Calcium Lactate Manufacturing Plant Project Report 2024

The report is the result of extensive primary and secondary research, offering a detailed analysis of current market trends. It profiles key industry players, giving insights into their market strategies, production capacities, and financial performance, which are crucial for benchmarking and competitive analysis.

It delves into historical, current, and forecasted price trends, helping stakeholders understand market dynamics and price volatility. The report provides a thorough analysis of the mass balance and raw materials requirements, ensuring a clear understanding of the input-output ratios essential for efficient production. Detailed examinations of the various unit operations integral to the calcium lactate manufacturing process are included, highlighting process optimisation techniques and technological advancements.

The report presents a comprehensive capital cost analysis, detailing the financial investment required for setting up a calcium lactate plant. This includes an exhaustive breakdown of costs associated with raw materials, catchem, utilities, labour, packaging, transportation, land acquisition, construction, and machinery. Additionally, it offers an in-depth look at the operating costs, providing clarity on the recurring expenses involved in running the plant.

Projected profit margins and optimal product pricing strategies are outlined, offering guidance on maximising profitability. The report also addresses regulatory frameworks, environmental impacts, and sustainability measures pertinent to the calcium lactate industry.

About Calcium Lactate

Calcium lactate is a calcium salt derived from lactic acid, commonly used as a food additive for its stabilising, thickening, and flavour-enhancing properties. It was first synthesised in the late 19th century and has since been used in food preservation and nutritional supplementation. Its safety was affirmed by the FDA, categorising it as generally recognised as safe (GRAS). Today, it is also employed in dietary supplements to prevent calcium deficiency and in veterinary medicine to treat hypocalcemia in livestock. This compound is recognised for its low toxicity and better palatability compared to other calcium salts.

Properties of Calcium Lactate

Calcium lactate is a white, crystalline or granular powder, known for its low solubility in water and slightly efflorescent nature. It is stable under normal conditions and has a mild, slightly sweet taste, making it suitable for food applications. With a molecular formula of C6H10CaO6, it can exist in various hydration states, including anhydrous, monohydrate, trihydrate, and pentahydrate. Calcium lactate is non-toxic and safe, making it widely used in food products, supplements, and pharmaceuticals.

Manufacturing Process of Calcium Lactate

The production of calcium begins with the preparation of raw materials, primarily calcium carbonate (CaCO3) and lactic acid, along with water as a solvent. The first step is mixing the lactic acid in water, followed by the gradual addition of calcium carbonate. This mixture is then maintained at a temperature of 28-32°C for approximately 10 minutes to facilitate the reaction. Next, a specific amount of medicinal alcohol is introduced to the solution to promote crystallisation. The mixture is allowed to stand for 5-7 hours at a temperature of 10-20°C, which aids in the formation of crystalline calcium lactate. Next, the solid product is separated from the liquid through filtration, and it is then washed and dried. The result is a loose, uniform white granular solid of calcium lactate, boasting a purity of up to 99.9% and a yield of approximately 87.2%.

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Synthesis of Calcium Lactate

The production of calcium lactate involves a reaction between lactic acid and calcium carbonate or calcium hydroxide, which is described below:

1. Raw Materials:

• Lactic acid (C3H6O3)

• Calcium carbonate (CaCO3) or Calcium hydroxide (Ca(OH)2)

Steps Involved:

Step 1: Preparation of Reactants

• Lactic Acid: High-purity lactic acid is sourced, usually in the form of a liquid.

• Calcium Carbonate or Calcium Hydroxide: High-purity calcium carbonate or calcium hydroxide is used, usually in the form of a fine powder.

Step 2: Reaction Process

• Reaction Vessel: The reaction is typically carried out in a reactor vessel made of materials resistant to acids and bases, such as stainless steel or lined with anti-corrosive materials.

• Addition of Lactic Acid: Lactic acid is added to the reactor vessel.

• Addition of Calcium Carbonate or Calcium Hydroxide: Calcium carbonate or calcium hydroxide is slowly added to the lactic acid in the reactor.

Step 3: Reaction Conditions

• Temperature Control: The reaction is mildly exothermic, so the temperature is carefully controlled, usually kept between 30°C and 50°C.

• Stirring: The mixture is continuously stirred to ensure that the calcium carbonate or calcium hydroxide is completely dissolved and reacted with the lactic acid.

Step 4: Formation of Calcium Lactate

• The reaction between lactic acid and calcium carbonate or calcium hydroxide produces calcium lactate, water, and carbon dioxide gas (when using calcium carbonate).

• The produced carbon dioxide gas (if any) is vented off from the reactor.

Chemical reaction when using calcium carbonate: 

2C3H6O3 + CaCO3 → Ca(C3H5O3)2 + H2O + CO2

Chemical reaction when using calcium hydroxide: 

2C3H6O3 + Ca(OH)2 → Ca(C3H5O3)2 + 2H2O

Step 5: Filtration

The reaction mixture is then filtered to remove any unreacted solids and impurities.

Step 6: Concentration and Crystallisation

The filtered solution is concentrated by evaporating excess water. Upon cooling, calcium lactate crystallises out from the concentrated solution.

Step 7: Drying

The crystals of calcium lactate are separated by filtration or centrifugation. The separated crystals are then dried to obtain the final product.

Step 8: Packaging

The dried calcium lactate is packaged in appropriate containers, typically bags or bulk containers, for storage and shipment.

Applications and Drivers of Calcium Lactate

Calcium lactate is used in the pharmaceutical industry as a calcium supplement to treat conditions like osteoporosis, hypoparathyroidism, and hypocalcemia. In the food industry, calcium lactate is added to products such as toothpaste, mouthwash, fruits, vegetables, and baked goods to enhance texture, flavour, and shelf life. It is also used as a preservative and to increase the size and sponginess of desserts like Rasagulla, a popular sweet in India. In the animal feed industry, calcium lactate is added as a supplement to cattle, poultry, fish, and prawns. The increasing demand for calcium-enriched products and the growing awareness of the importance of calcium in maintaining bone health are the primary drivers for the use of calcium lactate in these industries.

Key Features of the Calcium Lactate Production Cost Report:

This production cost analysis report by Expert Market Research scrutinises the calcium lactate manufacturing process, offering a comprehensive overview necessary for stakeholders considering venturing into this sector. Based on the latest economic data, the report encompasses detailed insights into the primary process flow, raw material requirements, reactions involved, utility costs, operating costs, capital investments, pricing strategies, and profit margins. This report is an indispensable resource for entrepreneurs, investors, researchers, consultants, business strategists, and all those who have any kind of stake in the calcium lactate industry. It equips them with essential information and strategic insights to effectively navigate the complexities of the market.

The following sections detail the comprehensive scope of the prefeasibility report for a calcium lactate production plant:

• Market Dynamics and Trends: This section analyses the prevailing market conditions, growth drivers, and trends impacting the calcium lactate industry. It offers a thorough examination of demand fluctuations and projections.

• Geographic Analysis: Detailed insights into the major regions active in calcium lactate production and consumption, highlighting regional market specifics and growth potential.

• Key Industry Players: Profiles of leading manufacturers in the calcium lactate sector, outlining their market share, strategic positions, and operational strengths.

• Price Fluctuations: Analysis of historical, current, and projected price trends, providing stakeholders with essential pricing intelligence.

• Technical Specifications and Process Description: A detailed overview of the calcium lactate production process including the technology used and innovations within the industry.

• Raw Material Requirements and Sourcing: Evaluation of necessary raw materials, their sourcing strategies, and cost implications.

• Utility Requirements and Costs: Detailed analysis of utilities needed to produce calcium lactate, such as electricity, steam, and process water along with their cost assessments. 

• Labour Force Dynamics: Insights into manpower requirements, including skill specifications and labour cost projections.

• Packaging Needs: Overview of packaging requirements for calcium lactate to ensure product integrity and cost efficiency.

• Logistics and Transportation: Examination of transportation needs and logistics planning for distribution and supply chain efficiency.

• Capital and Operating Costs: An in-depth look at investment requirements, including land acquisition and its development cost, civil work costs, construction, machinery procurement, and ongoing operational expenses, such as salaries and wages, plant overheads, tax and insurance as well as packaging, transportation, and administration costs.

• Financial Performance and Profitability Analysis: Projected profit margins and return on investment based on current market and operational parameters.

• Product Pricing Strategy: Recommendations on pricing mechanisms based on industry benchmarks and production costs.

• Environmental Impact and Regulatory Compliance: Analysis of environmental considerations and compliance with local and international regulations.

• Risk Assessment and Mitigation Strategies: Identification of potential risks associated with calcium lactate production and strategies to mitigate them.

Key Questions Addressed:

• What are the detailed unit operations for calcium lactate production?

• Who are major technology licensors with their process evaluation?

• How are raw materials or catchem procured and what are their cost implications?

• What utilities are essential for production and what will they cost?

• What are the labour requirements and how does this affect operational costs?

• What packaging solutions are optimal for cost and efficiency?

• What logistical arrangements are necessary for efficient product distribution?

• What are the estimated land and construction costs for a new calcium lactate plant?

• How can profitability be maximised in the calcium lactate market?

• What pricing strategy should be adopted for calcium lactate to remain competitive?

This prefeasibility report aims to equip potential investors and existing manufacturers with crucial insights to make informed decisions in the calcium lactate industry.