INDUSTRIAL GRANT SCHEME (IGS) 2004 - SAIFUL IRWAN ZUBAIRI

PRODUCT COSTING OF ROTENONE PILOT SCALE PRODUCTION

Maximum capacity : 300 L/run Extraction ratio : 1 kg Fine Root: 10 L Solvent : 25 kg Fine Root: 250 L Solvent

Direct Production Cost 1) 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

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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/Run

3) UTILITIES

(Washing & Evaporation Process – Water & Electricity) = RM 50/Run

NEED TO BE CLARIFYING FURTHER IN TERMS OF ENERGY USAGE.

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3) FILTRATION PROCESS (Membrane filter - STRAINER) = RM 30/Run

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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

INDUSTRIAL GRANT SCHEME (IGS) 2004 - SAIFUL IRWAN ZUBAIRI

DATA 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.i

820.00 mg of A.i ______ × 230,000 ml of crude extract

283.00 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 LIQUID CRUDE EXTRACT TO BE ACHIEVED IS 50 mg/ml AND THE ROTENONE CONTENT IS RETAINED (666,431.09 mg) BEFORE AND AFTER THE

CONCENTRATION 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)/Run

50 mg/ml (Rotenone Conc.) ------------ 13.33 L of Liquid Crude Extract (CONCENTRATED)/Run

CALCULATION: 50 mg/ml ×××× Y (VOLUME OF CONCENTRATED LIQ) = 666,431.09 mg of Rotenone

So, Y (VOLUME OF CONCENTRATED LIQ) = 666,431.09 mg/50 mg ×××× 1 ml

∴∴∴∴= 13.33 L/Run

13,328.62 ml (13.33 L) of Concentrated Liquid Crude Extract contains 666,431.09 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 rotenone

50 mg of rotenone ------------- 1 ml of Concentrated Liq. Crude Extract IF, 1g of A.i ------------ 1ml/50 mg ×××× 1g = 20 ml So, 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

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 LIQUID

CRUDE EXTRACT TO BE ACHIEVED IS 50 mg/ml AND THE ROTENONE CONTENT IS RETAINED (666,431.09 mg) BEFORE AND AFTER THE CONCENTRATION 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)/Run

50 mg/ml (Rotenone Conc.) ------------ 13.33 L of Liquid Crude Extract

(CONCENTRATED)/Run CALCULATION:

50 mg/ml ×××× Y (VOLUME OF CONCENTRATED LIQ) = 666,431.09 mg of Rotenone

So, Y (VOLUME OF CONCENTRATED LIQ) = 666,431.09 mg/50 mg ×××× 1 ml

∴∴∴∴= 13.33 L/Run

13,328.62 ml (13.33 L) of Concentrated Liquid Crude Extract contains

666,431.09 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 Rotenone

Production 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 ml

3. Water : 320 ml

INDUSTRIAL GRANT SCHEME (IGS) 2004 - SAIFUL IRWAN ZUBAIRI

In 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/Run

2. Surfactant : 13.3 L × 0.08 L × RM 800/209 L (209 L/Drum)

= RM 4.07/Run

3. 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/Run

OPERATING 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/Run

LABORATORY 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)/Run

AMOUNT OF FORMULATED PRODUCT CAN BE PRODUCED /RUN:

600 ml (0.6 L) of SEMI PRODUCT contains with 30 g (3 % A.i) is needed to produce 1 L of Formulated Product.

The amount of SEMI PRODUCT/RUN = 13.33 L. So, THE AMOUNT OF FORMULATED PRODUCT CAN BE PRODUCED/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)