Establishment of a Multipurpose Gamma Irradiation Facility (MGIF) in Sri Lanka

by

Samantha KulatungeHead

Radiation Processing SectionAtomic Energy Authority

No. 60/460, Baseline RoadOrugodawatte, Wellampitiya

Content: What is radiation and related units? What is Gamma irradiator? What are the applications of Gamma radiation and why

do we use radiation? Multipurpose Gamma Irradiation Facility in Sri Lanka Selection of land Throughput (Capacity) of the facility Potential revenue Estimated Irradiation Market Profit & Loss Analysis

What is radiation?

Electromagnetic radiation

Measurements:QUANTITIES UNITS

Length Meters or KmDose Grays or kGyActivity (Source strength) Curie or kCi

Dose: The quantity of energy that the irradiated product absorbs. 1GRAY (Gy) = 1J/kg

Activity: Number of curies. Also improperly called source strength.1 Curie (Ci) = Activity of 1g of 226Ra1g of 226Ra disintegrate 3.7x1010 atoms per second 1 Ci = 3.7 x 1010 dis/s

Emitted when radioisotope cobalt-60 decays

Beta Particle

Gamma Rays(photons)

GAMMA RADIATION

Made from cobalt-59Half life : 5.24 years

Becomes nickel

How Co-60 produces gamma radiation

How it can be used in processing of How it can be used in processing of products?products?

g :- Surgical gloves

Sterilized rubber glove

Kills microorganisms

Co-60 radioactive source

(gamma rays)

PROCESSING WINDOW Minimum dose : threshold to achieve effect

Maximum dose : threshold of undesirable effect

When a product expose to radiation;

OVER PROCESSING

UNDER PROCESSING

Delivered energy = dose (in Grays = Joules per kilogram)

Multipurpose Gamma Irradiation Facility (MGIF)

Source rack in pool

Conveyor unloading

Bunker

Conveyor loading

Multipurpose Gamma Irradiation Facility

Gamma Irradiator Principle

Source rack in poolConveyor

Bunker

Slug & Pencil of cobolt-60 (Buiding blocks of a radiation source rack)

Cobolt 60 slug Cobolt 60 source element (an

inner capsule containing slug of cobolt-60)

Source pencil (contain 2 source

elements) Source module (contains up to

48source pencils) Source rack (contains modules in

different configurations, depending on irradiator design)

GAMMA IRRADIATOR

Ozone formed by irradiation of oxygen in airAir continuously ejected through chimneyOzone concentration < 1 ppm in limit of site

Radiation stopped by walls

Radiation stopped by water and ground

Pool water is safe to drink

No radioactivity in the air

Sources returned to supplier after 20 years of usage. No longer radioactive after 180 years

Pose no environmental problem

Control panel of the irradiator

Application of MGIF:Application of MGIF:

Immediate applicationsImmediate applications Sterilization of surgical gloves & medical productsSterilization of surgical gloves & medical productsDecontamination of spices, dried vegetablesDecontamination of spices, dried vegetablesDecontamination of medicinal herbs, Ayuvedic Decontamination of medicinal herbs, Ayuvedic products, health diet supplementsproducts, health diet supplementsSterilization of food and pharmaceutical packagingSterilization of food and pharmaceutical packagingDecontamination of dried pharmaceutical and cosmetic Decontamination of dried pharmaceutical and cosmetic ingredientsingredients

Mid term applicationMid term application Quarantine treatment of wooden objects and coir pithQuarantine treatment of wooden objects and coir pithPasteurization of frozen or fresh seafoodPasteurization of frozen or fresh seafood

Long term applicationsLong term applications Sprouting inhibition of onions and garlicSprouting inhibition of onions and garlic

Why Radiation Sterilization ? No recontamination Non-toxic No chemical residues Reliable & safe Treated product can be used immediately Complete product penetration Gamma irradiation produces no heat( therefore

preserves properties & characteristics) Precise and reproducible treatment process Proven use for 30 years Environmental friendly

Radiation Sterilization of Medical Products

Human Tissue Sterilization:

PHARMACEUTICAL PRODUCTS

EXAMPLES

Medicinal herbs and food supplements

Antibiotics in dried form

Eye ointments and veterinary products with antibiotics

COSMETIC PRODUCTS

EXAMPLES

Plants, Seaweeds

Talcum powder

Clay and sea mud

Mineral and organic dyes

Shampoo and shower gel

Brushes

Contd..

Food IrradiationApplication: Delay in ripening Disinfestation / Insect control Microbial control Quarantine treatment Shelf life extension Sprout inhibition Sterilization

Why food Irradiation ?

No chemical residues Preservation can be done after packaging Environmental friendly process Proven for more than 30 years

Insect Control

Shelf-life extension

Sprout Inhibition

Food Item Purpose Max Dose (kGy)

Spices Microbial controlDisinfestation

101

RiceRice products

DisinfestationDisinfestation

11

Potatoes Sprouting inhibition 0.15

Garlic Sprouting inhibition 0.15

Onions Sprouting inhibition 0.15

Vegetables Disinfestation 1

Meat Microbial control 7

Other Applications

Preservation of antiques, artefacts, mummies

Sanitation of rawhide pet toys

Quarantine treatment of wooden pallets, souvenirs and handicrafts

Sanitation of stuffed toys

Coloration of glass

Etc.

Multipurpose Gamma Irradiation Facility in Sri Lanka

MGIF in Sri Lanka

Required land area :02 acres Total area of the building :3250 M2

Activity :3 million ci Initial activity :150 kCi Power requirement : 45 kw (200kw) Water : comparable to a

large house

Capital costCapital costCost Component Estimated cost

( Rs. Million)Project Management 7.03Land 15Consultancy 25.6Civil Construction 320Machinery 151.7Taxes 65Vehicles 7.5Others 18

Total 609.83

Operating Costs (per year)Operating Costs (per year)

Item Amount (1000Rs)Salaries (Manager, Engineer, secretary, 2 Operators and 6 Helpers)

3,000

Maintenance and repairs 1,000

Utilities and communication 1,000

Miscellaneous supplies and services 1,000

Annual replacement and up-grading of Co-60(12.5% of initial load)*

40,000

Total 46,000

** Can vary depending on the demand for irradiation servicesCan vary depending on the demand for irradiation services

Total Cost for the facility:Total Cost for the facility:

purpose Estimated Cost (1000SLRs)

Capital Cost 610,00

Operating cost (including annual replacement and upgrading of Co-60 which is 12.5 % of initial load)

46,000

Total Cost 656,000

Selection of a locationSelection of a location

Criteria for selection of a location:Criteria for selection of a location:

Absence of opposition to the projectAbsence of opposition to the project Relative proximity to main usersRelative proximity to main users Good accessibility to main roads and portGood accessibility to main roads and port Privileges that can be obtainedPrivileges that can be obtained Price of land and management feePrice of land and management fee Security of the locationSecurity of the location Absence of vulnerability to natural hazards such Absence of vulnerability to natural hazards such

as floods and landslidesas floods and landslides Soil characteristicsSoil characteristics

Proposed site for Irradiator

Area to be acquired to provide vehicular access for non BOI products

RETAINING WALLSite Levelling

RETAINING WALL

6.0m. min.

6.0m.

min.

VEHICULAR ACCESS FOR

BOI PRODUCTS

VEHICULAR ACCESS FOR NON

BOI PRODUCTS

ENTRANCE FOR OFFICE

PROPOSED

BUILDING

Throughput or Capacity of the Throughput or Capacity of the facilityfacility

Throughput of the facilityThroughput of the facility

Potential throughput is proportional to the source Potential throughput is proportional to the source activityactivity

Actual throughput depend onActual throughput depend on Proportion of the time that facility is used forProportion of the time that facility is used for Downtime for maintenanceDowntime for maintenance Lack of products at certain periodsLack of products at certain periods

Throughput of a Gamma Irradiator with 150 kCi Throughput of a Gamma Irradiator with 150 kCi will be 100,000 kGy of products will be 100,000 kGy of products With a density of 0.2 tons/m3With a density of 0.2 tons/m3 If facility operates for 7880 hrs per annum (or If facility operates for 7880 hrs per annum (or

utilization ratio is 90%)utilization ratio is 90%)

Product Minimum dose (kGy)

Throughput per annum

Product density

Onions - Sprouting inhibition

0.1 500,000 tons 0.5 ton / m3

Cereal products- Insect control

0.5 30,000 tons 0.6 ton / m3

Dried fruit- Insect control 0.5 60,000 tons 0.3 ton / m3

Spices-Microbial control 5 6,000 tons 0.3 ton / m3

Latex gloves- Sterilization

25 4,000 m3 0.2 ton / m3

The quantity of products that can be irradiated with

the initial capacity of 150,000 Ci

Potential revenue

Potential revenue for different products Potential revenue for different products with an activity of 150,000 curieswith an activity of 150,000 curies

Potential revenue Potential revenue for different for different products with an products with an activity of 150,000 activity of 150,000 Curies Curies

MinimumMinimum dose dose

(kGy) (kGy)

ThroughputThroughput per annum per annum

ProductProductdensitydensity (ton / m(ton / m3)3)

TentativeTentative unit priceunit price (1) (1)

PotentialPotential revenuerevenue per annum per annum

(2) (2) USDUSD

Onions Onions Sprouting inhibition Sprouting inhibition 0.1 0.1 500,000 tons500,000 tons 0.5 0.5 10 USD / ton 10 USD / ton 5,000,0005,000,000

Cereal products Cereal products Insect control Insect control 0.5 0.5 30,000 tons30,000 tons 0.60.6 20 USD / ton 20 USD / ton 1,200,000 1,200,000

Dried fruit Dried fruit Insect control Insect control 0.5 0.5 60,000 tons60,000 tons 0.30.3 20 USD / ton 20 USD / ton 1,200,000 1,200,000

Spices Spices Microbial control Microbial control 5 5 6,000 tons6,000 tons 0.30.3 100 USD / 100 USD /

ton ton 600,000 600,000

Latex gloves Latex gloves Sterilization Sterilization 25 25 4,000 m4,000 m3 3 0.2 0.2 60 USD / m60 USD / m3 3 240,000 240,000

Estimated Irradiation MarketEstimated Irradiation Market

Estimated Irradiation MarketEstimated Irradiation MarketYear Year Volume (m3)Volume (m3) Need Need

(m3 x (m3 x kGy)kGy)

Source Source (kCi) (kCi)

Gloves Gloves (% (%

total)total)

Free Free capacity capacity

Total Total Lalan Lalan Prime Prime Glob Glob SurgSurg

SpiceSpice Total Total

20102010 11,927 11,927 7,000 7,000 3,333 3,333 260 260 1,333 1,333 316,691 316,691 443443 95%95% 85%85%

20112011 16,694 16,694 11,00011,000 3,500 3,500 527 527 1,667 1,667 450,964 450,964 631631 94%94% 79%79%

20122012 22,902 22,902 16,500 16,500 3,675 3,675 727 727 2,000 2,000 621,305 621,305 870870 93%93% 71%71%

20132013 24,619 24,619 17,500 17,500 3,859 3,859 927 927 2,333 2,333 665,090 665,090 993993 92%92% 69%69%

20142014 26,345 26,345 18,500 18,500 4,052 4,052 1,127 1,127 2,667 2,667 709,213 709,213 1,0331,033 91%91% 68%68%

20152015 +4 % +4 % 1,0741,074 67%67%

20162016 1,1171,117 66%66%

20172017 1,1621,162 64%64%

20182018 1,2081,208 63%63%

20192019 61%61%

20202020 60%60%

Why starting with small Co 60 activity?Why starting with small Co 60 activity? It limits the cost of decay during the learning phase. It limits the cost of decay during the learning phase. Time is needed Time is needed

To test and commission the plant, perform the safety various tests that To test and commission the plant, perform the safety various tests that need to be done and characterize the dose distribution pattern within a need to be done and characterize the dose distribution pattern within a range of products of different densities used as models range of products of different densities used as models

To implement a quality system that is not only on paper but tested in To implement a quality system that is not only on paper but tested in reality. This is required by organizations that will have to certify the reality. This is required by organizations that will have to certify the quality system to ISO 9000, ISO 13485 and EN 552, certificates that are quality system to ISO 9000, ISO 13485 and EN 552, certificates that are necessary to sterilize medical products that are exported to Europe, the necessary to sterilize medical products that are exported to Europe, the US, Japan or Australia. US, Japan or Australia.

For the personnel to learn the jobFor the personnel to learn the job For the customers to learn how to use the facility (packing, logistics, For the customers to learn how to use the facility (packing, logistics,

paper flow, etc.). This amount of cobalt-60 can be transported in a single paper flow, etc.). This amount of cobalt-60 can be transported in a single F-168 type transportation container, thus minimizing the cost of source F-168 type transportation container, thus minimizing the cost of source transportation. transportation.

C0-60 purchase costC0-60 purchase cost

Year 1 2 3 4 5 6 7 8 9 10

Installed kilo Installed kilo curies curies

150150 443443 631631 870870 931931 993 993 1033 1033 1074 1074 11171117 1162 1162

Occupied Occupied design design capacity capacity

5%5% 15% 15% 21% 21% 29% 29% 31%31% 33%33% 34%34% 36%36% 37%37% 39%39%

Purchased Purchased curies (kCi)curies (kCi)

311311 241 314 166 174 159 165 172 179 186Cost of Cost of decay decay (‘000LKR)(‘000LKR) 39283928

13,966

20,683

29,635

32,993

36,589

39,574

42,804

46,297

50,074

Cost of Cost of purchased purchased cobalt cobalt (‘000LKR)(‘000LKR)

67,87267,872 63,311

85,787

47,040

51,233

48,785

52,766

57,072 61,729

66,766

Export of spices: Export of spices: TonsTons 20012001 20022002 20032003 20042004 20052005

Cinnamon Cinnamon 10,444 10,444 10,837 10,837 11,025 11,025 11,391 11,391 12,367 12,367

Pepper Pepper 2,161 2,161 8,026 8,026 7,859 7,859 5,003 5,003 8,248 8,248

Cloves Cloves 1,964 1,964 4,044 4,044 2,489 2,489 3,428 3,428 5,517 5,517

Nutmeg & Nutmeg & Mace Mace

1,138.1 1,138.1 1,665 1,665 1,833 1,833 1,368 1,368 1,935 1,935

Cardamom Cardamom 33 33 44 44 1111

Total Total 15,710 15,710 24,574 24,574 23,210 23,210 21,194 21,194 28,078 28,078

Profit & Loss Analysis

Profit & Loss Analysis (b)Profit & Loss Analysis (b)Project Year 0 1 2 3 4 5 6 7 8 9 10

Calendar Year 2010 2011 2012 2013 2014 2015 2016 2017 2018 2019 2020

TURNOVER   76,498

104,827

142,877

153,032

162,616

169,121

175,885

182,921

190,238

197,847

COST

Staff (418)

(850)

(1,003)

(1,158)

(1,254)

(1,317)

(1,383)

(1,452)

(1,525)

(1,601)

(1,681)

Insurance   (1,000)

(1,030)

(1,061)

(1,093)

(1,126)

(1,159)

(1,194)

(1,230)

(1,267)

(1,305)

Other operating cost (830)

(4,500)

(4,680)

(4,867)

(5,062)

(5,264)

(5,475)

(5,694)

(5,922)

(6,159)

(6,405)

General Administration cost

(1,850)

(3,600)

(2,386)

(2,481)

(2,581)

(2,684)

(2,791)

(2,903)

(3,019)

(3,140)

(3,265)

Total Depreciation   (51,601)

(56,456)

(62,616)

(64,200)

(65,795)

(66,821)

(67,888)

(68,997)

(70,151)

(71,352)

Cobalt- 60 Depreciation  

(11,452)

(16,308)

(22,468)

(24,051)

(25,647)

(26,672)

(27,739)

(28,849)

(30,003)

(31,203)

Plant and equipment Depreciation  

(40,149)

(40,149)

(40,149)

(40,149)

(40,149)

(40,149)

(40,149)

(40,149)

(40,149)

(40,149)

TOTAL COST (3,098)

(61,551)

(65,556)

(72,184)

(74,189)

(76,186)

(77,630)

(79,131)

(80,693)

(82,318)

(84,008)

Earnings Before Interest and Tax

(3,098)

14,947

39,271

70,694

78,843

86,430

91,491

96,754

102,228

107,920

113,840

Interest

- (31,750)

(30,186)

(28,388)

(26,320)

(23,941)

(21,206)

(18,061)

(14,444)

(10,285)

(5,501)

Earnings Before Tax

(3,098)

(16,802)

9,085

42,306

52,523

62,489

70,285

78,693

87,784

97,636

108,338

Taxation @ 15%

-

- (1,363)

(6,346)

(7,879)

(9,373)

(10,543)

(11,804)

(13,168)

(14,645)

(16,251)

Net profit (loss) (3,098)

(16,802)

7,723

35,960

44,645

53,115

59,742

66,889

74,616

82,990

92,088

Cumulative profit (loss)

(3,098)

(19,900)

(12,177)

23,783

68,428

121,543

181,285

248,174

322,791

405,781

497,869

Profit & loss analysis (a)Profit & loss analysis (a)Project Year 0 1 2 3 4 5 6 7 8 9 10

Calendar Year 2010 2011 2012 2013 2014 2015 2016 2017 2018 2019 2020

TURNOVER   63,632

87,333

119,050

127,642

135,760

141,190

146,838

152,711

158,820

165,172

COST

Staff (418)

(850)

(1,003)

(1,158)

(1,254)

(1,317)

(1,383)

(1,452)

(1,525)

(1,601)

(1,681)

Insurance   (1,000)

(1,030)

(1,061)

(1,093)

(1,126)

(1,159)

(1,194)

(1,230)

(1,267)

(1,305)

Other operating cost (830)

(4,500)

(4,680)

(4,867)

(5,062)

(5,264)

(5,475)

(5,694)

(5,922)

(6,159)

(6,405)

General Administration cost

(1,850)

(3,600)

(2,386)

(2,481)

(2,581)

(2,684)

(2,791)

(2,903)

(3,019)

(3,140)

(3,265)

Total Depreciation   (32,790)

(36,999)

(42,337)

(43,709)

(45,092)

(45,981)

(46,906)

(47,868)

(48,868)

(49,908)

Cobalt- 60 Depreciation   (9,925)

(14,133)

(19,472)

(20,844)

(22,227)

(23,116)

(24,041)

(25,002)

(26,002)

(27,043)

Plant and Equipment Depreciation  

(22,865)

(22,865)

(22,865)

(22,865)

(22,865)

(22,865)

(22,865)

(22,865)

(22,865)

(22,865)

TOTAL COST (3,098)

(42,740)

(46,098)

(51,905)

(53,699)

(55,483)

(56,790)

(58,149)

(59,563)

(61,034)

(62,564)

Earnings Before Interest and Tax

(3,098)

20,892

41,235

67,145

73,943

80,276

84,400

88,689

93,148

97,786

102,608

Interest -

(19,060)

(18,121)

(17,042)

(15,800)

(14,373)

(12,731)

(10,843)

(8,671)

(6,174)

(3,302)

Earnings Before Tax (3,098)

1,832

23,114

50,103

58,142

65,904

71,670

77,846

84,477

91,612

99,306

Taxation @ 15% -

(275)

(3,467)

(7,516)

(8,721)

(9,886)

(10,750)

(11,677)

(12,672)

(13,742)

(14,896)

Net profit (loss) (3,098)

1,557

19,647

42,588

49,421

56,018

60,919

66,169

71,806

77,870

84,410

Cumulative profit (loss)

(3,098)

(1,540)

18,107

60,695

110,116

166,134

227,053

293,222

365,028

442,898

527,308

Thank you