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MTP 695 Report on

BIOFUEL PRODUCTION FROM HORTICULTURAL PROCESSING WASTE


Submitted in the partial fulfilment of the requirements
Of the degree of
Master of Technology in Technology and Deelopment
!y "ishal Singh
#Roll $o% &'((5)))*+
,uide
Prof% -mit -rora
.entre for Technology -lternaties for Rural -reas #.T-R-+
/ndian /nstitute of Technology !ombay
Po0ai1 Mumbai 2 3)))*6
December1 ')&(
Certificate
This is to certify that the seminar report titled 4!iofuel production from horticultural
processing 0aste5 prepared by "ishal Singh bearing registration number &'((5)))* is
approed for submission at .entre for Technology -lternaties for Rural -reas #.T-R-+1
//T !ombay1 Po0ai%
#December ')&(+
6666666666666666666666666666666666666
#.hairperson+
6666666666666666666666666666666666666
Prof% 7ogendra Shastri
#89ternal 89aminer+
6666666666666666666666666666666666666
Prof% !a:ul Rao
#/nternal 89aminer+
6666666666666666666666666666666666666
Prof% -mit -rora
#,uide+
i
Declaration
/ declare that this 0ritten submission represents my ideas in my o0n 0ords and 0here others;
ideas or 0ords hae been included1 / hae adequately cited and referenced the original
sources% / also declare that / hae adhered to all principles of academic honesty and integrity
and hae not misrepresented or fabricated or falsified any idea<data<fact<source in my
submission% / understand that any iolation of the aboe 0ill be cause for disciplinary action
by the /nstitute and can also eo:e penal action from the sources 0hich hae thus not been
properly cited or from 0hom proper permission has not been ta:en 0hen needed%
66666666666666666666666666
#"ishal Singh+
ii
Roll $o% &'((5)))*
Acknole!"e#ent
/ sincerely than: my guide and adisor Prof% -mit -rora for helping me during the entire
research process% / also e9tend my heartfelt than:s to other faculty members from .T-R- for
their continuous guidance and support%
My special than:s to $asi: "intners and Sula ineyards $asi:= >ain /rrigation1 >algaon=
-lchemy Processes Pt% ?td% -urangabad= @art Aoods1 Sion= 7oBa: Co:an Mea1 Ratnagiri=
"aibha Products1 Ratnagiri= Ruchi Products1 Ratnagiri and arious others 0ho 0ere the real
sources for qualitatie information%
/ am deeply grateful to Carishma !huyan1 Paitra Sharma1 -bhiram Sahasrabuddhe1 Ddit
Sharma and all my colleagues for helping me 0hen needed% / also than: my family and
friends for their 0armth and support 0hich motiated me to 0or: hard%
iii
A$%tract
-griculture finds an important place in the /ndian economy% @orticultural products such
as fruits and egetables are increasingly faoured by farmers due to shorter gro0th
cycles1 multiple cropping and a ready mar:et% This has led to a tremendous gro0th in the
area and production under horticultural products in the last fe0 years% /ndiaEs horticulture
production recorded an increase of ()F in the last fie years% /n the year ')&)6&&
#MOSP/+1 /ndiaEs contribution 0as about *5 million metric tons #MMT+ of fruits #9F of
0orld production+ and &&) million metric tons of egetables #&&F of 0orld production+
#A-O+% @o0eer1 the percentage of the total produce getting processed is reported at a
meagre '%'F% .onsidering the unorganised sector inoled in the AP/s1 this number may
be any0here bet0een 56*F% Gith progressie policies and increased goernmental
support1 this percentage is set to increase quite rapidly in the near future%
8nergy is a primary industrial and household need and petroleum products are getting
costlier by the day% Sustainable energy products are the tal: of the hour and the quest for
green energy sources is getting aggressie% The use of horticultural processing 0aste is
not unheard of for the production of biofuels% - lot of ongoing research supports the fact
that biofuels can successfully be made out of 0aste% - large percentage of the total fruitEs
0eight is discarded as 0aste after processing% This 0aste is a rich source of arious
biological components 0hich can be successfully utilised to produce alue added
products%
?o0 ash containing biomass proides a unique opportunity to produce a solid fuel #direct
combustion+1 liquid biofuel #ethanol+ or gaseous biofuel #gasification or bio6
methanation+% This study ma:es an attempt to compare the options for conerting the
horticultural processing 0aste into biofuels so as to ascertain their appropriateness is6H6
is the e9isting disposal options%
i
Ta$le of Content%

ii
Li%t of Ta$le%
Table &I The maBor policy initiaties to promote AP/
(
Table 'I ?ogical frame0or: for interention into @PG to bioenergy proBects
3
Table (I Pro9imate composition of horticultural processing 0aste
J
Table 3I Reported aerage productiity and potential possibility
9
Table 5I -rea under arious fruits in arious districts of Maharashtra #@a+
9
Table 6I $umber of ne0ly registered AP/ units in Maharashtra1 '))36')&&
&)
Table * .ombustion details of horticultural 0astes
&'
Table JI !iogas yield from different horticultural 0aste
&(
Table 9 ?ist of biomass gasifiers around the 0orld
&3
Table &)I /ndustrial yield of ethanol from pure substrates
&5
Table &&I SGOT analysis for arious options of biofuel production from @PG
&*
ii
Li%t of Fi"&re%
Aigure &I @orticulture in /ndia1 area and production
&
Aigure 'I Production of arious horticultural products in /ndia
'
Aigure (I Total e9ports of arious horticultural products from /ndia
'
Aigure 3I 8nergy ?adder
3
Aigure 5I Share of energy sources 0ith ,DP per capita
3
Aigure 6I "arious possible uses of horticultural processing 0aste
&&
ii
&)
C'a(ter )
Intro!&ction
/ndia is primarily an agricultural country and e9cels in production of arious food1 fruits1
fibres and other agricultural products% /ndiaEs current production is estimated to be about *5
million metric tons of fruits #9F of 0orld production+ and &&) million metric tons of
egetables #&&F of 0orld production+ K&L% -ccording to the statistics of the Aood and
-griculture OrganiMation= '))91 /ndia is the 0orldEs largest producer of fresh fruits1 bananas1
mango1 mango6steens1 guaas1 tropical fruits1 papayas1 and arious other agricultural
products% .urrently1 the /ndian food processing sector employs about &( million people
directly and about (5 million people indirectly% /n '))32)51 food processing sector
contributed about &3 per cent of manufacturing ,DP 0ith a share of /$R '1J)1))) .r #N3%5
!illion DSO+% Of this1 the unorganiMed sector accounted for more than *) per cent of
production in terms of olume and 5) per cent in terms of alue% #/? P AS ')&&+
The bar graph belo0 sho0s the trend of the horticultural industry in /ndia% The left a9is sho0s
the area under production represented by the bars 0hile the right a9is sho0s the total
production depicted by the line #data%go%in ')&(+%
Aigure &I @orticulture in /ndia1 area and production
/ndia is the 0orld number one producer of bananas1 mango1 mangosteens1 guaas1 papayas1
tropical fruits1 and arious other fresh fruits% The e9port olume is ho0eer not present due to
lac: of processing facilities and a0areness amongst farmers% ?ac: of scientific handling and
storage after haresting causes huge amounts of post6harest losses% The first chart belo0
sho0s the trend of production of some of the largest horticultural products of the country% The
second chart sho0s the total e9ports of the some largely e9ported products from /ndia #faostat
')&(+%
&&
Aigure 'I Production of arious horticultural products in /ndia
Aigure (I Total e9ports of arious horticultural products from /ndia
/t is eident from the aboe charts that in spite of haing huge production of arious
horticultural products1 /ndia lags in the e9port sector% "ery lo0 number of processing facilities
are present hence a ery lo0 quantity of the total produce could get processed and presered
and eentually The adent of latest technology and deelopment of adanced fruit processing
machinery has been captured by a fe0 segments of mango producing regions and henceforth
the processed quantity is on a rise% !anana1 ho0eer has a ery lo0 percentage of processed
output as compared to the total produce% The capital inestment in setting up a processing
facility is large and is one of the maBor inhibitor for ne0 players in the sector% The peels and
seeds of fruits are the maBor 0astes produced at any e9isting food processing facility%
-gricultural and food 0astes are the largest section of oerall 0aste generated in /ndia% There
is a lot of prior research aailable on feasibility and production of alue added goods from
0aste% Aood processing industries generate a large quantity of 0aste of ery consistent
&'
chemical composition% This proides an opportunity of refining the AP/ 0aste and obtaining
arious products%
The current percentage of total agricultural produce getting processed is reported at a meagre
'%'F% /f the unorganised sector 0or:ing in the food processing industries is accounted for1
this number may be any0here bet0een 56*F of the total production quantum% The percentage
is ery lo0 as compared to established leaders in food processing such as .hina1 DS- and
others% ?ac: of adequate handling and starage facilities also add to a huge amount of post6
harest losses% Aood processing industry is one of the fastest gro0ing and promising
industries for the coming years% The Ministry of Aood Processing /ndustries #MAP/+ got
established in >uly &9JJ 0ith a an aim to proide support to food processing sector in the
country% The ,oernment of /ndia is ery aggressiely promoting processing and e9ports
through arious support measures and policies% $ational Mission on Aood Processing has
seeral schemes 0hich can bring about huge improement in the industry% Schemes for
technology up gradation1 setting up and moderniMation of food processing industries= scheme
for supporting cold chain facilities1 for human resource deelopment= schemes for
promotional actiities and such other plans hae astly improed the e9isting scenario
#guBagro ')&(+%
Table &I The maBor policy initiaties to promote AP/
Aood processing sector identified as industry 0ith employment potential
Most processed food items e9empted from licensing under the /ndustries #Deelopment P
Regulation+ -ct1 &95& #e9cept items resered for SS/ and alcoholic beerages+
$-!-RD created a refinancing 0indo0 0ith corpus of /$R &) !illion
/$R &%5 !illion earmar:ed for #$ational @orticulture Mission+ $@M for terminal mar:ets
Aor easy credit aailability1 AP/ included in the list of priority sector for ban: lending in
&999
-utomatic approal for foreign equity up to &))F aailable for processed food items
#e9cept items resered for SS/ and alcoholic beerages+
89cise duty on processed fruit and egetables brought do0n from &6F to )F in the !udget
'))&6)'
/n the budget of '))36)5 income ta9 holiday and other concessions announced for certain
categories of food processing industries
Dnder /ncome Ta9 -ct1 a deduction of &))F of profit for 5 years and '5F of profits for the
ne9t 5 years allo0ed in case of ne0 AP/ set up to process1 presere and pac:age fruits and
egetables
Seeral such schemes hae been floated already and many others are in the pipeline%
@o0eer1 there still remains so much yet to be achieed in the industry of food processing%
Gith an increase in the agricultural produce of land 0ith application of technology1 a number
of food processing industries are set to come up% - lot of effort is being put for0ard in the
area of food processing by the enterprises1 the administration and the multi6nationals
corporates% The quanta of 0aste generated is also set to increase gien the siMe of the industry
and the disordered manner in 0hich the industries treat and dispose their 0astes% This offers a
unique opportunity for alue addition through 0aste disposal techniques% The state of
Maharashtra leads in the production of arious fruit products and has a substantial area
dedicated to egetable production as 0ell% The trend of gro0ing fruit and egetable crops has
increased amongst farmers due to their utility as cash crops% The adent of large food
processing industries has also supported this trend in a maBor 0ay% This has led to a
&(
tremendous gro0th of area under cultiation as 0ell as the number of industries inoled in
processing% "arious other enterprises not inoled in processing but inoled in trading and
e9ports of the finished products hae also seen a huge gro0th in the state in the last fe0 years%
)*) Moti+ation
The motiation for the study 0s authorEs stay in the illage Dhaulali1 Ratnagiri district1
Maharashtra% -s obsered by the author1 in many illages in and around Co:an #.omprising
of districts of Thane1 Raigad1 Ratnagiri and Sindhudurg+ small and medium AP/s are 0or:ing
in most productie seasons% Small processing plants #eg% Ruchi products1 Ratnagiri+ process
about ') tons of mango in t0o months for arious product amounting to a total output of
about &) tons% ,o:hale products1 Ratnagiri1 utilises arious aailable local fruits and
egetables for a ariety of products such as :o:am Buice1 potato6gingerbeer1 Bamun pulp1 etc%
The unorganised nature and location of these industries ma:e it difficult to dispose there
0aste in an organised fashion% Most of the times1 the 0aste is allo0ed to dry for some time
and once sufficiently dry1 is burnt in open or in ery inefficient boilers% This brings us one
more problem of enironmental haMard caused by organic 0aste%
Ghile energy is a prime requirement for lielihood to sustain1 the form of usage determines
the deelopmental leels of society% The concept of energy ladder proides a clear ie0 as to
the moement of a locale to0ards cleaner and easily manageable sources 0ith deelopment
and better prospects%
Aigure 3I 8nergy ?adder Aigure 5I Share of energy sources 0ith ,DP per
capita
)*, Met'o!olo"-
The table belo0 obBectiely describes the interention logic1 erifiable indicators1 sources of
erification and assumptions and ris:s inoled in a large scale @PG to energy proBect in the
/ndian conte9t%
Table 'I ?ogical frame0or: for interention into @PG to bioenergy proBects
Inter+ention
lo"ic
In!icator%
So&rce% of
+erification
A%%&#(tion.Ri%k%
,oal To produce bio6
fuel from
horticulture
processing 0aste
Optimum 8nergy
capture
Testing1
applications
?o0 conersion
efficiency
ObBecties Gaste
Management
Reduction in
0aste disposal
issues
Municipal report
@ealth Report
.apital inestment
compared to other
techniques for same
&3
Reduction in
health issues
produce
!io6fuel
production
"iability of
production for
applications
?ab test
Pilot testing
?o0 productiity
compared to other
feed stoc:s
8nergy .apture
.ombustion
properties of
produce
.omparison of
empirical data
0ith theoretical
alues
.ost of replacement
of e9isting
alternaties
89pected results Successful
production of
bio6fuels
Replace ability
of e9isting fuels
/ndustrial
application of
bio6fuels
Auel ersus food
security
Sustainable
0aste disposal
/mproement in
sanitation
Reduction in
load on
Municipal 0aste
disposal actiity
Municipality .ost of disposal
.reation of a
successful
business model
.reation of
employment
!usiness
opportunities for
small scale
industries
8conomic
sureys1
Aeasibility
models
Scepticism of people
for ne0 technology1
?o0 ProBect Success
confidence
Githin such a logical frame0or:1 an interention in the @PG field should be made% /t is to be
noted that the latest technology plays a ery important role and seeral other parameters li:e
policies1 climatic conditions and atmospheric changes hold :ey importance in decision
ma:ing%
The methodology for this study comprised of three sections 0hich are field isits1 telephonic
conersations and questionnaires% These are e9plained belo0%
)*,*) Fiel! +i%it%
- isit to the $asi: "intners Priate limited1 Sula "ineyards Priate ?imited and surrounding
grape farms 0ere made by the author% Obserations about grape processing1 0ine ma:ing and
0aste disposal 0ere noted% -ssociated pictures are attached to -nne9ureQ
- isit to >ain Aood Par:1 >algaon1 Maharashtra 0as made by a research team to assess the
0aste generating processes and handling procedures during arious processing operations%
"arious isits 0ere made to food processing industries in Sion1 fruit mar:ets at .ST% Aruit
0holesalers near MasBid and local fruit sellers 0ere also engaged in conersations%
)*,*, Tele('onic con+er%ation
89tensie amount of data and qualitatie information 0as collected by telephonic
conersations 0ith arious enterprise o0ners and managers of food and egetable processing
industries% Small scale industries 0ere focussed so as to get primary user information about
0aste generation and after0ards of it%
&5
)*,*/ 0&e%tionnaire
- small set of questions 0ere deised so as to engage the conersant in minimum time to get
ma9imum details about 0aste quantum and post processing procedures in practise% The
questionnaire can be found in the anne9ure%
)*/ O$1ecti+e%
!ased on literature reie0 and analysis of obtained information from arious sources1 the
follo0ing research questions 0ere articulated 0hich 0ill guide us to the solution for handling
0astes from horticultural processing industries and to find suitable conersion to utilise them
as fuels% The research questions areI
&% Ghat are the arious types of fuels that can be made from horticultural processing
0astes and 0hat are the conersion processesR
'% Ghat is the energy recoery of each processR
@ence1 the report has the follo0ing primary obBectiesI
S Gaste quantum estimation and discussion of e9isting methods of disposal%
S Possibilities of bio6fuel formation from horticultural processing 0astes%
S .omparison of techniques%
&6
C'a(ter ,
Literat&re Re+ie
,*) C'aracteri2ation of a%te
The characteriMation of horticultural processing industry 0aste 0ill discuss the follo0ing
points in detailI
S The pro9imate composition of 0aste
S The quantum of generation
S The e9isting disposal options in practice
/ndia ran:s 0orld number one in production of banana 0ith about '9 million MT in ')&)6&&
alone #agrie9change ')&(+% /ndia produces about ')F of the total production of banana oer
the 0orld% @o0eer1 the amount of banana being processed is a ery small fraction of the total
product aailable% The e9ports are also a miniscule part of the pie% - maBor reason for this is
insect bites on the fruits 0hich deelop into blac: spots and render the fruit unsuitable for
e9port to the mar:ets of Dnited States of -merica1 8urope and ,ulf countries 0hich are the
largest consumers of imported banana% The state of Maharashtra ran:s third in banana
production amongst all the states of /ndia 0ith a production of (%6 million MT #agrie9change
')&(+% The aBor poc:ets of concentrated banana cultiation falls in the districts of >algaon1
Dhule and !uldhana 0hile sporadic cultiation is done all oer the state% MaBor ariety
produced for table consumption is D0arf .aendish 0hile arious other arieties are also
produced in smaller quantities% Dsage of plastic crates and shoc:6proof handlers hae
decreased the post6harest losses to a great e9tent% MaBor 0astes generated by banana are
peels and the pseudo6stem 0hich bears the plantain and is disposed after that% The peel
contains high amounts of carbohydrates%
Mango #Mangifera indica+ is the most important fruit of /ndia and is :no0n as 4Cing of
fruits5% /ndia is 0orld number one in the production of mangoes and controls about 3)%3JF of
all 0orld production% The total production of mango in /ndia 0as about &5%&9 Million MT for
the year ')&& 0hile the total area harested 0as ''9* thousand hectares% Maharashtra comes
second only to Tamil $adu in the production of mango% The maBor concentrated poc:ets of
mango production in the state of Maharashtra are the follo0ing districts% Ratnagiri1
Sindhudurg1 Raigarh1 Satara Sangli% Coihapur1 ?atur% $asi:% !eed1 -:ola1 >alna% -hmednagar%
!uidhana% Osmanabad% The maBor e9ports of fresh mango and mango pulp ta:es place from
Mumbai1 0hich is also the capital city of the state% Mango is typically gro0n in the 0estern
half of the state 0hile the processing industries are situated densely in the Co:an belt% There
are a huge number of mango processing plants that hae come up due to rising demand of
mango based drin:s all around the year% Many small and medium enterprises 0ith total
production as lo0 as &) MT per annum are into the business of processing mango and
canning of pulp% Ghile the pulp constitutes 35665F K'L of the total fruit 0eight1 the rest mass
including peels1 pulp 0aste and stones #:ernels+ are discarded and disposed of at most places%
- large amount of such 0aste is generated eery year 0hich is causing disposal and
management problems for the processing enterprises as 0ell as enironmental concerns for
the areas 0here it is being disposed% The maBor species gro0n in Maharashtra for processing
and e9ports are -lphonso1 Cesar and Pairi% Man:ur1 Sindhu1 !ainganpalli etc% are some other
preferred table arieties% There are also arious hybrids deeloped by arious institutes 0hich
are being tried for cultiation K(L% The processing of mango produces a lot of 0astes% The by6
&*
products<0astes aailable after processing of mango includes cull fruits #fresh fruits
unsuitable for human consumption+1 mango stones #containing :ernels 0ith 6T&6 percent
mango oil on DM basis+1 mango peels and pulp 0astes% Peels constitute about &56')F of the
total fresh 0eight% Stones constitute about &)6')F of the total 0eight% Pulp 0astes constitute
&)6&5 F of the fresh 0eight% The total pulp content pac:ed after processing is about 35665F
of the total processed quantity K3L% "arious techniques hae been adopted to get rid of the
0aste% Peels are disposed of summarily by processing facility o0ners and is dumped for
landfill% -t some places in Maharashtra1 typical mango processing industries are composting
the peel 0aste in open pits% .omposting of peels is1 ho0eer not easy due to high cellulose
content% The stones are let a0ay to be burnt in the boilers% Pulp 0astes and 0ashings are
utiliMed in e9isting biogas plants or Bust drained off% Many a times1 the industries een hae to
pay to remoe the 0aste accumulated at their processing sites% $ot much of alue addition is
achieed through e9isting measures of disposal% The mango peels constitute about &56')F for
the arieties being processed in Maharashtra #-lfonso and Totapuri+%
Similarly1 there is a huge amount of 0aste generated in processing of other fruits such as
grapes1 citrus and lemon% The quantum aailability of banana and mango processing 0astes is
larger due to a larger production and also more number of enterprises inoled in trade and
processing% Presently most of this 0aste lands up either in a landfill or an open pit 0ith almost
negligible alue addition%
,*)*) Pro3i#ate co#(o%ition%
@ere the pro9imate composition of arious horticultural processing 0astes are discussed%
Processing 0astes usually contain the peels1 seeds #stones+ and 0aste0ater% /n a fe0 cases
there might be pulp 0aste as in mango peeling and citrus Buicing% Maharashtra is a state rich
in diersity of horticultural products being farmed and a large section of agricultural land is
dedicated to horticultural farming% /n this discussion the compositions of only some products
li:e mango1 grape1 banana1 citrus fruits namely lemon and orange 0ill be discussed%
Table (I Pro9imate composition of horticultural processing 0aste
.ompound Moisture .arbohydrate .rude fibre Protein Aat -sh
Aresh mango peel 656*5 &J6'3 &6( &6( U& &6'
Dry mango peel J6&) 5566( &'6&* 36J 56* 56J
Aresh mango seed 3)65) (66(9 '6( '65 669 &6(
Dry mango seed J6&) 55665 96&' 56J &)6&( '63
,rape pulp &)6(5 (5635 &J6'3 J6&( (6&) '6(
?emon pulp '56(( 3(63* &36&* 66J &6' (63
.itrus peel '56() 3(63* &*6&9 66J U& '6(
Aresh banana peel J)69) 66J (63 U& U& &6'
Dry banana peel 66J 5566( '56() &6' &6( *6&)
The compositions of arious fruit 0astes has been ta:en from aailable literature on the
pro9imate composition of arious horticultural processing 0aste products% The e9act
composition of the arious components of the 0aste aries 0ith the specie of fruit being used
and the oerall enironmental conditions% This is a maBor limitation for designing any system
using @PG as a source of ra0 material%
&J
,*)*, E%ti#ation of a%te "enerate!
The agricultural farms of Maharshtra are stretched far and 0ide and gro0 almost all types
agricultural1 horticultural and other crop based products 0hich the land and climate allo0s%
The oerall productiity of the land is ho0eer reported lo0er than the reported productiities
in other agriculture based countries% The reported aerage productiities in tons<hectare and
the potential as compared 0ith test conditions are listed in the table belo0% #$@M+
Table 3I Reported aerage productiity and potential possibility
.rop State -erage Potential
& Mango (%5 &5
' ,rapes 'J%' ()
* ?emon 9%65 &)
( Mandarin Orange 9%& &5
3 S0eet Orange &( &5
6 !anana 5J J*%5
8en though the reported aerage productiities might not be close to the possible ma9imum
outputs1 the huge area of land dedicated to arious fruits and egetables ensures that there is a
huge output of the same eery season% The table belo0 proides an oerie0 of the estimated
areas under arious fruits in the state of Maharashtra%
Table 5I -rea under arious fruits in arious districts of Maharashtra #@a+
Mango ,rape ?ime Mandarin
Orange
S0eet
Orange
!anana
-hmednagar J156& 5') ('&
-mraati &1*9* 3)13&6 6J&
>algaon (63 6'1*5'
$agpur '1**9 ''196(
$asi: &61''6
Pune 51J59 &1)(( *5J 636 &96 93J
Ratnagiri (61()5
Sindhudurg &51)*3 &9&
Solapur '13)5
Ghile there is a large amount of production1 the amount being processed is a ery miniscule
fraction of the total product and amount to a about '6(F% There is ho0eer a mar:ed rise in
the number of AP/ units and it is eident by the increasing number of ne0 units getting
registered eery year% The table belo0 gies the details on the no% of AP/ units ne0ly
registered in the last fe0 years in the state%
&9
Table 6I $umber of ne0ly registered AP/ units in Maharashtra1 '))36')&&
Description '))36
)5
'))56
)6
'))66
)*
'))*6
)J
'))J6
)9
'))96
&)
')&)6
&&
Meat 5( 53 9J ** 9) J5 &&5
Aish and sea food ()9 (3( (&J (3) (5' (59 3(6
Aruits and "egetables 5JJ 5JJ 66) *(5 *)9 J(' &1)5'
"egetable P animal oils and
fats
'15(3 '1563 '1(J3 '15&5 '13'9 '13'& (1()*
Dairy Products 9'* &1)39 &1)&5 &1)96 &1&)) &1&&' &139(
,rain Mill products &'13J5 &'1*'6 &'1*99 &'1J)* &(1363 &(1(9* &*1*9'
Starches P Starch products 6(3 633 5(J 33' 5J9 6*) *5*
!a:ery products &1)'& 9(9 9&9 955 99( &1)56 &135)
Sugar J5) J&9 *93 **J *(( *33 J95
.ocoa1 chocolate and Sugar
confectionery
()3 (36 (6J 3)3 356 366 5)9
Macoroni1 $oodles1 .ouscous
P Similer farinaccous
products
'J 3& 33 *( 6& 5& J(
Prepared meals P dishes
6

6

6
6 35 &(9 (3(
Aood Products $%8%.% (1JJ9 (1J63 31&&9 31)9& 31'9) 31''5 51&&3
Prepared -nimal feeds 5') 5'( 53( 555 53* 6)6 6**
Distilling1 rectifying P
blending of sprits
'65 '69 '&* 'J) '9& '96 ('5
Manufacture of Gines *& *' ** 63 *9 69 *3
Manufacture of malt liquors
and malt
&&) &&5 &'& &') 96 &&* &53
Production of mineral 0ater P
other bottled 0aters1 Soft
drin:s
**( **) *35 JJ* J96 J(3 &1'63
Total '51(6& '51*'6 '51*59 '61'&9 '*1'') '*13*9 (51J(J
,*)*/ E3i%tin" !i%(o%al o(tion% for 'ortic&lt&ral (roce%%in" a%te
The possible post6processing options for horticultural 0astes has been described in the figure
belo0% @orticultural processing 0aste has been successfully processed into a arious products
ranging from animal feeds1 food addities1 biofuels1 bio actie compounds and others% The
present disposal options ho0eer are composting in open pits1 landfilling or municipal
')
disposal 0hich again is a combination of the other t0o% There ho0eer e9ist some facilities
0hich hae tried to use @PG for bio6methanation by anaerobic digestion process in a closed
pit% The details are discussed later in the section% - lot of seeds and similar lo0 moisture
content is burnt after some initial drying% The energy sometimes is captured in boilers and
many a times it is burnt in the open to ease disposal%
Aigure 6I "arious possible uses of horticultural processing 0aste
,*, Hortic&lt&ral (roce%%in" a%te to $iof&el
This study focuses mainly on the possible options of conersion of arious horticultural
0astes into biofuels% Maharshtra has a total no% of J'31')( biogas plants and there are also
about *&5) biomass gasifiers including both rural and industrial #MOSP/+% Ghile the report
on energy statistics of /ndia by MOSP/ indicates a possibility of a total of &JJ* MG of
biomass energy1 &'5) MG of cogeneration bagasse energy and about 'J* MG of energy from
0aste1 the e9isting energy production facilities running on biomass amount a total of 6)(%*)
MG as on (& Mar ')&' in the state of Maharshtra% The gro0th and adancement in energy
production and related technologies coming up 0ith supporting policies and handholding by
the goernment 0ill definitely ensure a bright future for all biofuel related proBects%
@enceforth1 arious aailable options of conersion of horticultural processing 0aste into fuel
forms hae been discussed%
,*,*) Co#$&%tion
The follo0ing discussion 0ill proide energy statistics related to @PG% /t 0as found that
seeds can proe to be a good solid fuel% -s an e9isting practice1 the seeds of mango fruits are
ta:en a0ay to be burnt in boilers% The peels and seeds can be sun6dried to lo0er the e9isting
moisture leel% Dried seeds contains about 59F carbohydrates1 &)F fibers and &&F fats 0hile
dried peels contains about 59F carbohydrates1 &5F fibers and *F fats% -ll the three families
of compounds are highly combustible and produce good calorific alue per unit 0eight of the
seeds being burnt% "arious local industries are utiliMing seeds as a cheap boiler fuel during the
months of its aailability% The table belo0 proides the percentage of total olatile matter1 ash
and fi9ed carbon present in arious horticultural 0astes% The bottom t0o ro0s also indicate
the obsered gross calorific alues and net calorific alues for the different items in ><g% The
last column displays bagasse and its related alues so as to compare other horticultural 0astes
0ith it in combustion properties #bagasse is sugarcane 0aste remaining after sugar e9traction1
commonly used as a burning fuel+%
Table *I .ombustion details of horticultural 0astes
,rape
pruning
,rape
pomace
.itrus
0aste
Dry
mango
Dry
Mango
!agasse
'&
seed peel
".M **%'J 6J%53 *&%36 J*%5& J5%&' *(%*J
ash '%5& 9%3J (%&J '%5J 3%J* (%(6
fi9ed
carbon
')%'& '&%9J &*%(3 '&%J* ')%3( &3%95
,." &9&() ')(3) &*&36 N&*))) &5)JJ &9)(*
$." &*93) &9&3) N&5))) N&'5)) &**J'
,*,*, Bio4#et'anation
-ailable scientific research sho0s that horticultural processing 0aste can be utilised for bio6
methanation #a process of anaerobic digestion of biomass for methane gas production+%
!anana peels are used in many parts of the country as animal feed% @o0eer1 the usage as
fodder is limited by the fact that fresh peels hae a high moisture content and dried peels hae
high ash content% Peels contain a considerable amount of tannins that migrate to the pulp or
get degraded by polyphenol o9idases and pero9idases 0ith ripening of the fruit #Thomas
@appi 8mega '))*+% !io6methanation of banana peel 0astes studied at arious @RT #@ighest
Retention Time+ sho0ed a higher rate of gas production at lo0er retention time% The lo0est
possible @RT for banana peel 0as found to be '5 days1 resulting in a ma9imum rate of gas
production of O% *6 <<day 0ith (6F substrate utiliMation= ho0eer1 0ith banana peel an
@RT belo0 '5 days sho0ed a drastic reduction in methane content% #$irmala !ardiya &996+%
The t0o components of mango seed1 the outer hus: and the inner :ernel1 0ere studied and
characteriMed by ultimate and pro9imate analysis% .ellulose1 hemicellulose and lignin 0ere
quantified% Ghile both sho0ed high percentage1 hus: contained more cellulose than
hemicellulose and the inerse 0as reealed in :ernels K5L The composition of mango seed
:ernel flour sho0s that the total starch content is about 5)F and about '%*5F soluble sugars%
Aresh mango peels are used at some places for anaerobic digestion1 ho0eer the methane
yield is not as good 0ith fresh peels as compared to ensilaged peels% Dried and ensilaged
mango peels 0ere tested for 6 months for methane production by the anaerobic digestion
process% The yield for ensilaged mango peel 0aste 0as )%6J m
(
<:g 0ith methane content of
5(F 0hile the dry peels sho0ed a yield of )%3( m
(
<:g 0ith a methane content of 5)F% The
units depict olume of biogas generated per unit 0eight of olatile solids added K6L%
''
Table JI !iogas yield from different horticultural 0aste
7ield #m
(
of gas per :g
olatile solids+
Source
Mango peels #fresh+ )%6J K6L
Mango peels #ensilaged+ )%3( K6L
!anana peels )%*) K*L
?ime )%*' KJL
.itrus )%6( KJL
,rape pomace )%66 K9L
The maBor challenges in bio6methanation of horticultural 0astes is their lo0 leels of nitrogen
content and lo0 p@ alues 0hich act as inhibitions for proper microbial gro0th inside the
digester% Seeral additions of nitrogen rich substrate hae been suggested and bio methanation
of horticultural processing 0astes is successfully being done at many places in Maharshtra%
The yield ho0eer is reported to be quite lo0 due to aboe mentioned reasons and the
susceptibility and sensitiity of the process on the 0hole%
,*,*/ Ga%ification
,asification is a thermochemical process of conerting biomass to producer gas% /n this
process organic matter is partially o9idiMed at high temperatures to produce a gaseous fuel
:no0n as producer gas and other products such as char and clin:er% This technology is quite
old but is in tal:s no0 due to a rene0ed interest in biomass based po0er% "arious researches
hae sho0n that decomposition of the organic materials1 including aromatic rings1 starts at
temperatures aboe 55)V.% -t 65)V.1 the model compounds hae been completely conerted
to gases1 giing a hydrogen6rich product gas K&)L% Through the use of a metal catalyst1
gasification of 0et biomass can be accomplished 0ith high leels of carbon conersion to gas
at relatiely lo0 temperature #(5) V.+% /n a pressuriMed60ater enironment #') MPa+1 near6
total conersion of the organic structure of biomass to gases has been achieed in the presence
of a ruthenium metal catalyst K&&L% 89perimental results sho0 that directly gasifying of 0et
biomass faours hydrogen% Aor gasification of 0et biomass1 a ne0 method has been
deeloped 0ith optimal operating temperature in the 9'(29*( C range K&'L% Dnder test
conditions1 supercritical 0ater gasification of 0et biomass 0as found to be adantageous oer
bio6methanation of the same substrate K&(L% ?arge industrial scale biomass gasifiers are but a
fe0 and the table belo0 lists the 0orld &5 largest biomass gasifiers in operation% The
possibility of small scale biomass gasifiers cannot be disregarded% There e9ist a large number
of small scale gasifiers around the 0orld o0ing to a surge in demand of green energy% Most of
these gasifiers ho0eer use dried biomass #moisture content U')F+% This poses a problem for
@PG to be used a successful substrate because almost al0ays they carry a high percentage of
moisture 0ith them%
'(
Table 9I ?ist of biomass gasifiers around the 0orld
,*,*5 Et'anol (ro!&ction
@orticultural processing 0aste and horticultural residues comprise of lignocellulosic biomass1
0hich is seen as a potential source of biofuel production by many% Aermentable sugars can
be e9tracted successfully from lignocellulosic biomass for production of bioethanol% The yield
of bioethanol during the conersion process depends on the cellulose1 hemicellulose and
lignin content1 the cellulose crystallinity and the ash content of the ra0 material%
?ignocellulosic biomass comprises mainly of cellulose follo0ed by small amounts of
hemicelluloses and lignin% The yield is influenced by cellulose content as it is the primary
substrate 0hich proides the fermentable sugars for the production of bioethanol% ?ignin
ho0eer preents the enMymatic degradation of cellulose by obstructing the access of
enMymes to cellulose and hemicellulose #@immel et al%1 '))*+% -n ideal substrate for
bioethanol production 0ould therefore hae a high cellulose and lo0 lignin content%
MaBor 0astes generated by banana are peels and the pseudo6stem 0hich bears the plantain and
is disposed after that% The peel contains high amounts of carbohydrates% !anana peels contain
')6() F $DA1 and the quantity of starch and soluble sugars aries 0ith maturity K&3L% ,reen
banana peels contain about 3) F starch that conerts to sugars 0ith maturity% ,reen banana
peels contain much less starch #about &5 F+ 0hen green 0hile ripe peels contain up to ()F
free sugars% ?ignin content increases 0ith ripening #from * to &5 F DM+% Plantain peels
contain less fiber than banana peels K&3L% .lean and finely ground banana peels 0ere made
into a slurry and the e9traction of cellulose 0as performed in an al:aline solution% The results
sho0ed that the acquired product 0as not concentrated enough and it 0as concluded that
al:ali e9traction is not an effectie process in producing cellulose from banana peelings% K&5L
- large ethanol producer in 8cuador uses banana 0aste because of its high !ri9 content #One
degree !ri9 is & gram of sucrose in &)) grams of solution+% The material readily ferments 0ith
e9cellent yield that is cheaper than using corn syrup1 but the critical olume is unaailable%
K&6L% The feasibility of using banana peel for the production of cellulase by Trichoderma
viride ,/M (%))&) in solid6state fermentation 0as ealuated and results indicate that it
proides necessary nutrients for cell gro0th and cellulase synthesis% K&*L
'3
The mango peels and seed :ernels contain a good percentage composition of sugars and
starch and hence can be successfully conerted to ethanol% "arious studies hae proen
successfully the feasibility of ethanol production from peels% !io6ethanol 0as produced from
dried ground po0der of mango peel% Obtained po0der 0as dissoled in distilled 0ater and
sugar concentration 0as adBusted to a leel of &5F% Dsing ba:erEs yeast1 Saccharomyces
cereisiae1 this substrate solution 0as fermented and the ethanol 0as produced after fie days
of incubation% The properties of bioethanol from mango peel 0ere determined and found to be
reasonably comparable 0ith conentional gasoline K&JL% Direct fermentation of mango peel
e9tract gae about 5%&(F #0<+ of ethanol 0ith a slo0 rate of fermentation% "arious nutrients
such as yeast e9tract1 peptone and 0heat bran e9tract 0ere tested for the supplementation of
mango peel medium and it 0as obsered that the nutrient supplementation increased the
ethanol production up to *%&3F #0<+ K&9L% The fermentation efficiency of mango peel 0as
found to be &J%96F after pretreatment 0ith dilute @
'
SO
3
and the ethanol productiity 0as
found to be %'( F0<0<hr K')L% The t0o components of mango seed1 the outer hus: and the
inner :ernel1 0ere studied and characteriMed by ultimate and pro9imate analysis% .ellulose1
hemicellulose and lignin 0ere quantified% Ghile both sho0ed high percentage1 hus: contained
more cellulose than hemicellulose and the inerse 0as reealed in :ernels K5LThe composition
of mango seed :ernel flour sho0s that the total starch content is about 5)F and about '%*5F
soluble sugars% This proides a great opportunity for ethanol production from starch through
enMymatic process% The process is already being used for producing ethanol from a ariety of
similar substrates% The table belo0 sho0s industrial output of ethanol in liters per ton of dry
matter input of pure substances%
Table &)I /ndustrial yield of ethanol from pure substrates
/nput #:g+ 8tO@ yield Source
Starch &))) 35( K'&L
.ellulose &))) '*( K''L
,lucose &))) 363 K'(L
'5
C'a(ter /
Re%&lt% an! !i%c&%%ion
!iofuel production from arious cheaply aailable agricultural 0aste1 garden 0aste1
processing 0aste etc% is on a definite rise in the last fe0 years and the trend is not e9pected to
decelerate in the near future% Ghat remains a topic of concern though1 is the feasibility and
iability of such proBects on a scale large enough% Aor a successful interention in the 0aste
management scenario catering especially to the horticultural processing section is not unheard
of% Most of the citrus processing 0aste in Alorida1 DS-1 for e9ample is utilised by local
fermenters to produce ethanol and citrus feed pellets for animals% The ecosystem suries due
to a huge citrus production in the state and a large amount getting processed% Similar
ecosystems do e9ist in /ndia% The need ho0eer is to identify the processing clusters and
establish logical routes for post processing of @PG% "arious researches sho0 that ethanol
production from @PG can be a iable option as it can utiliMe a large quantity of 0aste and
produce bio6ethanol 0hich is a clean fuel source% @o0eer1 it is a capital intensie option and
0ill require a large inestment to be made upfront% -n animal feed plant as such is a much
smaller option as compared to the preious option if the siMe of inestment is considered% The
utility of peel 0aste such as mango and banana is ho0eer limited as a substrate to animal
feed due to high moisture and lo0 protein content% - small improement in feed quality can
be done by fermenting or ensiling the MPG before being conerted to feed% Other options for
disposal include anaerobic digestion 0hich produces a larger quantity of methane if ensiled
MPG is used as compared to dry% .omposting of MPG does not add much to the economic
alue of the 0aste% Oil e9traction from :ernels can proe to be a good source of arious fatty
acids and other compounds% There is a lot of scope in the processing of arious fruits and
egetable products% The atmosphere is positie and the goernment is supporting AP/s in all
possible manners% /t is required to find noel 0ays of 0aste management in this sector% @uge
opportunities a0ait in the production of biofuel as alue added products from processing
0aste as these are set to increase at a rapid pace in the coming years% Similar options are
aailable or other horticultural 0astes and processing reBects% ,rape pomace has been 0idely
used to prepare compost manure after Buice e9traction% Ghile there e9ist many a technologies
that can and hae been successfully applied for utilisation of 0aste%
'6
The follo0ing table proides SGOT analysis of the earlier discussed biofuel options from
@PG%
Table &&I SGOT analysis for arious options of biofuel production from @PG
Strength Gea:ness Opportunity Threat
.ombustion S $o inestment
S Wuantum
aailability
S Production
cycle
S /ncreasing
calorific
alue
through pre6
treatment
S 8nironmental
haMard
S /nefficient
energy capture
!io
methanation
S ?o0 inestment
S 89isting
infrastructure
S Seasonality
S ?o0 yield
S ?arge plants
in icinity of
processing
plants
S ?o0 return on
inestment
S ?ong paybac:
period
,asification S @igh grade
gaseous fuel
S $egligible side
products
S ?arge
capital
inestment
S .ontinuous
production
cycle
S Wuantum
aailability
S ?o0
procurement
cost
S Reduction in
carbon
footprint
S ?ac: of 0or:ing
e9amples
S Aood <s fuel
debate
S Translational
success of
model unproen
8thanol
production
S @igh grade
liquid fuel
S 8nironment
ally friendly
S ?arge
capital
inestment
S Sensitie
process
parameters
S Policy
support
S 89isting
mar:et
S @uge
potential
S $on industrial
usage of ethanol
S 8ase of e9isting
techniques
'*
C'a(ter 5
Concl&%ion an! f&t&re ork (lan
5*) F&t&re ork
@orticultural processing 0aste is being researched by scientists and researchers all around the
0orld for alue addition through minimal processing% The current research can be e9tended to
other biofuel options not considered a part of this study #e%g% bio6diesel+% The follo0ing future
0or: can be planned for arious discussed options%
5*)*) Co#$&%tion6 - huge lot of peels and seed 0aste are dried before burning% This aids in
lo0ering the moisture percentage and increasing the $."% Small scale designs for solar driers
made of conentional material could be a good field proBect% "arious addities for increasing
$." can be tested and arious different forms such as pellets and briquettes can be tested
after drying%
5*)*, Bio4#et'anation6 Possibility of usage of @PG in e9isting biogas plants can be
researched% The addition of arious different additional substrates can be tested and effects
thereof on the total productiity can be enhanced using local materials% 8stablishment of a
biogas plant 0hich can utilise different 0astes in different seasons can be a lucratie field
proBect%
5*)*/ Ga%ification6 .urrently gasification of dried biomass is being done successfully1
ho0eer use of fresh and high moisture containing biomass such as @PG is technically
challenging and poses a lot of challenges% Research in this area may proide optimistic results
in near future%
5*)*5 Et'anol (ro!&ction6 "arious aailable literature suggest and sho0 that there e9ists a
possibility of successful ethanol production from arious horticultural processing 0astes%
"arious parameters 0hich decide the rate and yield of ethanol production from cellulosic
biomass such as cellulose1 hemicellulose and lignin content1 cellulose crystallinity and ash
content can be tested and determined for locally aailable substrate and scale models for
ethanol production can be designed%
5*, Concl&%ion
There is a huge scope in deelopment of biomass based energy technologies and this is the
greenest period eer for upcoming energy proBects% - detailed study of ethanol production
process can proe to be a feasible solution gien the quantum of 0aste and the pro9imate
compositions%
'J
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peels from three arieties of banana15 1sian Journal o( Food and 1%ro-Industr" 4(,1)
pp% (&6361 ')&&%
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Anne3&re II6 Proce%%in" Wa%te 0&e%tionnaire
General infor#ation6 C'aracteri%tic% of t'e e%ta$li%'#ent
$ame of the business<enterprise
$ame of the manager
Type<O0nership of firm
7ear of start of operations
Does this enterprise do one actiity or more than one actiity #fruits+
Principal actiity #fruits+ of the enterprise
Secondary actiity
Does it operate the entire year1 seasonally1 or only some months
Perfor#ance
Total cost of labor1 including 0ages1 salaries and benefits
-erage daily<monthly ra0 materials inta:e
-erage daily<monthly sales
Total ra0 materials daily<monthly produced
Aacilities for 0aste disposal= types and capacities
Auel types used and cost
Other costs of production not included aboe
Sale%
8stablishmentEs main product
Total sales
/nputs for production
Arom 0here the inputs are obtained<purchased
Theft1 brea:age or spoilage
Aull production capacity capability
Wa%te
Description of the 0aste
Wuantity of the 0aste
Particulars on process generating 0aste
?ocation 0here the 0aste 0as treated
Type and details of 0aste management facility
Infra%tr&ct&re an! Ser+ice%
Electricit-
-ailability<sufficiency of electricity
-erage monthly bill
!ac:up facilities #/f any+
Water
-ailability<sufficiency of 0ater1 source
-erage monthly requirement< payment
Type of meter #commercial<residential+
!ac:up facilities #/f any+
Ot'er%
-ailability of fi9ed line<mobile
Dse of internet
Total commercial space #O0ned<rented<leased+
.onstructed area #self<rented+
Total godo0n<storage space
Total selling space
@o0 many hours per day do employees 0or:= shifts
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$o% of permanent KhiredL employees
@o0 many salaried employees 0or:ed for enterprise in last & month
Does the business hire or gie 0or: to anyone on a contract or casual basis
@o0 many contractual 0or:ers 0or:ed for enterprise in last & month
De"ree of Co#(etition
$umber of competitors in establishmentEs mar:et
Technology licensed from a foreign o0ned company
.ompetition from unregistered or informal firms
Co##ent%
Date
Time
Place
Other comments
(*

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