liquid form and oleoresin. We have to supply to the manufacturers in dry powder form. For that we need to dry or filter the impurities and dry in driers.
The filtration equipment include nutch filter, and centrifuge is used to remove the unwanted parts. There are driers with vacuum trays which function on a basic oven system. We put the syrup in the trays, close the lid, and the material gets dried in the reduced temperature and pressure. We get it in the cake form, we put it in the grinding equipment. As this is our finished product, we cannot use the MS built structure but only SS structure. Once the material is received, they will be of different percentages. We have to mix them to get homogenous powder into huge quantity for supply. We can use the packing materials to get the powder packed.
The machinery used for the purpose are boiler for steam generation, water cooling towers, vacuum pumps, water chilling units, soft water plant with capacity of 200 litres per hour, electricity generator for power backup, air handling units for raw materials, final processing water cooling towers, chilling water system which may be of different designs, and cooling towers of various categories. The cooling towers reduce the temperature from 35 degrees to 22 degrees Celsius, but chilling towers reduce temperature from 15 degrees to 8 degrees or lower. The vacuum pump creates a negative pressure so that when we put the material in the reactor when the solvent is very less quantity, and if we use vacuum it creates a vacuum to lower volume material to be removed from the product. The product is categorised based on the HPLC method. For that we need basic set up of analysis of raw materials, to analyse intermediate solvents and compounds.
What is the ideal soil weather conditions for cultivating ashwagandha plants and to get good yield?
I am just an expert in extracting the active ingredients from the ashwagandha dried materials.
Can you let us know about market demand for ashwagandha product, and how can entrepreneurs tap into the market?
The business has scope in the pharmaceutical sector. The extract we get are in high demand in this industry. Companies like KSM 66 are using ashwagandha in capsules for applications.
What are the various stages involved in processing ashwagandha, and how can entrepreneurs ensure the quality of the final product?
The processing of ashwagandha is done with some basic steps. Collection of raw materials, grinding, further processing of extraction, solvent recovery, concentration, purification, drying, and crystallisation, and finished product testing. Ashwagandha is extracted using HPLC and … methods which have basic processing difference in concentration, purification, and crystallisation.
Are there any tools or equipment to set up ashwagandha processing unit and the cost?
The cost to set up one ton per day input raw material including plant, equipment, extraction, processing, evaporation, filtering, drying, and finished good processing are included in plant equipment. Laboratory equipment to analyse produce and raw materials are needed. We can get the third party to test the materials, but we need utilities, plant, equipment, land, and building. Land can be of 3500 to 4000 sq.mt. The size can vary too. It depends on the project. For one ton per day consumption basis 2000 1500 sq.mt is enough. For a solvent storage and utility more area is needed. If we organise these things properly we can reduce the area requirement.
What is the common mistake that entrepreneurs make when they set up ashwagandha processing unit, and how should they avoid them?
Entrepreneurs usually think they can do all things by themselves, but if somebody is an expert, they have to take their opinion. When they are investing huge money, they have to go for consultants to get the second opinion and optimised solutions.
Can you explain the regularity requirements and certification that entrepreneurs need to set up the ashwagandha processing unit?
We have to get clearance from pollution department to set up a project like this, submit application to DIC office, labour pollution department and some more. Once we get clearance from CET, we can set up the unit. CTO has to be obtained to start manufacturing. The CTO application is sent to DIC office, and they will approve it based on what is mentioned in the CTO after checking. Then we can start processing and manufacturing facility. Explosive license has to be obtained for solvents. all these can be done with guidance from consultants. Without these certifications, we cannot start manufacturing.
Can you mention some successful stories in this sector and what contributed to their success?
Cennet Biopharma have done a tremendous work with consultancy from the best people. They have not faced any hurdle in getting licenses.. They have a turnover of Rs. 35 to 40 crores. It is a 3-year old company.
What are the emerging trends in ashwagandha processing? What are the opportunities and challenges in exporting ashwagandha?
We are working on two products, and we can achieve 95% purity. The prices when exported are doubled. We can get good business when exporting. If we do not follow the government laws, we will face lot of hurdles.
Please let us know your career background and how you got into agriculture field.
I am a chemical engineer from Karnataka and go associated with an herbal extraction unit. I realised this has great potential, and so I wanted to invest and start the unit. The cost that I mentioned for the unit set up may vary based on the capacity and is tentative. By going into complete details and taking guidance we can reduce the cost of the project. Anyone in need of guidance to start and run the project, can contact us.
Those interested in setting up the projects can approach us. Apart from ashwaganth we also provide consultancy for setting up any type of herabal extraction unit.
Mr. Ashish Singh
Managing Director
Phyto Ingredients Biopharma Pvt Ltd
Haridwar, Uttrakhand
www.phytoingredients.com
E-Mail: phytoingredients@gmail.com
Telephone: 8840804180