The preliminary installation of R&D facilities at Abhay Cotex has done an extensive process development work and established the Unique Process technology for Cottonseed., i.e., “Single Stage Continuous Extraction followed by On-line Miscella Refining of Cotton Oil” successfully by end of 2008 and started implementing the same by end 2009.The deviations observed against R&D and the plant scale implementation were resolved by mid of 2010 and now the processing plant was fully stabilized and able to process near to 1,00,000 Metric Tons of Cotton seed successfully.
The uniqueness of the developed process technology is scientific and works based on the vast differentiation of densities of extracted liquids and functions with very low level of process water & other utility consumptions, further produces ZERO DISCHARGE (No Trade Effluents from the Miscella Refining process). Preliminary R&D was able to implement the SCEMR process at a large commercial scale of 600 TPD or 200000 Metric Tons per annum of Cotton seed which is the largest of its kind in INDIA.
The products produced were of premium in quality had received good applaud both from domestic and international markets consistently. Further the Abhay Cotex‘s research and development activities focus on value-chain technologies of Cottonseed and its by- products, with a special emphasis on further value added new product exploration.
All research activities adhere to the fundamental objectives of the company on cottonseed and its bye products, and to improvise the existing conventional process technology India practices since years. ABHAY COTEX’s developed process technology produces better quality product at low cost and saves huge foreign exchange annually and produces right product in desired direction of utilization.
Process development to produce AFLOTOXIN Free COTTON PROTEIN MEAL
CMSA Process Enhancement (Continuous Miscella Soap Acidulation) on-line based
Development of MUSHROOM cultivation & its growth with the specially produced ACPLs grade of COTTON HULLS .
DGCM process & product development (De-Gossypolized Cotton Meal of High Protein)
Production of Cotton Protein Meal for HUMAN CONSUMPTION
Active PROTEIN based PELLET meal for exclusive By-Pass Protein for Healthy Cattle.
R&D for process development on excess moisture removal in cotton seed without color reversion.
Working with CIRCOT (ICAR) for efficient delinting of cottonseed to minimize the power consumption.
The company has a state-of-the art laboratory with strong expertise to carry over all the above said Research & Development with highly qualified professionals and built up a significant IPR pool through its innovative efforts.
600 MT/Day Capacity Cotton-Seed Pre-Processing with Single Step Extraction & On-line Miscella Refining.
Abhay Cotex Private Limited with its unique process technology, is the first of its kind processing plant performing successfully in INDIA at a large commercial scale:
Environmental Protection: Process designed with ZERO DISCHARGE of effluents unlike the existing conventional process in INDIA.
Due to uniqueness in the process neutralization, there is no involvement of laborious process steps of 1st cut neutralization or even the 2nd cut neutralization which saves & reduces enormous quantity of water consumption in the process
Unlike existing INDIAN process there is no requirement of Water washing of neutralized oil or else the Vacuum Drying of washed oil.
No loss of precious oil during neutralization unlike the existing Indian process followed.
All these process optimization reduces the precious water consumption and avoid discharge of any trade effluents which harms the environment drastically.
No charring / burning of oil cells, being normal temperature of process
Superior in the quality of washed oil produced.
Easy to process bad quality of seed with high FFA or brownish colored fixed oil
Reduction of RED color units is excellent with less lye consumption.
Zero discharge of effluents from the plant
No additional cost - on E T P chemicals & its operations
No recurring expenses on maintenance of processing equipments.
Being single step extraction process De-oiled cake had advantages of high level of by-pass protein yields higher milk yield as cattle feed.
Over all nourishment and improvement of cattle health due to protection of natural amino acid profile in the Cattle.
Utilities consumption (steam & power) are better than conventional process.
ACPL has developed retail market segment for its “Abhay-Pro” Cotton De-oiled meal for cattle feed industry. ACPL's Patent Registration is under process for PATENT rights on “Abhay-Pro” Cotton De-oiled meal.