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IODISED SALT

CONTENTS SECTION I PRODUCT CHARACTERISTICS AND SPECIFICATION SECTION II PRODUCT APPLICATIONS SECTION III INDIAN MANUFACTURERS SECTION IV IMPORT/EXPORT LEVEL SECTION V PRICE TRENDS SECTION VI INDIAN DEMAND SECTION VII BROAD OUTLINE OF MANUFACTURING PROCESS SECTION VIII RAW MATERIAL REQUIREMENTS, UTILITY

AND AVAILABILITY SECTION IX GLOBAL SCENARIO SECTION X DISCUSSIONS ON ECONOMIC CAPACITY, PROJECT COST AND PROFITABILITY PROJECTIONS SECTION XI SWOT ANALYSIS SECTION XII FACTORS INFLUENCING THE POSITION FOR

A NEW INDUSTRY AND RECOMMENDATIONS

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SECTION I

PRODUCT CHARACTERISTICS AND SPECIFICATIONS 1.1 General Details Iodised salt is produced by iodising common salt. Iodine plays an important role in our body-system, as it is utilised by the thyroid gland for the synthesis of thyroxine, which is a hormone essential for the growth and developmental activities. Deficiency of Iodine in the body results in the impairment of synthesis of thyroxine, leading to reduced blood circulating levels. Such a situation, if continued for a prolonged period, leads to the enlargement of the thyroid gland commonly known as goitre. This is possibly the most common and visible manifestation of iodine deficiency in human body. 1.2 Specification Minimum requirement of iodine is 15 ppm (parts per million) at trade level with 35 ppm of factory level. IS Standards Standards IS 7224 introduced in 1973. This standard was revised in 1985. In this standard, various requirements are the same as prescribed in IS 253:1985 Edible common salt. The requirement for iodine content has been prescribed as 30 ppm, minimum at manufacturers' level and 15 ppm, minimum at the distribution channel. This standard also suggests the use of Potassium iodate as the potential iodizing agent for edible common salt, as it leads to a better shelf life for iodized salt. Iodised Salt Specification Salt : Edible grade Iodine : 40 ppm/25 ppm Method of analysis of Iodised Salt containing Potassium/Calcium Iodate: Determination of Iodine A. Reagents: 1. Potassium Iodate (KIO3) A.R. Grade 2. Potassium Iodate (KI) A.R. Grade 3. Sodium thiosulphate (Na2S2O3) A.R. Grade 4. Conc. Sulphuric Acid (H2SO4) A.R. Grade 5. Starch A.R. Grade

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B. Preparation of Standard Solutions: Potassium Iodate : 0.1N and 0.005 N. Dissolve 3.567 g of potassium iodate (over dried at 120 Deg C for 1 hour) in distilled water and make up the volume to one litre. The solution will become 0.1 N. Dilute further 0.1 N potassium iodate by 20 times the solution will be 0.005 N. Sodium thiosulphate: 0.1N and 0.005N. Dissolve 25 g of Na2S2O3 - 5H2O in distilled water and make up the volume to 1 litre. The solution will become 0.1N. Dilute further 0.1N Sodium thiosulphate solution by 20 times, the solution will be 0.005 N. Potassium iodide : 10 per cent. Dissolve 10 g of KI in distilled water and make the volume to 100 ml. Sulphuric acid Sulphuric acid 2N: Dilute concentrated sulphuric acid (36N) by 18 times e.g. 56 ml Sulphuric acid diluted with distilled water to litre. Starch indicator - 1: Take 1 g of starch and prepared a slurry in 50 ml of cold water. Add this slurry slowly in 50 ml of hot distilled water. C. Standardisation of sodium thiosulphate solution : Take 0.1 N Sodium thiosulphate solution in a burette and 25 ml of 0.1 N standard Potassium iodate in conical flask using standard pipette. Add 1 to 2 ml of 2N sulphuric acid and 5 ml. KI. Titrate the solution (liberated iodine) against sodium thiosulphate. Use starch as an indicator near the end of titration. The colour change will be from blue to colourless. Standardise 0.005 N Sodium thiodulphate using 0.005 N Potassium iodate in the same way calculation. N1 x V1 Normality of Sodium thiodulphate =- V2 Where N1 = Normality of Potassium iodate V1 = Volume of Potassium iodate N2 = Normality of Sodium thiodulphate V2 = Volume of Sodium thiosulphate D. Determination of iodine from iodised salt: Take 50 g of iodised salt and dissolve it in about 200 ml of water. Add 1 + .02 ml of 2N Sulphuric acid and 5 ml. of 10 KI. Titrate against 0.005N Sodium thiosulphate solution using starch indicator. Calculation: R x 20 x 103 x 0.127 x N2 Indine (±) ppm = 6 Where R = Reading of sodium thiosulphate

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N2 = Normality of sodium thiosulphate Note : In this calculation multiplication of 20 is to convery reading for 1000 g of salt and 103 is to convert g of iodine to mg of iodine.

SECTION II

PRODUCT APPLICATIONS The iodisation of salt is an effective, low cost long term and sustainable solution, to ensure that iodine reaches the entire population and is ingested on a regular basis. In the National Plan of Action for Children, India is committed to achieving the goal of "universal access to iodised salt": The adverse effects of Iodine deficiency extends to several vital areas such as child survival. The total number of still births and neonatal deaths attributable to iodine deficiency is over 90,000 per annum. In fact, the need for iodine starts even before a child is born. If the mother is iodine deficient, the foetus too suffers. During the period, the brain is developing (last six months of pregnancy) and the consequence of iodine deficiency could be disastrous. It is estimated that because of iodine deficiency in mothers, globally 30,000 babies are still born every year and over 1,20,000 are born mentally retarded, physically stunted, deaf mute or paralysed. Iodine is an essential dietary nutrient that helps the body to manufacture thyroxine-the hormone that regulates normal growth and development. More than one billion people in the world are at risk of iodine deficiency affliction. Women of child bearing age and children below the age of 15 are most susceptible to iodine deficiency. The most common and visible ill effect is goitre-an abnormal swelling in the neck. The less obvious and more serious condition affecting millions of children includes impaired intellectual performance, lowered IQ, muscular disorders and impaired coordination and sluggishness. During pregnancy, iodine deficiency may cause abortions, still births, infant deaths.

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SECTION III

INDIAN MANUFACTURERS

3.1. Major players in salt industry Tata Salt (Tata Chemicals) is the market leader with sales of 0.29m ton pa. Annapurna (HLL) and Captain Cook (DCW Home Products) are the two other major brands which sell about 0.2mn and 0.3mn ton pa each. While Captain Cook is positioned on the USP of free flowing nature of its salt, Tata Salt is positioned on purity platform and Annapurna is positioned on the health benefit impact of the iodine content in the salt. Nirma and Dabur are the two latest entrants in the branded salt market. Tata Salt, the first branded salt in the country, was launched in 1983. Tata salt is manufactured by Tata Chemicals as a by product of its water distillation plant. DCW launched salt in 1991. It has three plants in Maharashtra, Gujarat and Tamil Nadu. In August’ 98, Corn Products Company (India) Ltd (manufacturer of Knorr brand of soups) acquired the Captain Cook brand and the salt manufacturing facility at Gandhidham for a consideration of Rs.900mn. Corn Products, renamed as International Bestfoods Limited wef October ‘98, will now be one of the leading players in the segment. Hindustan Lever’s Annapurna was launched in 1996. HLL operates three plants at Maharashtra, Delhi & Bangalore. Nirma is setting up a soda ash plant which will produce 280,000 tpa of salt as by product. The company is currently test marketing Nirma Free Flow Salt. Nirma has the advantage of a well established distribution network of grocery stores (where its soap and detergent brands are typically sold). With its strategy of competitive pricing, the company has the potential to become a significant player in the segment Dabur has recently launched Nutra salt, a low sodium salt. Marico has also launched Saffola salt which is a mineral enriched low sodium salt. Both the above brands are positioned on the health platform, and are priced at a significant premium to normal salt brands.

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Besides there are a large number of other local/regional brands in refined and iodized salt. * Tamil Nadu Salt Corpn. Ltd. (A Government of Tamil Nadu undertaking) L.L.A. Building, 735, Anna Salai-600 002 Phone : 8418344 Fax : 91-44-8522259 Factory : Mariyur Vallnokkam Salt Complex Vallnokkam (Post), Sikkal (Via), Ramnad Dist.-623 528 Phone : 04576-62227 Fax : 04576-62227 Tamil Nadu Salt Corporation Ltd., was set up during the year 1974 by the Government of Tamil Nadu with a view to exploit the potential available for the production of salt and salt based by-products. Tamil Nadu Salt Corporation Ltd., has developed 2300 acres to produce industrial and edible salt out of the effective area of 4825 acres available for salt development in Mariyur Valinokkam Salt Complex, Valinokkam, Ramanathapuram District. The production would be increased from the existing level of 1,30,000 tonnes to 2,00,000 tonnes It has initiated action to produce double fortified salt based on technical know how provided by NIN, Hyderabad. Tamil Nadu Salt Corporation is producing Iodized salt in one-kilo packets. The corporation is at present manufacturing industrial grade salt and other fortified salt and other fortified salts viz. Iron Fortified Salt, Double, Fortified salt, Diethyl Carbomycine Medicated salt and Iodized "Arasu Salt". The Corporation, started with a minimal production of 700 tonnes of Salt in 1976-77. Tamil Nadu Salt Corporation Ltd., had started producing iodised salt at Valinokkam from November'98. Project implemented i. Mariyur Valinokkam Salt Complex (MVSC) Valinokkam, Ramanathapuram District. ii. Iron Fortified Salt Project (IFS) I, Valinokkam, Ramanathapuram Dist. iii. Iron Fortified Salt Project (IFS) II, Alathur, Kancheepuram Dist.

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The Tamil Nadu Salt Corporation (TNSC) is preparing a detailed project report for setting up a plant to produce refined free flowing Iodised salt. The plant estimated to cost Rs.6 crore would be set up at Valinokkam. Ramanathapuram district, where the corporation has its salt works; Mariyur Valinokkam Salt complex (MVSC). The corporation hopes to sell the free flow salt consumers for Rs.3 a kg against the current price of Rs.5.50-6 a kg. The plant will have a capacity to produce 36,000 tonnes per annum of free flowing salt and 3,000 tonnes of salt fines. The refined iodised salt from the plant will be free from impurities and can be used for double fortification with iron or iodine. At present, it is supplying iodised "Arasu" brand salt to fair price shops in Tiruchirapalli district to the extent of 600 tonnes per month since November 1998. Double fortified salt will soon be introduced in the State by the Tamil Nadu Salt Corporation. The corporation now supplies salt to seven districts of Karnataka and to families below the poverty line in Tamil Nadu. It is committed to extending all support to the Government and the United Nations Children's Fund in making the country iodine deficiency disorder-free. Salt testing laboratories and mobile units have been set up in the State to monitor quality. Of over 300 districts around the country surveyed by medical researchers, 283 suffered from goitre, a problem associated with iodine deficiency. Salt iodisation was taken up in 1962 but lack of strict vigil on transport of salt by road to various places, lack of awareness and education and the lifting of the ban on supply of uniodised salt in certain States are responsible for the rise in IDD. 3.2 Number of Iodised salts units and installed capacity With a view to ensuring Universal Access of iodised salt to eliminate goitre and other iodine and other iodine Deficiency Disorders in the country, the salt Commissioner’s Office has been declared as the Nodal Agency for the creation of adequate capacity for the production, distribution and quality monitoring of iodised salt at the production centres under the National Iodine Deficiency Control Programme (NIDDCP). Number of registered units 940 units Annual installed capacity 147 lakh tonnes

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SECTION IV

IMPORT/EXPORT LEVEL There is no import of iodised salt in to the country. There is no export of iodised salt from the country

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SECTION V

PRICE TRENDS

Present price level : Rs.5000/- per tonne Taxes and duties : Extra as applicable

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SECTION VI

INDIAN DEMAND 6.1. Indian salt production

6.2 Production of Refined and Iodised salt (in ‘000 tonnes)

0100020003000400050006000700080009000

Qua

ntity

in '0

00 to

nnes

1996 1997 1998 1999 2000 2001

Year

0100200300400500600700800900

1000

Qua

ntity

in '0

00 to

nnes

1998 1999 2000 2001

Year

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The total salt production in Southern Region, on an average, is around 20 lakh tonnes annually and on a conservative estimate. The main feature of this industry is that the non-license sector accounts for a good chunk of the production. Tamil Nadu produces 18 lakh tonnes of salt and there are 893 licenses. The total licensed area under salt production is stated to be 41,495 acres. The demand would further go up as the Government of India and State Governments are likely to insist on full iodisation in the country. 6.2. Importance of Iodised salt Iodine is an essential element for normal human growth and development. About 150 micrograms (15 ppm) of it keeps the individual away from the well known deficiency attack of goitre when the thyroid gland in the neck goes into a spree of synthesising two iodine containing hormones and swells up. 6.3. Demand level for Iodised salt The present estimated demand for Iodised salt in the country is around 4 million tonnes per annum. 6.4. Penetration Salt penetration at all India level is estimated to be 93.8%, comprising 96.8% in urban areas, 92.7% in rural areas. The penetration in medium and large size towns is significantly higher at 98-99%. The penetration of iodized salt however is very low, estimated at less than 5%.

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SECTION VII

BROAD OUTLINE OF MANUFACTURING PROCESS 7.1 General Details Iodised salt is prepared by blending high grade common salt with iodine compounds. Upgradation of common salt is achieved by numerous methods, based on repeated washing and drying and finally blending with suitable whitener. Anticaking agents may be used to maintain the free flow of the salt. 7.2 Iodised Salt From Lakes Lake salts from different sources show significant variation in their impurities including WIR and whiteness. Furthermore, salts from the same source also show variation from season. Therefore, to get uniform high quality salt, it is necessary to adopt secondary treatment for salts manufactured from the lakes. It is found that the salts from different sources, not only differ in whiteness, but also respond in different degrees to the identical treatment. Whiteness achieved in identical conditions for salts from two different inland sources are given below. Source I Source II Original whiteness(%) 71% 66% Plot Process I 73 (3) 67(1.5) Process II 75 (6) 69(4) Process III 77 (8) 70 (6) Process IV 74 (4) 70 (6) Process V 78 (10) 72 (9) Process VI 75 (6) 75 (14) * Whiteness in respect to pure MgO. Figure within parentheses show increase of whiteness (%) from the original.) It is seen that while in case of processors I to V, both the salts respond in similar way, but in case of process VI, the salt from Source II responds in a much better way than that from source I. Thus it is observed that different processes need to be adopted for upgradation of salts from different inland lakes.

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7.3 Broad Outline Manufacturing Process * Various countries have iodised the edible salts with potassium iodide, potassium iodate and calcium iodate. Potassium iodide is not stable and therefore stabilisers (like calcium carbonate) have to be added to reduce the loss of iodine, in case of using Potassium Iodide. * The iodate, on the other hand, is stable up to 560 Deg C. Except in extreme conditions, Potassium iodate does not deplete and can sustain even after 300 days in storage as iodised salt. * The Central Salt & Marine Chemical Research Institute (CSMCRI), Bhavnagar found that it is only on heating the iodised salt or boiling the solution, that there is significant depletion. * Potassium iodate has been approved by the Health Ministry for iodating the salt. According to the 1987 BIS standards, to get 30 ppm of iodine, 50 ppm of potassium iodate needs to be added. To get the iodised salt, the iodate is dissolved in water or saturated brine. Then the salt crystals are mixed with the aqueous solution to form iodised salt. 7.3.1 Stability of Iodised salt : A CSMCRI team studied the stability of iodised salt packed in HDPE bags stored for about 10 months and iodised salt kept in open heaps. It also analysed the stability of iodised salt after it is dissolved in water and boiling and direct heating at 120 Deg C for three hours. One reason for iodine loss, according to the scientists, can be the drainage of the bulk salt stored in HDPE bags. The scientists say that the common salt after mixing is not generally dried but packed directly. Sometimes, it is dried in the sun in open heaps before packing, but this does not remove all the moisture. But none of these, they say, can account for the high depletion down to well below 15 ppm as claimed by manufacturers. The team found that after the first 15 to 20 days in either HDPE bags or in open heaps, there was a 9 to 20 per cent loss in iodine. But thereafter, the iodine content of iodised salt remained constant. This initial depletion, the researchers say, is due to partial draining of iodised brine, sticking to the sides of the polythene bags. Even after boiling an aqueous solution of the iodised salt, both concentrated and dilute, after 30 minutes, the iodine loss was only between 4 and 10 per cent. After 60 minutes, the loss was 11 per cent. But the greatest loss of iodine of 40 to 60 per cent was when the iodised salt was heated in an oven for three hours at 120 Deg C.

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7.3.2 Process outline : Iodised salt can be produced either by Submersion process or Spray Method. The method of manufacturing iodised salt is not complicated and does not involve any costly machinery. Cement tanks and diesel or electrically operated pumps are the main requirement of the process. Common salt is taken in the submersion tanks (cement tanks) either manually or mechanically. A saturated solution of sodium chloride with fixed quantity of potassium or calcium iodate from the storage tank is then charged with the help of the pump till common salt is submerged completely in iodised brine. After giving about five minutes of contact period, iodised brine is discharged in the settling tank. After settling of mud impurities, iodised brine is taken into storage tank for 2nd cycle of operation. The wet salt from the submersion tanks is heaped for overnight draining. Next day, the salt is transferred to main heap, from where it is crushed by roller crusher and packed in polythene lined bags or closely woven sugar gunny bags. Iodine content of salt as well as iodised brine should be checked in each batch. Necessary level of iodine should be maintained in iodised brine to get 15 ppm of iodine in iodised salt. Source of technology * Central Salt Marine & Chemical Research Institute,

Bhavnagar Guajrat

Major plant & manchinery and suppliers

Name of the equipment Name of the suppliers

Submersion cement tank Local contractor

Storage tank Aristo Engineers

J-3, Vikas Udyog Nagar, Behind Kasturi Tiwer Phatak-Goddeo Road, Bhayander (E), Thane-401 105 B.M. Industries Plot No.5223, Phase IV GIDC, B/h. Klockner Windsor India Limite Vatwa, Ahmedabad-382 445

Roller crusher Varahi Engineers and Fabricators 40/12, Phase I, GIDC Opp. Nilsin Blue, Vatva Ahmedabad-382 445

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SECTION VIII

RAW MATERIAL REQUIREMENTS, UTILITY AND AVAILABILITY

The salt and Potassium Iodate are the raw material. Both the products are indigenously available. Salt Production in India In India, salt is mainly produced from sea water in coastal locations of Gujarat and Tamil Nadu. Other salt manufacturing locations#include coastal areas of Maharashtra and West Bengal and lake water in Rajasthan. In some countries like USA, salt is also produced by way of mining and quarrying (called rock salt). In India, sea water is abundantly available. Refined Salt : The percentage of sodium chloride in refined salt is as high as 99%. Raw salt has about 95% sodium chloride (Nacl) and 5% of other elements such as magnesium chloride, calcium chloride, magnesium carbonate and calcium carbonate. Other chlorides which are part of raw salt, can have harmful impact on health. In developed countries, only refined salt is consumed. But in India, about 95% of salt consumed is not refined. Market Size The salt market (organized as well as unorganized) is estimated to be around 5m ton pa valued at Rs 5 billion . The organized branded salt segment accounts for just 20% of the market ie1mn ton pa. Specifications and consumption of Raw materials Raw material Specification Required/tonne of product

(iodised salt) Salt Edible grade 1.05 tonnes Potassium iodate Technical grade 35.00 gms. Product Specification Salt Edible grade Iodine 40 ppm/25 ppm

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SECTION IX

GLOBAL SCENARIO World salt consumption increased to an estimated 190- 205Mt in 2000 and is rising chiefly in response to increasing demand in the countries of Southeast Asia and other developing nations. The salt markets in developed regions like North America and Western Europe are mature and are expanding at a rate a little below the average growth of the world economy. The main consuming regions are North America and Asia and the Middle East, each accounting for 30-35% of the total, and Western Europe (21%). In the immediate future, salt consumption is estimated to increase by 2-3%pa but this is dependent on continued demand for salt from the chlor-alkali sector, which could fall in response to the economic downturn in the USA at the end of 2001, and its less predictable consumption as a de-icer on roads. Much of the growth will be in East and South East Asia, and the balance of salt consumption will gradually shift away from the mature markets of Western Europe and North America to the growing markets in the Asia Pacific region. The recent trend in rationalisation and consolidation is likely to continue, with further potential for consolidation still existing throughout Europe and possibly in Australia.

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SECTION X

DISCUSSIONS ON ECONOMIC CAPACITY, PROJECT COST AND PROFITABILITY PROJECTIONS

Economic Capacity : 1500 tonnes per annum Project Cost : Rs.48 lakhs Assessment of project cost 1. Land S.No. Description Cost

Rs.in lakhs 1.1 Cost of land of 0.25 acre at Rs.5.5 lakh per acre 1.38 1.2 Cost of levelling, laying internal roads/fencing and

compound wall

0.14

Subtotal 1.42 2. Building S.No. Description Cost

Rs.in lakhs 2.1 Factory building of area 120 sq.m. at Rs.3200/sq.m. 3.84 2.2 Non-factory building of area 50 sq.m.at Rs.4500/sq.m. 2.25 Subtotal 6.09 3. Cost of Plant & Machinery S.No. Description Cost

Rs.in lakhs 3.1 Cost of basic plant and machinery 11.5 3.2 Instrumentation and control 0.86 3.3 Pipelines and valves 1.15 3.4 Structurals for erection 0.58 Subtotal 14.09 3.5 Octroi, excise duty, sales tax, etc.at 12%� 1.69 3.6 Packaging and insurance charges (2%) 0.28 3.7 Transportation charges (2%) 0.28 3.8 Machinery stores and spares (2%) 0.28 3.9 Foundation charges (2%) 0.28 3.10 Installation charges (2%) 0.28 Total cost of plant and Machinery 17.18 4. Technical know-how fees Rs.1.20 lakhs

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5. Miscellaneous fixed assets S.No. Description Cost

Rs.in lakhs 5.1. Electrification 0.8 5.2. Steam boiler and auxillaries 1.0 5.3. Water storage tank, borewell etc. 0.32 5.4. Fuel storage tank 0.32 5.5. Laboratory equipment 0.32 5.6. Office machinery & equipment 0.44 5.7. Material handling equipment, packaging machinery,

weigh balance, etc. 0.6

5.8. Diesel generator 4 5.9. Effluent treatment 0.8 Total 8.6 6. Preliminary & Pre-operative expenses: S.No. Description Cost

Rs.in lakhs 6.1. Preliminary expenses 0.8 6.2. Pre-operative expenses:- 0 6.2.1 Establishment 0.8 6.2.2 Rent rates and taxes 1 6.2.3 Travelling expenses 0.8 6.2.4 Interest and commitment charges on borrowings 1.20 6.2.5 Insurance during construction period 0.8 6.2.6 Other preoperative expenses and deposits 0 6.2.7 Interest on deferred payment 0 Total 5.4 7. Provision for contingency Rs. 2.37 lakhs 8. Working capital margin Rs. 5.4 lakhs 9. Total project cost Rs.47.66 lakhs 10. Means of Finance Promoter's contribution Rs.19 lakhs Term loan from financing institutions Rs.29 lakhs Total project cost Rs.48 lakhs 11. Financial statements

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A Variable cost

Rs. in lakhs

Raw material and utilities 34.09 Spares and maintenance 1.03 Selling expenses 3.75 Total variable cost (A)

38.87

B Fixed cost

Salaries and wages 6 Interest on term loan and working capital loan 8.14 Depreciation 2.58 Administrative expenses 2.25 Total fixed cost (B)

18.97

C. Total cost of production (A+B)

57.84

D. Selling price per kg. (in Rupees)

5

E. Annual sales turnover

75

F. Net profit before tax (E-C)

17.16

G. Breakeven point in %

53 %

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SECTION XI

SWOT ANALYSIS

Strength Large production level of salts

Weakness Inadequate distribution to remote areas

Opportunity Growing need for the product on health grounds

Threat Seasonal factors affecting production level of salt from time to time

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SECTION XII

FACTORS INFLUENCING THE POSITION FOR A NEW INDUSTRY AND RECOMMENDATIONS

Salt is one of the best carrier of iodine. Iodine is one of the key micro-nutrients identified by the World Health Organization (WHO), deficiency of which in developing countries is of major concern. Iodine deficiency causes diseases like goiter. There is significant deficiency of iodine in people living in developing world. Considering the growing demand for Iodised salt, strong case demand for building further capacity for Iodised salt in the country. However, the manufacturing units need to have adequate distribution mechanism for the product for successful marketing.