AYURVENTURE: A WAY TO ESTABLISH AN AYURVEDIC MANUFACTURING INDUSTRY AT SMALL & MEDIUM SCALE - Concept, Components & cost Estimation, Legal Steps, Paper Works etc.

AN OVERVIEW & COST ESTIMATION OF AYURVEDIC MANUFACTURING INDUSTRY AT SMALL AND MEDIUM SCALE:

In the current century Ayurveda holds a solid vincity of health care procedure. Chiefly Ayurvedic medicines are obtained from our mother, nature. Due to lack of proper facilities and methodologies till today it is not so highly profitable business. It is our aim how to establish and development an Ayurvedic manufacturing unit as well as Ayurvedic industry at small and large scale. There has been a shift in universal trend from synthetic to herbal medicine at current scenario. It is an ancient wisdom that plants have therapeutic value and are used to treat various diseases since Neanderthal age.

[1] MASTER PLAN:

v Schematic lay out

Find the layout plan in auto cad presentation.

v Concepts

a. Basic layout supports the GMP schedule “T”.

b. Sufficient space has been provided in each department to support 50% annual growth for the next 3/5 years. Thus space for additional equipment has been provided or proposed plant & Machinery plans visualize annual 50% growth.

c. In the facilities, the uniflow system of production is incorporated.

d. Departments are so placed, to eliminate any possibility of contamination of any kind.

e. Strong quality control set up is also provided to facilitate routine analytical tests as well as to ensure that international quality standards are met.

f. Independent maintenance department is provided with generator to avoid interruption in production process due to power failure.

g. Modern plant and machinery are chosen to produce the best quality medicine with desirable output.

v Components

a. Excellently planned civil work.

b. Modern machinery and equipment.

c. Skilled personnel.

[2] BUILDINGS

v Facilities

(A)Production:

a) Panak (Syrup) (ground floor)

b) Churna (Powder) (ground floor)

c) Tablets (ground floor)

d) Capsule (ground floor)

e) Tail(Oil) (ground floor)

f) Ointment (ground floor)

(B)Production Support:

a) Stores (ground floor)

Ø Raw material

Ø Packing material

Ø Finished product / Quarantine

b) Quality Control (ground floor)

Ø Physicochemical section

Ø Instrument section

Ø Microbiology section

(C) Utility Support:

a) Potable water reservoir (roof)

b) RO water plant (ground floor – in factory campus)

c) Elevator (ground floor to top floor)

d) Cloak room (ground floor )

e) Toilets (ground floor)

(D) Maintenance:

a) Generator, electrical panel room (ground floor – in factory campus)

b) Tool & servicing room (ground floor – in factory campus)

c) Administration & IT support (ground floor – in factory campus)

d) Service floor - AHU etc. (on extended cantilever adjacent to

1^st.& 2^nd. floor)

(E) Administration:

a) Director’s secretariats

o Plant manager’s Room

o Conference room

o Administration and accounts

o Reception (ground floor in factory campus)

o Canteen (ground floor in factory campus)

o Lunch room (ground floor in factory campus)

BUILDINGS (contd.)

v Programs (Products category)

1. Panak (Syrup) – capacity 500lts. to 1000lts. per batch

2. Churna (Powder) – capacity 100kgs. to 500kgs. per batch

3. Tablet – capacity 50000tabs. to 100000tabs. per batch

4. Capsules – capacity 50000caps. to 100000caps. per batch

5. Taila (Oil) – capacity capacity 500lts. to 1000lts. per batch

6. Ointment - capacity 100kgs./Lts. to 200kgs./Lts. per batch

2. Area (existing land area & required / utilized area)

1. Utilized open area for building construction : 6000.00 SFT (approx.)

(Length – 140ft. X Breadth – 40ft.) + back side construction (400sft)

2. Ground floor (carpet area) : 5000.00 SFT (approx.)

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Total factory carpet area : 5000.00 SFT (approx.)

v Concept parameters, concept designs

1. G plus 4 plan having. Present construction will be of two storied.

2. Main walls are of 10” thickness with required column structure.

3. Cantilever from first & second floor will be done to act as service floor.

4. RCC ceiling height is of 10 to12ft.

5. Partition walls are all of 6” thickness having 4 to 5ft. in height and up to false ceiling aluminum glass partition to be fixed.

6. General water supply will be of PVC and RO water supply will be of SS 304 grade inner electro polished pipe line.

7. Floor will be of kota stone (some area epoxy could be done).

[3] IMPLEMENTATION

v Costs (no. – 1)

Civil structure (ground & back side with boundary wall) ::
Area 6000 SQ. FT (in total land area)
Putty with plastic / oil paint::

4. Aluminum, glass partition ::

5. Electric wiring (including all material etc.

6. Electrical panel cost

7. Deep tube well 800 to 1000ft depth

8. Aluminum door

9. Flooring with kota stone

10. Boundary wall with gate (LS)

11. Plumbing & sanitary

12. Paint outside

13. Aluminum window (view panel)

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6000sft. @ Rs.1500.00 Total = Rs.90,00,000.00

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[3] IMPLEMENTATION

vSchedule (duration)

1. Civil work :

2. Aluminum glass partition :

To be completed with in

three months span of time.

3. Putty and Painting :

4. Electric wiring :

e) Phasing of construction job

I. Civil structure

II. Kota stone flooring

III. Electric wiring

IV. Utility line (water etc.)

V. Putty

VI. Aluminium, glass partition, doors etc.

VII. Painting

REQUIRED EQUIPMENTS FOR PRODUCTION
Production		Department: Oral Liquid:500 Littre Capacity
Sl No.	Name of the new Equipments		Capacity	Approx. Cost (Rs.)
[01]	S.S decoction vat		500lts.	1,20,000.00
[02]	S.S blending vat with stirrer		500lts.	1,00,000.00
[03]	S.S storage tank		500lts.	50,000.00
[04]	S.S filling tank with twin out let		200lts.	30,000.00
[05]	S.S filter press		6bed x 8”dia.	70,000.00
[06]	Semi automatic twin head filling		5000 to 8000 btls. per 8hrs.	65,000.00
[07]	Semi automatic sealing		5000 to 8000 btls. per 8hrs.	65,000.00
[08]	Bottle washing system		5000 to 7000 btls. per 8hrs.	45,000.00
[09]	Checking box			7,000.00
[10]	S.S transfer pump			35,000.00
TOTAL COST: 5,87,000.00
Production		Department: Oil (Taila):500 Littre Capacity
[01]	S.S decoction vat		500lts	1,20,000.00
[02]	S.S blending vat with stirrer		500lts	1,00,000.00
[03]	S.S storage tank		500lts	50,000.00
[04]	S.S filling tank with twin out let		200lts	30,000.00
[05]	S.S filter press		6bed x 8”dia.	70,000.00
[06]	Semi automatic twin head filling		5000 to 8000 btls. per 8hrs.	67,000.00
[07]	Semi automatic sealing		5000 to 8000 btls. per 8hrs.	67,000.00
[08]	S.S transfer pump			35,000.00
[09]	Checking box			7,000.00
TOTAL COST: 5,46,000.00
Production		Department:Powder (Churna):500kg. Capacity
[01]	S.S grinder, pulverizer		50 to100kg/hr.	1,50,000.00
[02]	S.S disintegrator		50 to 100kg/hr.	65,000.00
[03]	S.S ribbon blender		100kg.	2,15,000.00
[04]	S.S Sifter		N/A	1,05,000.00
[05]	S.S drier		24trays	1,40,000.00
[06]	Augur filler		Digital control	1,60,000.00
[07]	Heat foil sealer		N/A	15,000.00
[08]	S.S storage tank		250kg.X 2	60,000.00
TOTAL COST: 9,10,000.00
Production		Department: Capsule: 100000 Caps. Capacity
[01]	S.S Cone blender		50 Kg.	1,00,000.00
[02]	Manual capsule filling machine		30000caps/8hrs.	90,000.00
[03]	Strip packing machine (2 Track )		N/A	2,20,000.00
TOTAL COST: 4,10,000.00
Production		Department: Tablet: 100000 Tabs. Capacity
[01]	S.S Mass mixer		100 kg.	1,25,000.00
[02]	Multimill / granulator		N/A	85,000.00
[03]	Vibro sifter 30”		N/A	1,50,000.00
[04]	Paste kettle		100 Liter	1,40,000.00
[05]	Tray drier		24 Tray	1,40,000.00
[06]	Drum mixer		N/A	1,20,000.00
[07]	Compression machine (16stn.)		N/A	3,20,000.00
[08]	Polishing pan		N/A	50,000.00
[09]	Strip packaging machine		N/A	2,10,000.00
TOTAL COST: 13,40,000.00
Production		Department: Ointment: 100 Littre. Capacity
[01]	S.S Jacketed Vat with Mixing arrangement		100 lt.	1,60,000.00
[02]	Semi automatic tube filling Machine( Double Head )		20-25 NOS. /Minutes.	1,10,000.00
TOTAL COST: 2,70,000.00

REQUIRED EQUIPMENTS FOR QUALITY CONTROL
Q.C		Department: CHEMISTRY / INSTRUMENTS / MICROBIOLOGY
[01]	Hot air oven		Digital	9,500.00
[02]	Water bath		Thermostatic controlled	5,000.00
[03]	Hot plate with magnetic stirrer		Digital	7,500.00
[04]	Bulk & tapped density apparatus		Digital	17,500.00
[05]	Moisture balance		Precision Model	13,500.00
[06]	Heating mantle		N/A	2,000.00
[07]	Muffle furnace		Digital	16,500.00
[08]	TLC kit with UV cabinet		N/A	17,500.00
[09]	Single pan electrical balance		N/A	13,500.00
[10]	Refractometer		N/A	13,500.00
[11]	pH meter		Digital	8,000.00
[12]	D.T apparatus		N/A	21,000.00
[13]	Friability test apparatus		Digital	23,500.00
[14]	Polari meter		Digital	24,000.00
[15]	Top pan balance		Upto3^rd.decimal	16,000.00
TOTAL COST: 2,08,500.00

Q.C/R & D		Department: CHEMISTRY / INSTRUMENTS / MICROBIOLOGY
[01]	Bacteriological incubator		Digital	14,500.00
[02]	B.O.D incubator		Digital	42,000.00
[03]	Colony counter		Digital	11,500.00
[04]	Colorimeter		Digital	10,000.00
[05]	Autoclave		Digital	32,000.00
[06]	Centrifuge machine		4 tubes	12,000.00
[07]	LAF system		Horizontal	70,000.00
[08]	Binocular Microscope		Oil immersion	30,000.00
TOTAL COST: 2,22,000.00

ESTIMATED PROJECT COST
SR. NO.	HEADS	UNIT	COST
[01]	Land Cost	Rs.
[02]	Building Cost	Rs.	90,00,000.00
[03]	Building Design (civil, structural)Cost	Rs.
[04]	Equipment Cost (a) Production (b) Laboratory	Rs.	4,063,000.00 4,30,500.00
[05]	Furniture etc. Cost (LS)	Rs.
[06]	Others § Computers with printers & UPS § Generator (150KVA) § DM plant – all SS 304 (2000lts.)	Rs.
TOTAL COST: Rs.1,34,93,500.00 (One core thirty four lack ninety three thousand five hundred rupees only)

LEGAL STEPS

1. Land mutation & conversion with appropriate documents.

2. Trade license (NOC from municipality or panchayat) Purpose: manufacturing & sales or distribution of ayurvedic medicine & cosmetics.

3. Plan layout of land (factory premises/stock premises) on managing director’s pad(for pvt. Ltd company) or firm’s letter head (for partnership firm) with stamp & signature by signing authorized partner.

4. Memorandum of article of association/pvt. Ltd. Or partnership deed or registered partnership deed copy.

5. Law reading to drug & cosmetics act (Bijoy malik,22^nd edition; schedule ‘T’)

6. Fire license issued by competent authority

7. Pollution license issued by competent authority

8. No objection by neighbor

9. Company name registration and trade mark application

10. MSME registration

PRIMARY STEPS

STEP 1: Partnership deed/ Memorandum of article.

STEP 2: Trade license.

STEP 3: Professional tax.

STEP 4: Current bank account.

DOCUMENTS REQUIRED FOR PARTNERSHIP DEED/PVT LTD

1. Company name.

2. Company address.

3. Name, c/o & address of every individual partners/ directors

4. Nature of business.

5. Percentage of every partner or director/ % of profit or less of partners or directors

6. Banking operation (any two).

7. Capital amount(initial & total)

8. Salary system.

9. Rubber stamp of company.

10. Stamp paper should be buying at company’s name.

DOCUMENTS REQUIRED FOR TRADE LICENSE:

1. Form from municipality or panchayat.

2. Letter head of company or firm.

3. Rubber stamp of company or firm.

4. Partnership deed.

DOCUMENTS REQUIRED FOR PAN CARD:

1. Partnership deed.

2. Trade license.

3. Signature of one partner with rubber stamp.

DOCUMENTS REQUIRED FOR PROBESSION TAX:

1. Partnership deed.

2. Trade license.

3. Pan card of company.

DOCUMENTS REQUIRED FOR C/C CURRENT BANK ACCOUNT OF COMPANY:

1. P. deed

2. T. license.

3. Pan card.

4. P. tax.

FORMULATION:

There have two major types of formula for ayurvedic medicines as well as products. One is classical formula which is already described in classical ayurvedic text like Ayurvedic formulary of India, Ayurved Samgraha, Rasaratna Samucchhaya, Rasajal Nidhi, etc and other is patent or proprietary formula which should be approved after standard testing’s, clinical trials, research works etc.

Classical formulation can be easily approved by competent licensing authority of state after their expert committee meeting and there has no need of proof concept for formula. But for patent or proprietary formula proof concept along with master formula is very essential to get approval for manufacturing of that product.