Internship Report

Internship at
Rushabh Agro Industry
(Nashik, Maharashtra)

Industry guide
Mr. Manish Kankariya

Submitted by
Tanvi Vilas Shinde
Ty Bsc Biotechnology
 H.P.T ARTS AND RYK SCIENCE
COLLEGE,NASHIK

ACKNOWLEDGEMENT

The Internship opportunity I had with Rushabh Agro Industry was a

great chance of learning and professional development. Therefore, I
consider myself as a very lucky individual as I was provided with an
opportunity to be part of it. I am also grateful for having a chance to
meet so many wonderful people and professionals who lead me
through this internship period.

I extend my heartfelt thanks to Mr. Manish Kankariya, company

guide, rushabh agro industry, for providing me the facilities to carry
out the internship successfully. I wish to express my sincere gratitude
to mr. Kankariya for his valuable support, guidance and suggestions
for the completion of my internship.
OBJECTIVE OF INTERNSHIP

The Internship was conducted at Rushabh Agro Industry is

undertaken with clear cut objective which are defined below:
- To study about the coco peat manufacturing process.
- To study the function of cocopeat manufacturing processing
machines.
- To study rope making from coconut husk.
- To study the function of rope making machines from coconut
husk.

SCOPE OF INTERNSHIP

It helps to understand about various factors and activities which are

assigned to various people in industry. Internship helps to gain
knowledge about the real life situations faced by industrial employees
in each stage of work. It is very beneficial because they provide both
theoretical and practical knowledge regarding coco peat making and
coir rope making machines.

INDUSTRY PROFILE

Rushabh Agro Industry fully set up in march, 2021 for the systematic
development of coir industry in state. The corporation has
manufacturing facilities in Nashik, Maharashtra. It's diversified
operation include coco peat manufacturing and allied product sectors.

The corporation believes in the philosophy of producing quality built

in products through a dedicated team of staff and workers from top to
bottom. This commitment to quality enables the industry to face any
sort of challenge in this sector.

In Rushabh Agro Industry, the corporation can manufacture coir rope

with the help of specially trained workforce.
In Rushabh Agro Industry, latest management techniques are applied
in the areas of man, material and machine management so as to give
out the best products possible.

A highly successful, statistical quality control device has been

involved for on line production, quality check up and also to ensure
timely delivery of goods.

PRODUCT PROFILE

Types of products in rushabh agro industry

⮚ Cocopeat

⮚ Coir rope
Coco peat :
Cocopeat is a multi purpose growing medium made out of coconut
husk. The fibrous coconut husk is prewashed, machine dried, sieved
and made free from sand and other contaminants such as animal and
plant residue. Cocopeat is a very good alternative to traditional peat
moss and rock wool. Its air filled porosity and high water holding
capacity makes it an ideal growing medium for the plant crops. It is
100% organic and eco friendly, free from soil borne pathogens and
weeds. It has a pH of 5.7-6.5, EC level <1mS/cm is ideal for plant
growth.
Cocopeat have a high amount of nutrients. It contains nitrogen,
phosphorus, high potassium content, magnesium, zinc, etc.
Applications of cocopeat:

Cocopeat is better substitute than any other peat products and can be
used in the following areas:
As soil supplement:
Re-hydrated coir block mixed with soil improves water holding
capacity and aeration.
For seed germination:
Coir dust in starter containers speeds up germination and profuse
rooting of seedlings
For tissue culture:
Wetted coir brick in poly bags encourages initial growth phase of
tissue cultured plant and grafted seedlings.
Cocopeat is used in various fields such as:

⮚ Potting mix suppliers

⮚ Green houses

⮚ Hydroponic growers

⮚ Nursery and garden centre professionals

⮚ Substrate in seedling nurseries

⮚ Lawn and golf course constructors

⮚ Horticulture and floriculture applications

⮚ Home gardening and for landscaping use

Coir rope :

Rope can be made out of a variety of materials, using either natural

and synthetic fibers. There’s one natural fibre, however, that is far
superior to the others when it comes to its uses and benefits. It's called
coir rope, a high-quality and versatile product made from the inner
husk of coconuts.

The benefits of coir rope:

 One of the main benefits of coir rope is that it is all natural. For
growers, this can be very attractive because, unlike other
gardening materials, it won’t leach chemicals into the
surrounding soil.
Coir rope is not only natural but can also be composted after
you’re done using it for the season. This helps eliminate
unnecessary waste and is a greener option than many other ropes
on the market.
Another benefit is that coir rope is often more affordable than
other natural ropes, such as sisal or hemp.

Coir rope uses:

Coir rope can be used for aquatic farming purposes. Oyster growers,
those that cultivate sea squirts, and other oceanic farmers benefit from
using coir. Because it's natural, it's safe to use in the water. And coco
coir rope can soak in salt water without damaging its fibres and
reducing its durability.
Coir rope has several other uses in the garden and around the home. It
can be used to create woven floor coverings, hang clotheslines, put up
bird feeders, and much more. It's also suitable for trellising and tying
plants beyond hops. It's durable and can be added to your compost
pile at the end of your growing season.

MACHINES USED IN COCO PEAT

MANUFACTURING:

1)Defibering Machine:
Function: to extract coir and coco-pith tender
coconut
Capacity: 6000-8000 husks/ 8 hours
Size: 2.4m x 0.75m x 2.5m
Defibering machine is used to comb the husk to separate the fibre and
foreign materials. The machine is assembled with two drums with
7.5HP and 5HP motors respectively. The motor is directly connected
with drum with help of pulley and “V” belts. But motor RPM is 1440
and drum RPM is 960. Two wheels are rotated with help of gearbox
and motor, in between two rollers, we can feed the husk. The wheels
are holding the husk and combing process will done. We will get the
brittle fibre or length fibre according to our husk size.
In this process, the machine is combing the husk. Fibre will not be
damaged. So, we will get lengthy and quality fibre from this system.
DEFIBERING MACHINE
2) Screening Machine:
Application: coir pith screening
Capacity: 1000-1500kg/hr
Screener size: 10 feet length

Dried coir pith screening:

It consists of lump breaker, coir pith screener, destoner, conveyors for
coir pith screening. As per site layout conveyor arrangements can be
done. This automation helps in obtaining quality coir pith without
foreign particles.
The screener is screened small fibre and pith from the fibre.
Reduction gear box driving arrangements with anti friction ball
bearings for the main shaft.
In this process, the machine is combing the husk. Fibre will not be
damaged. So, we will get lengthy and quality fibre from this system.
SCREENING MACHINE
COCOPEAT MANUFACTURE
PROCESS/STEPS:

Step 1: Collection
collect coconut husks from the coconut shops or the farmers,etc. And
make sure to store them in a clean place.

Step 2:Defibering
With the help of defibering machine pull out fibers and dry them
completely.
Defibering process: a process for the defibering of coconut husk
comprising the steps of crushing coconut husk in a crusher to ensure
maximum exposure of the husk to microbial action without damaging
the husk or the pith; soaking the husk in a tank filled with microbial
inoculants consisting of I.Pseudomonas putida, 2,Streptomyces
viridosporus, 3.Bacillus pumilus, 4. Bacillus licheniformis, 5.
Clostridium butricum; heaping the husk in the shade for enabling the
microbes to act on the phenol and pectin of the husk and break them
down by the enzymes released by the microbes, the excess salt in the
husk also easily leaching away during the process; feeding the husk
into a pre-conditioner for squeezing the husk to an optimum moisture
level; decorticating the husk in a first decorticator for breaking the
husk into smaller pieces; decorticating the husk in a second
decorticator and screening the same for complete separation of fiber
and pith.
Step 3: Testing
After washing with fresh water, the coco peat is checked for optimal
pH and EC value. Later, the sieving is done, where the fibre chunks
and impurities are removed. And further moved to moisture removal
by drying.
Testing Methods for Cocopeat:
The following are the methods of testing some important properties
of cocopeat. Some suppliers may follow a different method from the
methods described below. Unless specified otherwise in the quotation,
the testing methods for different major properties of cocopeat shall be
as below.
There is no standard specified for testing cocopeat, however the
following methods describe industry accepted methods of testing.

Electrical Conductivity:
The following describe two major methods of testing cocopeat.

Wet method: This is the method followed by us generally. It is also

comparatively more stringent than the dry method. This method is
followed by suppliers to European countries. It is also referred to as
the 1:1.5 method.
Take samples of the cocopeat, either from a single block or from a
number of blocks. Crush the compressed coco peat by hand to powder
it. Rub between the palms to separate the cocopeat from the fibre.
Measure the EC of demineralised water or RO water (ECw) using a
calibrated handheld EC meter. Mix the cocopeat with just the right
amount of demineralised water to fully expand the compressed
particles. One way is to mix three times the weight of the cocopeat to
be tested (30ml of water with 10g of cocopeat). Take 100 ml of this
mixture and to it add 150 ml of demineralised water.
Stir well and allow to soak for about 15 minutes. (Usually for
cocopeat the EC doesn't change much after one minute. But for
coconut husk chips the soaking is very important and the
recommended time is 30 minutes). Strain the cocopeat and collect the
solution in a glass or plastic container. The cocopeat may be pressed
during straining using a spoon.
Measure the EC of the solution with the EC meter (ECc). Ensure that
there is sufficient quantity of the solution to completely immerse the
measuring tip of the EC meter, otherwise the readings will be
erroneous.
The EC of cocopeat is measured by the formula
ECc-ECw (mS/cm)

Dry method: This is the method specified by Korean buyers. It is also

known as the 1:5 method.
In this method after the fibre is separated, the dust is not wet with
water. One part of dry dust is mixed with five parts of demineralised
water by volume (100 ml to 500 ml). Stir, soak and strain the solution
and measure the EC (ECc).
The EC of cocopeat is measured by the formula
ECc-ECw (mS/cm)
Apart from this there are other methods followed such as 1:2 wet
method and 1:3 dry method. Some buyers in India use a 1:10
gravimetric method. However, volumetric method is always preferred
over gravimetric method as sand content can affect results in
gravimetric method.
While measuring the raw materials for quality control, less water
should be used for measuring EC as EC increases with drying and
compression.

pH (Potential Hydrogen):
pH is measured in the same method as EC using handheld pH meter.
The most popular method for pH however, is 1:5 dry method. But the
1:1.5 wet method gives a more realistic pH reading. Ensure the water
used for measuring pH is neutral (7.0). The pH reading of the solution
directly gives the pH of the cocopeat.
Another method of measuring pH would be to add pH neutral water 5
times the weight of the cocopeat (500 ml to 100 grams). This quantity
of water would completely soak the cocopeat imitating growing
conditions. Allow to soak for 15 mins, squeeze the material and
measure the pH of the solution. This method usually gives a lower pH
reading than other methods.

Moisture content:
Moisture content is important as it shows how much water you are
purchasing for the price of cocopeat. The moisture content of sun
dried cocopeat blocks is typically between 15 to 20%. It is not
possible to dry cocopeat to below 15% moisture without external
heating as cocopeat tends to retain some moisture just like seasoned
wood. The moisture content helps in the compression of the cocopeat
dust into blocks. Cocopeat of zero moisture content and cocopeat of
very high moisture content will not form properly compressed blocks.
However when cocopeat is sold in uncompressed loose form in bags,
the moisture content can be very high.
To measure the moisture content, take 100 grams of crushed and
powdered cocopeat and heat in a hot air oven at 100 deg. C till all the
moisture is removed. Measure the fully dried cocopeat when it is hot
(W). Moisture content is given by the formula
Moisture content = (100-W) %
Moisture content can also be directly measured approximately in
cocopeat blocks using a hand held moisture meter. The reading of the
moisture meter directly gives the moisture content., But this method
can only be used for blocks or large chips. Simply press the pins of
the moisture meter into blocks and note down the moisture content
readings.
When buying a cocopeat in a loose, moist condition, much of the
weight of the cocopeat could be in the form of water. This is
illustrated by the Moisture to Dry Matter ratio. It shows how much of
the purchased product was water. The moisture:matter ratio is
determined by the hot air oven method described above and is simply
arrived at by the following formula.
moisture:matter ratio = (100-W):W
For fully sun dried cocopeat of 15% moisture, the moisture:matter
ratio would be 15:85 or 1:5.7 (ie., 1 part water for 5.7 parts cocopeat).
However, for moist loose cocopeat specifying 60% moisture, it would
be much higher. The 60% moisture mentioned here would be the
moisture that would be removed by sun drying and not hot air oven
drying. So in reality, the total moisture would be 60% (sun drying) +
15% (hot air oven drying) = 75% moisture. For 75% moisture, the
moisture:matter ratio would be 75:25 or 3:1 which means there are 3
parts water for every 1 part cocopeat. Note that a cocopeat can easily
absorb 5 parts water to 1 part cocopeat and three times moisture
would not appear very wet to the user. However, in certain cases,
buying loose moist would be unavoidable such as when the cocopeat
is amended with bio active agents which would die if the cocopeat
were to be sun dried.
Fibre content:
Break a large piece of cocopeat from a single block. Weigh the
cocopeat (Wc). Crush the cocopeat by hand into dust. Then rub the
cocopeat powder between the palms of the hand so that the dust falls
down and the fibre stays in the hand. In this way, separate all the fibre
from the dust. Some tiny fibres may be allowed to fall down with the
cocopeat. Repeat till the fibre and dust are separated satisfactorily.
Weigh the fibre (Wc). The fibre content is given by the formula

Fibre content = Wf/Wc x 100%

Fibre measured by sieving can give varied results as there is no

standard for mesh size, wetness and due to cocopeat particles clinging
to clumps of fibre during sieving.

Sand content (Impurities):

Break off a slice of the cocopeat block so that the slice measures 1
kg. In a large tub filled with water immerse the 1 kg slice till it
completely expands and floats in the water. The floating cocopeat are
removed first by hand and later by carefully decanting the tub. Repeat
till all the floating cocopeat and fibre are removed. The sediment
contains heavy husk particles and heavier sand particles. Slowly swirl
the sediment with a small quantity of water and pour out the swirling
heavy husk particles with the water. Repeat till only the sand is left in
the tub. Dry and measure the weight of the sand (Ws) in grams.

Sand content is given by Ws/1000x100%

Expansion (or) Breakout Volume:
Break off a slice of the cocopeat block so that the slice measures
more than 1 kg. Break and crush the slice by hand into dust particles.
Remove the fibre by rubbing between the palms.
Measure one kg of the dust and add to a large tub. To the dust slowly
mix three litres of water and completely expand all the cocopeat
particles. Measure the volume of the loose expanded fluffy cocopeat
without compacting on a litre by litre basis. The number of litres gives
the expansion or breakout volume.

Water retention:
Break off a 1 kg slice of the cocopeat block. Place it in a tub and add
water slowly to completely expand the cocopeat. Continue adding
water till water is no longer absorbed by the cocopeat. Transfer the
cocopeat on to a mesh so that the excess water is drained. Measure the
weight of the wet material after one hour (W kg).

Water retention is given by (W-1)/1x100%

Step 4: Drying
The cocopeat is dried naturally under sunlight on the floor. Once the
moisture is reduced to 18% of its former, it is sent for final screening.

Step 5: Screening
This is the final screening method for the removal of any impurities or
sand with the help of automated screeners. In this process, cocopeat is
thoroughly tested.

Step 6: Packing
Cocopeat packed as the required of the customers or into standard size of
packing with label of Rushabh Agro Industry.
COIR ROPE MAKING MACHINES:

1)Willowing machine:
Function: to clean the fibre by removing
waste materials
Capacity: 350-400kg/ 8 hr.
Size: 0.75m x 0.75m x 1.0m

This machine is used to clean and separate the coir

fibre.
WILLOWING MACHINE
2)Coir rope making machine:
Function: making rope
Capacity:5000 no.’s of husk per hour
Size: 7’ x 5’ x 8’

Rope making machine is used for make

ropes from the coir.

COIR ROPE MAKING MACHINE

COIR ROPE MAKING PROCESS/STEPS:

Step 1: Fibre Extracting

The dried husk is taken to defibering process. The husk is directly
sent into defibering machine. The machine separates the fibre from
the husk. This extracted husk is again refined to remove the impurities
and the hard coconut skin.
A willowing machine is used to refine the husk. The refined husk is
gathered and pilled which is again sent for the rope making process.

Step 2: Automated rope making

The coir is refined using an automated machine. In this process, the
cleaned coir is dried and it is taken to the rope making machine. The
coir is continuously fed into the fibre tray, the coir automatically
twisted and rolled in a container which is placed at the other end of
the machine. This roughly spinned coir is again fed into the machine.
The final twisting of the coir is done by the two spools which are
attached to the machine. These automated machines are run by a
single operator.

Step 3: Packing
Coir rope bundles ready for marketing.
COIR ROPE BUNDLES
DAILY LOG

⮚ Day 1

- Introduction to the industry

- Management and working of the industry

⮚ Day 2

- Study of products and their by-products received at the end

of process

⮚ Day 3

- Studying and understanding of defibering machine that use

in cocopeat making machines

⮚ Day 4

- Studying and understanding of screening machine use in

cocopeat
⮚ Day 5

- Making of cocopeat

⮚ Day 6

- Making of cocopeat

⮚ Day 7

- Processing of cocopeat

⮚ Day 8

- Packing of cocopeat

⮚ Day 9

-Studying and understanding willowing machine use in rope

making from coir

⮚ Day 10
 - Studying and understanding coir rope making machine

⮚ Day 11

- Processing of rope making by coir

⮚ Day 12

- Rope packing

⮚ Day 13

- Marketing the product- Cocopeat

⮚ Day 14

- Marketing the product- Coir rope

LEARNING SUMMARIZATION

In the rushabh agro industry, the manufacturing process of cocopean

was studied well.
In this internship, I learned about some new technologies in the coco
peat manufacturing process.
Learned the process of coir rope making from coconut husk.
Functions of machinery that were used in the coco peat manufacturing
process and coir rope making process studied well.
CONCLUSION

A substantial part of the initial targets for the project to develop

technologies to produce better quality and more attractive coir
products with better consumer acceptance have been achieved.
Technology has been widely introduced in the market and has
contributed substantially to the diversification of product design.
BIBLIOGRAPHY

https://cocoandcoir.com/blogs/gardening/the-
benefits-of-coco-coir
https://www.cosmiccoir.com/benefits.html
https://soakandsoil.com/6-advantages-and-5-
disadvantages-of-coco-peat/
https://coir.com/utility/coir-twine-benefits-and-
uses/
https://coir.com/utility/coir-rope/
https://askinglot.com/why-coconut-coir-fibres-are-
used-for-making-ropes
http://www.usesofcoconut.com/benefits-and-uses-
of-coconut-coir/