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Technologies Developed / Released

  • High Volume Flux Bonded Fly Ash Ceramic Technology for Building Components  |  First of its kind in India, the process developed utilizes up to 80% by weight of fly ash with certain glass forming additives to red coloured building components such as bricks, pavements, tiles, glazed tiles etc. after firing in the range 850-9500C as in the case of clay products.

    The process is adaptable to the traditional brick and tile industry with appropriate mechanization and conserves upto 80% of natural clays and use up to 80% of fly ash. The cost calculations based on the pilot plant demonstration trials show that the price of the fly ash products will be in the similar range as clay products. The plant should be preferably in the premises of the thermal power plants and the process is suitable for pond ash and stored ash as also with dry fly ash. All machineries and the binders/additives are available in the country.

    Investment required : Total investment for a plant producing 60,000 bricks/tiles/glazed tiles: Rs.2-2.5 crore. Brick cost Rs.2.50-3.0 per piece, tiles at Rs. 4-5 per piece and glazed products Rs. 6-8 per piece.

    Returns /Benefit: 15-18% returns on investment over a period of 5 years.; Validation level: Pilot-scale.; IPR Status: Patented in India.

  • Clean Bioprocess for Natural Fibre Extraction |  This biological process yields superior quality fibres while shortening the processing time substantially. Here separation of fibres from their matrices is achieved by enzymatic cleaving of cementing compounds with in situ microbial growth and enzyme production. The organic residue generated by the process is converted to methane that can be recovered for fuel. In abstract, this bioprocess technology would help to achieve better quality, speed and pollution control.

    The conventional extraction processes like retting leads to serious problems like methane and sulphide emission, water contamination and other environmental pollutions. Emission of methane and sulphide during the retting process is a major source of environmental pollution as they contribute to greenhouse gases. Owing to the above factors, Biological method is preferred to mechanical and chemical routes for extracting fibres of good quality from the embedding matrix. It is in this context that NIIST devised a clean bioprocess which has the potential to replace the traditional method of retting in which the plant materials are left to decay in humid conditions or in water to free the fibre from matrices.

    Validation level : Real life.; IPR Status : Filed.

  • Clean Bioprocess for white pepper production |  A simpler, more cost-effective and pollution-free microbial technology that ensures production of superior quality white pepper within a short span of time as compared to the conventional routes. This microbial process has been developed for bulk production of white pepper by enabling clean removal of pepper skin from fresh and dried black pepper. The process is designed to cleave the pectin molecular bonding between the skin and oil glands of the pepper kernel by the actions of enzymes produced in-situ. The process uses enzymes to degrade pectins, the cementing tissues present in between the skin and oil glands on the pepper kernel. The process also generates methane gas and organic fertilizer as a by- products…

  • Indigenous Casting Simulation Software for Small & Medium Scale Foundries |  Virtual Casting makes it possible to shift the trials from the shop floor to the computer, saving time, effort, energy and material. Virtual casting helps the foundry men to design the feeding system before submitting the design to simulations and actual trials, and therefore it holds a large bearing on Indian Foundry outfits, which are fairly large in number.

  • Fresh Ginger Processing Technology |  A commercially viable generic technology to process fresh spices to make essential oil and spice powders. The new patented technology for the recovery of ginger oil from fresh ginger and other botanicals offer several advantages over the conventional process of recovery of the oil from dried ginger. The major advantages are
    • Yield of oil 30 % more than the conventional process
    • Processing time reduced to 4 hours instead of 18 hours.
    • Reduced energy consumption
    • Processing cost around 12 % of the total cost of production
    • Superior quality of flavour
    • Possibility for byproducts utilization

  • Beta-Glucosidase for Biofuel Application |  CSIR-NIIST had isolated a filamentous fungus from decaying wood in 2005, which was identified as Aspergillus niger and designated isolate no. NII 08121. The fungus produced a BGL which was active at 0.5M glucose and had a glucose inhibition constant (Ki) of 0.2M. The technology developed is a solid state fermentation process for the production of NII 08121 BGL.

    Beta-Glucosidase (BGL) is a key ingredient in the enzyme blends used for biomass hydrolysis for bioethanol production. It is the rate-limiting enzyme in the cellulase complex. Cellulases for hydrolysis of biomass are typically sourced from fungi like Trichoderma reesei whose cellulases lack sufficient quantities of this important enzyme. Commercial preparations of cellulase contain BGL from heterogeneous sources. Aspergilli are used as sources of BGL. Globally, there are only a few suppliers of BGL for biomass hydrolysis. BGL in these preparations are inhibited by high concentrations of glucose.

  • Banana Fabric Polymer Composite | 

    A Process for making banana fiber polymer composites. It is a cost-effective substitute for glass fiber reinforced plastic to make variety of products e.g. simple trays, mirror casings to voltage stabilizer cover and electrical panels.

    The process consists of preparing moulds of metal, wood or plaster of paris; mixing the resin and dye in requisite proportion; shaping the banana fabric by laying it over the mould; reinforcing the polymer over banana fabric; curing the mould; demoulding; cutting, trimming and polishing.

  • Nano Rare Earth Oxides and Phosphates  |  Nano metal oxides and phosphates are types of materials with growing market on a global basis. Most of the nano metal oxides commercially available from countries abroad are very expensive.

    CSIR-NIIST  has developed a process for the production of Nanoparticles starting through hydrolysis-peptisation technique. The process in general consists of hydrolyzing titanyl sulphate or chloride to titanyl hydroxide by addition of ammonium hydroxide followed by washing and removal of all the undesirable ions.

    Investment required: For a plant size of 10 kg/batch capacity, the cost of the plant will be about Rs. 250 lakh. The machinery cost will be about Rs. 160 lakh.

    Returns /Benefit: The abundant deposits available in the country could be gainfully utilized.

    Validation level: Till now, the process has been optimized in the laboratory and being scaled up to Bench/Pilot scale with M/s Indian Rare Earths Ltd., Mumbai which is set up in IREL Kollam is expected to get commissioned in June, 2010. The average cost of the nanoparticles will be Rs. ~1000-2000 per Kg only.

    IPR Status : Filed.

  • Clean Bioprocess for Quality Coir Fibre Production & Energy Recovery  | 

    A clean bioprocess has been developed by NIIST for the extraction of quality coir fibre from coconut husk. This method carries out separation of fibres from their matrices by enzymatic cleaving of cementing compounds with in situ microbial growth and enzyme production. This bioprocess not only converts all the organic pollutants emanated from the extraction process to methane, but also facilitates its recovery as an Energy Source. Since the methane production is almost exclusively from the Up flow Anaerobic Sludge Blanket Method (UASB) methanogenic reactor and no significant quantity of methane is generated from the retting tanks, therefore the collection of methane is possible without expensive gas tight covering of the retting tanks.

    This bioprocess can also be used for processing of natural fibres like jute, banana and pineapple leaf.

    Investment required : Capacity : 16000 husk/day; Investment : Rs.1.4 crore; Production per day :1.4 t fibre @ Rs.20,000/t; 0.8 t pith @ Rs.250/t; 800m3 biogas @ Rs.5/m3

    Validation level : Real life.; IPR Status : Filed.

    Returns / Benefit : 

    • Environmental-economic benefits of clean bioprocess
    • Value of Biogas : Rs.150 Crore/ year
    • Certified Emission Reduction @ $5.0/(tCO2e) : Rs.16 Crore/ year
    • Energy potential from clean bioprocess
    • White fibre production : 1.2 lakh ton/year
    • Husk retted : 15 lakh ton husk/year
    • Biogas : 82,500,000 m3/year

     

  • Chilli Processing Plant  | 

    The Byadgi Chilli, which is known for its high colour is currently processed in the traditional manner which result in loss of carotenoids during the sun drying operation. The new process developed employs a fluid bed drier for bringing down the moisture to acceptable levels of fresh chilli hygienically. The resulting end product will have a 10% increase in colour value when compared to the conventionally processed raw material. The raw material is washed, size reduced, dried in the fluid bed drier and then de- seeded. The contact time in the drier is less than 15 minutes and the entire operation is automated. All the machineries are interlocked and the manpower requirements are marginal. High pressure steam is used as the heating medium and the plant is engineered to ensure high thermal efficiency.

    Investment required: The facility can be set up at a cost of approximately Rs.2.5 crore for a 20 Ton/day fresh red byadagi chilli processing unit.

    Returns / Benefit: The unit can provide direct employment to 30 people and indirectly benefit a large number of farmers ensuring fair price for the produce.

    Validation level: Pilot scale.

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