PRODUCTION TECHNOLOGY OF CHITOSAN FROM SHRIMP SHELL WASTE

Dr.Ir.Gatot Trimulyadi Rekso,

Centre for Research and Development of Isotopes and Radiation Technology

NATIONAL NUCLEAR ENERGY AGENCY

Jl. Cinere ,Ps Jumat, PO Box 7002 JKSKL, Jakarta 12070

Fax: 021-7513270, E-mail: gatot28 @ batan.go.id

The remarkable rapid and successful expansion of prawn industry in Indonesia.

Suggests the possibility of utilizing prawn processing waste as raw material for manufacture of many valuable product such as chitin and chitosan.

Chitosan is the deacetylated product of chitin, which is polymer of 1,4 n acetylglycosamine.

Typycaly manufactured from the solid waste generated drying shrimp and crab processing .

The protein component in the solid waste are conventionally extracted with dilite hot alkali and minerals extracted by dilute hydrochloric acid.

Introduction

WASTE OF FISHERY INDUSTRY

Crab shell Shrimp shell

chitin

Chitosan is a linier polysaccharide derived from chitin A mayor component of the shell of the crustacean organisms The second most abundant biopolymer in nature next to cellulose.

In the last year chitosan has proved to be valuable product for using in different application such as seed coating, chelating and growth promoters etc

Chitosan reported to have various biological functions, for instance, anti microbial activity, growth inhibitor of some pathogens

DEACETY-LATION

CHITOSAN

Isolation of chitinThere is two step process for preparation of chitin ; deproteination and

Demineralization.

DeproteinationShrimp shell

NaOH 4 %

Solid 1

Filtrate

1. To deproteinize the shell, aqueous 4 percent sodium hydroyde was used to remove protein from a known weight of particular fraction.

2. The shell were heated in sodium hydroxide at 80 0C for 120 minutes with 10 : 1 liquid solid ratio.

3. The mimixed solution was cooled and filtered, the filtrate obtained was discarded and the solid phase then washed by mean of water until netral

DemineralizationSolid 1

HCl 3,5%

Solid 2

Filtrate

The deproteinated shell were then demineralized by mean of 3,5 % hydrochloride acid in order to remove inorganic salts.

The shell fraction, first of all, was heated in hydrochloric acid for 1 hr at 800 C with a 10 : 1 liquid solid ratio.

The supernatant was removed and the solid was washed with water until the pH of the cleaning water is neutral.

RESULT OF THE EXPERIMENT 1. The average yield of isolation chitin from prawn shell is shown in

Table I.

2. The data obtained shows that the number of extraction affected the yield of chitin . It was reported that the number of stage of extraction affected the mineral removal significantly

The yield of chitin at various number of extraction

Parameter Number of extraction

Single Double Triple

Yield ( %) 22,7 20,4 18,5

Visual appliance

- Color Brown Brown-light Brown-light

- Odor Weak No No

Spectrum FTIR of chitin

PREPARATION CHITOSAN

DEASETILATION

CHITIN CHITOSAN NaOH 50 %

The conversion of chitin to chitosan was achieved by extracting chitin in 50 percent sodium hydroxide with solid –liquid ratio = 1 : 15 at temperature

1000C

Therefore the overall extraction yield of dried prawn shell in chitin form around 18 – 25 % and chitosan form was around 15- 18 %.

The degree of deacetylation was determined by means of FTIR spectrophotometer.

It is determined by the base line method. An infrared spectrum was recorded in a range 3500 – 500 cm-1 and absorbency at 2870 cm-1 ( the C-H ) and 1550 cm-1 (the amide band) were evaluated by base line method.

The degree of deacetylation at various time of reaction

Parameter Time of deacetylation ( minutes)

120 240 300

Yield of chitosan from chitin 85,5 82,6 80,2

Degree of deacetylation 60,4 65,2 73,0

Deacetylization reactor

ECONOMIC ANALYSIS FOR HOME INDUSTRYProduction processes of chitin from prawn shell

PROSESS washing Drying

Demineralization 1 (proses 1) 1 N HCL ( 4 L + 100L water)

washing drying

Deproteination 1 (proses 2) I N NaOH ( 4000 g NaOH + 100 L water)

Washing Drying

Deminneralization 2 (proses 3) 1 N HCL ( 3 L + 75 L air)

Washing Drying

Deprotenisiasi 2 (proses 4) I N NaOH ( 2000 g NaOH + 50 L air)

washing Drying

Chitin

Cost analysis Basic calculation is production of 2 kg chitin/day (720 kg / year)

No Component Cost

1. Land and building

Rp.800.000.000,-

2. Mixer reactor (2, 150 L) Rp. 50.000.000,-

3. Washing vessel (2, 200 L) Rp. 30.000.000,-

4. Pumping system Rp. 40.000.000,-

5. Storage tank ( 10 , 200 l) Rp 10.000.000,-

6. Tray dryer Rp. 100.000.000,-

Sub- Total

Miscellaneous (10 %)

Rp.1.030.000.000,-

Rp 103.000.000,-

- Total Cost

Rp. 1.133.000.000,-

(Rp. 1.140.000.000,-)

Fixed Assets Component

Working CapitalWorking Capital for 1 month production of

chitin( 60kg)

Component of cost Cost (Rupiah)

Raw Materials

1. Shrimp shell, 300 kg @ Rp 2000,-

2. NaOH 180kg @ Rp4000,-

3. HCL 210 L @ Rp 4000,-

4. Packaging

Rp.600.000,-

Rp.720.000,-

Rp.840.000,-

Rp.500.000,-

Total Rp.2.660.000,-

Total Capitals

Total Capitals : Fixed assets + Working capital

= Rp. 1.133.000.000,-+ Rp.2.660.000,-

= Rp 1.135.660.000,- ( Rp. 1.136.000.000)

Manufacturing costManufacturing cost for production capacity of

720 kg/ year No. Componen Cost (Rupiah)

1. Raw material

- Shell wasre, 3600 kg @ Rp2000,-

- NaOH 2160 kg @ Rp4000,-

- HCl 2520 kg @ Rp4000,-

2. Maintance ( 1 %)

3. Depreciation (15 years)

Rp.7.200.000,-

Rp. 8.640.000,-

Rp.10.080.000,-

Rp. 230.000,-

Rp.15.000.000,-,-

Manufacturing cost Rp.41.150.000,-

Production cost

Production cost = Manufacturing cost / product capasiti per year

= Rp 41.150.000,-/ 720 = Rp. 57.152 /kg

From that condition we can concluded that the production cost of chitin is Rp

57.200,- /kg ( its around ($ 6 )

CONCLUSION

1. The method used for extraction of chitin and chitosan was found to play an important role in prepararing these products of an acceptable quality for sale in the market

2. The most important operational variables in preparation of chitosan were deacetylation time and deacetylation temperature.

3. It was found that prolonged deacetylation time and increasing temperature decreased the yield, molecular weight, viscosity.

4. Economic analysis of production of 720 kg chitin per year.

o Cost for investation : Rp. 1.140.000.000,- o Total capital cost : Rp. 1.136.000.000 o Manufactuing cost : Rp41.150.000,- o Production cost : Rp 57.200,- /kg

Another activty

Give training and lecture to introduce isolation of chitin