Bio-Pesticide Product Costing Template (Pilot Plant Scale Production April 2006)

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Bio-Pesticide Product Costing Template (Pilot Plant Scale Production April 2006)

  1. 1. INDUSTRIAL GRANT SCHEME (IGS) 2004 - SAIFUL IRWAN ZUBAIRI PRODUCT COSTING OF ROTENONE PILOT SCALE PRODUCTIONMaximum capacity : 300 L/runExtraction ratio : 1 kg Fine Root: 10 L Solvent : 25 kg Fine Root: 250 L SolventDirect Production Cost1) RAW MATERIAL (Fine Roots) 1 kg Fine Roots achieved from ----------------- ≅ 15 kg Whole Plant ∴ IF, 25 kg Fine Roots needed for Extraction ----- ≅ 25 kg F.R × 15 kg Whole Plant 1 kg Fine Roots ≅ 375 kg Plant needed for getting 25 kg of Fine Roots for Extraction COST: 1 kg Whole Plant ≅ RM 5.00 ∴ 375 kg Whole Plant ≅ RM 1,875.00/Run----------------------------------------------------------------------------------------------------------------2) SOLVENT (Acetone) Raw Material: Solvent = 1: 10 ∴ 25 kg Fine Roots : 250 L Acetone ACETONE a) Industrial Grade – Volume = 209 L/Drum – RM 800.00 Therefore, we need : 250L/209L × RM 800.00 = RM 957.00/Run3) UTILITIES (Washing & Evaporation Process – Water & Electricity) = RM 50/Run NEED TO BE CLARIFYING FURTHER IN TERMS OF ENERGY USAGE.----------------------------------------------------------------------------------3) FILTRATION PROCESS (Membrane filter - STRAINER) = RM 30/Run----------------------------------------------------------------------------------------------------------------
  2. 2. INDUSTRIAL GRANT SCHEME (IGS) 2004 - SAIFUL IRWAN ZUBAIRI DIRECT PRODUCTION COST (DPC) = RM 1,875 + RM 957 + RM 50 + RM 30 = RM 2,912/Run OPERATING LABOR (OL) = RM 0.02/g A.i × 666,431.09 mg of A.i = RM 13.32/Run × No. of Workers (3) = ∴ RM 40.00/Run LABORATORY CHARGES (LC) = 10 % Operating Labor = RM 4.00/Run TOTAL MANUFACTURING EXPENSES, AME = DPC + OL + LC = RM 2,912 + RM 40.00 + RM 4.00 = 2,956.00/Run DIRECT SCALE UP OF LAB SCALE PRODUCTION: Maximum Capacity of Extraction Vessel: 300L/run: SEMI-PILOT PLANT Based on the result in the latest development of Rotenone extraction process: 25 March 2004 using the Tuba Kota Johor Lama, Johor; the Rotenone yield, concentration & volume of crude extract are: Name of Samples Acetone Extract Concentration (mg/ml) (Unconcentrated)Tuba Kota Johor Lama – Crude Extract 2.90 Name of Samples Acetone Extract Yield (mg) (Unconcentrated)Tuba Kota Johor Lama – Crude Extract 820.00 Name of Samples Acetone Extract Volume of Crude Extract (ml) (Unconcentrated)Tuba Kota Johor Lama – Crude Extract 283/500 By up scaling the result from the laboratory to pilot plant process: (A.i = Active Ingredient - Rotenone) DATA FROM LAB SCALE: (50 g of raw material) YIELD: 1.64% (w/w) 283.00 ml of crude extract solution ------------ 820.00 mg of A.i
  3. 3. INDUSTRIAL GRANT SCHEME (IGS) 2004 - SAIFUL IRWAN ZUBAIRIDATA FOR SEMI-PILOT PLANT SCALE: (25,000 g of raw material)YIELD: 2.66% (w/w)If, 230,000 ml (230 L) of crude extract solution ----------? mg of A.i820.00 mg of A.i ______ × 230,000 ml of crude extract283.00 ml of crude extract= 666,431.09 mg of A.i/Run contain in the 230 L of LIQUID CRUDE EXTRACT.ASSUMING THAT THE CONCENTRATION OF CONCENTRATED LIQUIDCRUDE EXTRACT TO BE ACHIEVED IS 50 mg/ml AND THE ROTENONECONTENT IS RETAINED (666,431.09 mg) BEFORE AND AFTER THECONCENTRATION PROCESS.(ROTENONE LOSSES IS NEGLECTED – ASSUMING TO BE 100% RECOVERY OF A.i)2.90 mg/ml (Rotenone Conc.) ----------- 230 L of Liquid Crude Extract(UNCONCENTRTED)/Run50 mg/ml (Rotenone Conc.) ------------ 13.33 L of Liquid Crude Extract(CONCENTRATED)/RunCALCULATION:50 mg/ml × Y (VOLUME OF CONCENTRATED LIQ) = 666,431.09 mg of RotenoneSo, Y (VOLUME OF CONCENTRATED LIQ) = 666,431.09 mg/50 mg × 1 ml∴= 13.33 L/Run13,328.62 ml (13.33 L) of Concentrated Liquid Crude Extract contains666,431.09 mg of rotenone.IF, 1 ml of Concentrated Liquid Crude Extract – 666,431.09 mg/13,328.62 ml ×1ml∴1 ml of Concentrated Liq. Crude Extract --- 50 mg of rotenone50 mg of rotenone ------------- 1 ml of Concentrated Liq. Crude ExtractIF, 1g of A.i ------------ 1ml/50 mg × 1g = 20 mlSo, Cost per unit weight of Rotenone = AME / 666,431.09 mg of A.i/Run RM 2,956.00/Run/666,431.09 mg of A.i/Run = RM 0.0044/mg A.i COST OF SEMI PRODUCT/RUN: ∴RM 4.40/g A.i/20 ml of Concentrated Liquid Crude Extract (1 g of A.i that contains in 20ml of Concentrated Liquid Crude Extract (SEMI PRODUCT) per run = RM 4.40
  4. 4. INDUSTRIAL GRANT SCHEME (IGS) 2004 - SAIFUL IRWAN ZUBAIRI PRODUCTION OF FORMULATED PRODUCT (3 % A.i) FROM 13.33 L OF CONCENTRATED LIQUID CRUDE EXTRACT PRODUCT (SEMI PRODUCT)ASSUMING THAT THE CONCENTRATION OF CONCENTRATED LIQUIDCRUDE EXTRACT TO BE ACHIEVED IS 50 mg/ml AND THE ROTENONECONTENT IS RETAINED (666,431.09 mg) BEFORE AND AFTER THECONCENTRATION PROCESS.(ROTENONE LOSSES IS NEGLECTED – ASSUMING TO BE 100% RECOVERY OF A.i)2.90 mg/ml (Rotenone Conc.) ----------- 230 L of Liquid Crude Extract(UNCONCENTRTED)/Run50 mg/ml (Rotenone Conc.) ------------ 13.33 L of Liquid Crude Extract(CONCENTRATED)/RunCALCULATION:50 mg/ml × Y (VOLUME OF CONCENTRATED LIQ) = 666,431.09 mg of RotenoneSo, Y (VOLUME OF CONCENTRATED LIQ) = 666,431.09 mg/50 mg × 1 ml∴= 13.33 L/Run13,328.62 ml (13.33 L) of Concentrated Liquid Crude Extract contains666,431.09 mg of rotenone.IF, 1 ml of Concentrated Liquid Crude Extract – 666,431.09 mg/13,328.62 ml ×1ml1 ml of Concentrated Liq. Crude Extract --- 50 mg of RotenoneProduction ratio of 1000 ml formulated product:ASSUMING 3 % A.i (w/v)1. 3 % Active Ingredient (Rotenone) : 600 ml 0.03 × 1000 ml = 30 g A.i needed. IF, 0.05 g (50 mg) -- 1 ml of Concentrated Liq. Crude Extract So, 30 g A.i needed --- 1 ml/0.05 g × 30 g = 600 ml 600 ml of Concentrated Liquid Crude Extract is needed for obtaining the 30 g A.i (Rotenone)2. Surfactant : 80 ml3. Water : 320 ml
  5. 5. INDUSTRIAL GRANT SCHEME (IGS) 2004 - SAIFUL IRWAN ZUBAIRIIn order to produce 13,328.62 ml, we need:1. Active Ingredient : 13.3 L × 0.6 L × 30 g × RM 4.40/g A.i = RM 1,053.36/Run2. Surfactant : 13.3 L × 0.08 L × RM 800/209 L (209 L/Drum) = RM 4.07/Run3. Water : 13.3 L × 0.32 L × RM 1.50/0.5 L Water = RM 12.77/Run∴ Direct Cost : (RM 1,053.36 + RM 4.07 + RM 12.77)/Run : RM 1,070.20/RunOPERATING LABOR (OL) = RM 0.02/g A.i × 666,431.09 mg of A.i =RM 13.32/Run × No. of Workers (2) = ∴ RM 26.64/RunLABORATORY CHARGES (LC)= 10 % Operating Labor = RM 2.66/Run∴ TOTAL PRODUCTION COST: = (RM 1,070 + RM 26.64 + RM 2.66)/Run = RM 1,099.30/Run = RM 1,099.30/Run/13.33 L = RM 82.46/L Formulated Product (3 % A.i)/RunAMOUNT OF FORMULATED PRODUCT CAN BE PRODUCED /RUN:600 ml (0.6 L) of SEMI PRODUCT contains with 30 g (3 % A.i) isneeded to produce 1 L of Formulated Product.The amount of SEMI PRODUCT/RUN = 13.33 L.So, THE AMOUNT OF FORMULATED PRODUCT CAN BEPRODUCED/RUN: 13.33 L/0.6 L ≅ 22 BOTTLES OF FORMULATED PRODUCT/RUN COST OF FORMULATED PRODUCT (3 % A.i)/RUN: ∴RM 82.46/L Formulated Product (3 % A.i)

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