ANIMAL GLUE

CONTENTS

SECTION I PRODUCT CHARACTERISTICS AND SPECIFICATIONS

SECTION II PRODUCT APPLICATIONS

SECTION III INDIAN MANUFACTURERS

SECTION IV IMPORT/EXPORT TRENDS

SECTION V PRICE TRENDS

SECTION VI INDIAN DEMAND

SECTION VII BROAD OUTLINE OF MANUFACTURING PROCESS

SECTION VIII RAW MATERIALS REQUIREMENTS 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 Product Characteristics

Animal glue is a protein derived from the simple hydrolysis of collagen, which is a principal
protein constituent of animal hide

Glue is supposed to be an impure material deeper in colour with less thickening power but with
greater degree of dispersive efficiency.

The distinction between gelatin and glue is not very sharp. Commercially, gelatin is understood
to cover a very pure glue supplied as thin sheets, colourless (or) of very pale colour possessing a
high gelatinising power but comparatively poor agglomeration properties.

An interesting property of animal glue solution is that glue is transformed from a liquid to a gel
state on cooling and reverting to a liquid on reheating. This property is of primary importance in
many adhesive applications

Flakes
Chips
Commercial form Powder
Cake

Animal glue is commercially available in a number of forms including the dry granulated
products for use as hot glues, cold liquid glues for immediate use and a wide selection of
composition glues in cake or jelly form.

Approximate chemical composition Carbon 51.29

Hydrogen 06.39
Oxygen 24.13
Nitrogen 18.19

Density Approximately 1.27 gm per cc

Moisture 10% to 14%

Ash content 2.25% to 4%

Solubility Soluble in water,insoluble in oils, waxes, organic

solvents and absolute alcohol. They are
emulsified as water oil system under appropriate
conditions.

SECTION II

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 PRODUCT APPLICATIONS

The term glue refers to the crude form of Gelatine. Glue refers to the product finding
chiefly industrial applications as an adhesive in plywood, paper board, match, abrasive
and similar industries. Gelatine refers to the product in a much purer and cleaner form
finding use in food, pharmaceutical and photographic industry and in some specific areas
of industry as an adhesive.

Sector of application Nature of uses

Adhesive Used in bonding furniture, musical instruments,

decorative veneers,book binding, packaging,
Animal adhesives are of various kinds derived sizing
from skins and bones of the animals.
Animal blood glue is also utilised for various
The form is known as Hide glue and the latter purposes.
as Bone glue. Fish glue are derived from the
skin of various fishes, casein glue is derived
from casein obtained from milk of various
animals.

Miscellaneous In manufacture of abrasive papers, paper tube

winding and sealing cartons etc.

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 SECTION III

INDIAN MANUFACTURERS

There are number of producers of Animal glue in the medium and small scale sector. Indian
producers include the following

* Bhopal Glues & Chemicals (P) Ltd.

Jinsi, Bhopal-462 008

* Esdee Paints Ltd.,

203, Navketan, Chembur,
Mumbai-400 071.

* Galaxy Hotmelts and Industries, Palani,

Tamil Nadu

* Jiwan Glue Industries

Gill Road, Near Canara Bank
Ludhiana-141 003

* Kerala Chemicals and Proteins Ltd.,

(A joint venture of Kerala State Industrial Development
Corporation Ltd., Nitta Gelatin Inc., Japan and
Mitsubishi Corporation,Japan).
Kathikudam P.O.
(Via) Koratty, Trichur Dist - 680 308

Gelatin Division:
KEPIPL PB NO.3109,
Kusumagiri, Kakkanad, Kochi-682 030

* McAdams Chemical Mfg. Co.,

(Formerly known as Mcadams Balsen Chlorates (P) Ltd.,)
Tiruchirapalli

* Naina Glues and Chemicals Ltd.,

Maharashtra

* Pioneer Miyagi Chemicals Pvt. Ltd,

(Asia Glues & Chemicals Pvt.Ltd.,-Sister concern)
Cuddalore

* Rallis India Ltd.,

A-14/A, SIPCOT Industrial Complex,
Cuddalore-607 005
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* Sudes Chemicals.
Calcutta.

* Shaw Wallace & Company Ltd.,

Agriculture & Chemicals Division
166, Thambu Chetty Street,
Post Box No.14, Madras-600 001.

* Shibi Capsules,
Pitchaiveerampet,
Ozhukarai Commune,
Pondicherry-605 010.
* Strides Arcolab Ltd.
Strides House, Bilekehalli,
Bannerghatta Road, Bangalore-76

* V.P.N. Gelatine Pvt. Ltd.,

5, 1 Street, Sylvan Lodge Colony
Kilpauk, Chennai-600 010.

Factory :310-Chetti Ped Village,

Thandalam (P.O.), Sri Perumpudur Taluk,
Kancheepuram Dist.-602 105

Indian installed capacity

25,000 tonnes per annum

New projects - Gelatine

* Transgel Industries Ltd.

7-1-58, 1-305, 3rd Floor
Divyashakthi Complex
Hyderabad

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 SECTION IV

IMPORT/EXPORT TRENDS

Import level : Negligible quantity

Export level : Around 1000 tonnes

6
 SECTION V

PRICE TRENDS
Period: November 2002

Ex-factory price Rs.65 per kg

Excise duty 16%

CST 4%

7
 SECTION VI

INDIAN DEMAND
6.1 General Details

The Animal glue finds predominant applications in the match industry, abrasive industry
and in paper industry, particularly in security paper manufacture.

6.2 Typical Formulations

Animal glues are usually applied at 25 to 50% concentration and at 60 deg.C. In this state, it has a
paint like consistency and can thus be readily spread, in the form of a thin continous film. This
film thickens on cooling, permitting rapid development of desired tackiness and holds the
adhesive at joint surface and thus eliminates the danger of bleeding from the joint under pressure.

Book Binding Glue

Animal glue 30 parts

Water 29 parts
Glycerine 30 parts
Preservative 1 parts

Paper Box Glue

Bone glue 45 parts

Water 15 parts
Glycerine 39 parts
Preservative 1 parts
Formic acid,phenol and formaldehyde etc are suitable preservative.

Can Label Glue

Starch 100 parts

Water 700 parts
Animal Glue 10 parts
Sodium silicate 100 parts
Turpentine 50 parts

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6.3 The consumption pattern of glue in the country

Paper
20%

Abrasive and Match industry

miscellaneous 60%
20%

6.4 Demand Total estimated demand for glue in the country

including export demand is around 18,000 tonnes
per annum.

6.5 Growth rate demand : 7 to 8% per annum.

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 SECTION VII

BROAD OUTLINE OF MANUFACTURING PROCESS

The manufacturing process of the different types of animal glues primarily vary in the initial
treatment of the raw materials.

Process outline

The commercial production of Glue and Gelatine by hydrolysis of Collagen

Process

Alkali Process:-
Acid Process

This involves treatment of the

This involves essentially adjustment of
the pH value of Glue and gelatine and
subsequent extraction of gelatine at a low
temperature between 50 to 60 degrees
centrigrade.
collagenous material with alkali
under rigid controlled conditions of
temperature,pH value and time. In
general, a suspension of lime is used
as alkali medium; the treatment
being prolonged as long as 70 to 100
days.

Animal glue is generally produced under alkali process, whenever hide fleshings and bone sinews
are processed.

Normally, the hide fleshings are dumped in the washers, either mechanical or fluidised air
washers with running water for a period of two hours to remove the lime and then transfered to
soaking vats.

Soaking is carried out for a period of 6 to 8 days. The object of soaking is to remove the flat and
non-collagenous material. They are again trasferred to the washers. After running water wash,
dilute hydrochloric acid is used to remove the alkali till the stock becomes neutral. After the final
running water wash, the stock is transferred to the extraction tanks.

In the extraction tanks,the stock is filled with water and heated between 70 to 90 degrees
centigrade and extract is taken at periodic intervals.

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Process Details

Most of the skin used for the manufacture of glue and gelatine is the wash from tanneries, where
it receives a short treatment with saturated lime water. Skin pieces which are to be utilised for
glue manufacture are again subjected to liming for 12 to 15 days. After removal of alkali by water
and acid, the hides are placed various times in hot water so as to extract the glue.

Warming may be carried out in jacketed pans utilising some cheap mineral oil: castor oil serves
the purpose well, as heating medium.

Oil temperature should not exceed 120 Deg.C as this darkens the colour of glue. The water
temperatures should range between 105 Deg. and 120 Deg. The glue solution is removed and
evaporated under vacuum. Some clarifying agent such as alum is also added.

Concentrated solution is then allowed to set in small 8"x4"x1/2" pans. The jelly is then allowed to
get dried. The drying nets are 6'x3' with wire netting of about 3/4" mesh and wooden frame. The
glue thus prepared may contain about 15% moisture.

In the case of bone-glue manufacture, bones are crushed and washed. The bones are next soaked
in 2 to 8% hydrochloric acid converting the bone protein into gelatin. Wooden vats are used for
the purpose. Benzene is used for degreasing purposes as solvent. Degreasing requires from 4 to 6
hours and 15 tonnes of bone require 2,000 gallons of solvent. Glue is next extracted by cooking in
autoclaves by water. Glue is obtained from the solution as in the case of hide glue process.

Source of technology

McAdams Chemical Mfg. Co.,

(Formerly known as Mcadams Balsen Chlorates (P) Ltd.,)
70-B, Viralimalai Road,
Edamalaipatti Pudur,
Tiruchirapalli- 620 012.

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Major plant and machinery and suppliers

Name of the equipment Name of the company

Washing tank Billion Plastics Pvt. Ltd.,

912, Tulsiani Chambus, Nariman Point
Mumbai-21

Spark Engineers Pvt. Ltd.,

5/332, State Bank Colony II
Salem-636 004

Reactors Chemitherm Plants & Systems P. Ltd.,

30, Anandha Street
Alwarpet, Chennai-600 018

Texel Fabricators Pvt. Ltd.,

335, Sidco Industrial Estate,
Ambattur, Chennai-600 098, Tamil Nadu

Boilers Cethar Vessels Ltd.,

No.4, Dindigul High Road,
Trichy

Firetech Boilers Pvt. Ltd.

No.211, 2nd Cross,
38th Main, B.T.M. Layout
2nd Stage, Bangalore-68

Dryers The Anup Engineering Ltd.,

Behind 66 KV Electric Sub Station
Odhav Road, Ahmedabad-382 415

ATRE Thermal Products Pvt. Ltd.,

Pushpa Heights, 1st Floor,
Bibwewadi Corner, Pune-411 037

Evaporator Excel Industrial Services

White House, D-111/8,Ist Main Road,
Anna Nagar (East)
Chennai-600 102

Alfa Laval Saunders (India) Ltd.,

No.18, Gill Nagar, Fist Street
Chennai-600 094

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Filters Air Filter Industries
Mercantile Building
2nd Floor, G.P.O. Box 886
9A, Lal Bazar Street
Calcutta-700 001

Divya International
23A, Netaji Subhas Road,
8th Floor, Room No.28,
Calcutta-700 001

Vacuum pumps Southern India Instrumech Pvt. Ltd.,

160, Baba Nagar, Villivakkam
Chennai-600 049

Travaini-Maneklal Vacuum Technology Pvt. Ltd.,

Manek Mahal, 7th Floor,
90, Veer Nariman Road,
Churchgate, Mumbai-400 020

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 SECTION VIII

RAW MATERIAL REQUIREMENTS AND AVAILABILITY

8.1 Types of animal glue

1. Hide Glue
2. Bone Glue

Hide glue is derived from the collagenous material present in the hides and connective tissues.
Bone Glue is derived from the collagenous material present in the structure of bones.

8.2 Raw materials used for Hide Glue and Gelatin:

(a) Hide Fleshings

(b) Hide Cuttings
(c) Limed Hide Cuttings
(d) Salted Hide Cuttings
(e) Hide Splits
(f) Green Cattle Bones
(g) Degreased Bones
(h) Sun-dried Cattle Bones
(i) Bone Sinwes

The above raw materials are readily available in the country.

8.3 Raw material requirement

Basis: One tonne of Animal Glue

Fleshing/leather cuttings 4 tonnes

Other chemicals like Lime,soda ash and hydrochloric acid

8.4 Utility requirements per tonne of product

Power 500 units

Fuel 160 litres

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8.5 Raw material availability

8.5.1 Hides/Skins

Veg.chrome tanned hides (in Finished leather skins

000 pcs) (in 000 pcs)
1991-92 5448 26400
1992-93 7512 25596
1993-94 8004 30636
1994-95 11736 33096
1995-96 14760 28968
1996-97 15096 34560
1997-98 16605 48576
Present Production 18000 50000
level

Production of bovine hides and skin (Quantity in 000 tonnes)

1997 388.2
1998 389
1999 384
2000 401
2001 407

8.5.2 Bones

The total availability of offal/bones in the country generated from large slaughterhouses
is estimated to be more than 21-lakh tonnes per annum.

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 SECTION IX

GLOBAL SCENARIO

9.1 Global demand 0.25 million tonnes per annum

9.2 Global Growth rate in demand 2.5 % per annum

9.3 Global producers

* American Gelatin Co. Div. Of Health Processes Inc.,

20 Charing Cross Road,
Charleston, SC 29407
USA

* Norland Products Inc.,

695 Joyce Kilmer Ave
New Brunswick,
NJ 08902
USA

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 SECTION X

DISCUSSIONS ON ECONOMIC CAPACITY, PROJECT COST

AND PROFITABILITY PROJECTIONS

Economic capacity : 300 tonnes per annum.

Project cost : Rs.156 lakhs

Assessment of project cost

1. Land

S.No. Description Cost

Rs.in lakhs

1.1 Cost of land of one acre at Rs.5.5 lakh per acre 5.5
1.2 Cost of levelling, laying internal roads/fencing and 0.55
Compound wall

Subtotal 6.05

2. Building

S.No. Description Cost

Rs.in lakhs

2.1 Factory building of area 450 sq.m. at Rs.3200/sq.m. 14.4

2.2 Non-factory building of area 110 sq.m.at Rs.4500/sq.m. 5
Subtotal 19.4

3. Cost of Plant & Machinery

S.No. Description Cost

Rs.in lakhs

3.1 Cost of basic plant and machinery 44

3.2 Instrumentation and control 3.3
3.3 Pipelines and valves 4.4
3.4 Structurals for erection 2.2
Subtotal 53.9
3.5 Octroi, excise duty, sales tax, etc.at 12% 6.5
3.6 Packaging and insurance charges (2%) 1.1
3.7 Transportation charges (2%) 1.1
3.8 Machinery stores and spares (2%) 1.1
3.9 Foundation charges (2%) 1.1
3.10 Installation charges (2%) 1.1
Total cost of plant and Machinery 65.9

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4. Technical know-how fees Rs.2.5 lakhs

5. Miscellaneous fixed assets

S.No. Description Cost

Rs.in lakhs

5.1. Electrification 4.8

5.2. Steam boiler and auxillaries 4.8
5.3. Water storage tank, borewell etc. 1.7
5.4. Fuel storage tank 1.7
5.5. Laboratory equipment 1.2
5.6. Office machinery & equipment 1.2
5.7. Material handling equipment, packaging machinery, 1.6
weigh balance, etc.
5.8. Diesel generator 4.4
5.9. Effluent treatment 3.9
Total 25.3

6. Preliminary & Pre-operative expenses:

S.No. Description Cost

Rs.in lakhs

6.1. Preliminary expenses 1.1

6.2. Pre-operative expenses:-
6.2.1 Establishment 1.5
6.2.2 Rent rates and taxes 1.5
6.2.3 Travelling expenses 1.5
6.2.4 Interest and commitment charges on borrowings 6.7
6.2.5 Insurance during construction period 0.7
6.2.6 Other preoperative expenses and deposits -
6.2.7 Interest on deferred payment -
Total 13

7. Provision for contingency Rs.8.5 lakhs

8. Working capital margin Rs.14.5 lakhs

9. Total project cost Rs.155.15 lakhs

Say Rs.156 lakhs

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Means of Finance

Total project cost Rs.156 lakhs

Promoter's contribution Rs.62 lakhs
Term loan from financing institutions Rs.94 lakhs

11. Financial statements (Rs. in lakhs)

11.I. Cost of production

Variable Cost Rs.in lakhs

Raw material and utilities 110

Spares and maintenance 4
Selling expenses 9.75
Total variable cost 123.75
B Fixed cost

Salaries and wages 7.2

Interest on term loan and working capital loan 22.41
Depreciation 9.4
Administrative expenses 2.25
Total fixed cost 41.26
C. Total cost of production A + B 165.01
D. Selling price per kg. (in Rupees) 65
E. Annual sales turnover (Rs.in lakhs) 195
F. Net profit before tax (Rs.in lakhs) (E-C)) 30
G. Breakeven point in % 58%

SECTION XI

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 SWOT ANALYSIS

Strength Ready availability of raw material

Weakness Production of inadequate product grades
Opportunity Growing demand
Threat Environmental issues

SECTION XII
20
 FACTORS INFLUENCING THE POSITION FOR A NEW INDUSTRY AND
RECOMMENDATIONS

Animal glue is traditional product with important application in the adhesive sector.

Demand for the product is likely to go up steadily, necessitating additional capacity

creation from time to time in tune with the growing demand.

The technology is well established and there is no particular entry barrier for the project
from the point of view of technology or raw material availability

However, the environmental aspects have to be carefully managed and from this point of
view, ecologically favourable design and project location are vital factors.

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