1. INDUSTRIAL GRANT SCHEME (IGS) 2004 - SAIFUL IRWAN ZUBAIRI
PRODUCT COSTING OF ROTENONE PILOT SCALE PRODUCTION
Maximum capacity : 300 L/run
Extraction ratio : 1 kg Fine Root: 10 L Solvent
: 25 kg Fine Root: 250 L Solvent
Direct Production Cost
1) RAW MATERIAL (Fine Roots)
1 kg Fine Roots achieved from ----------------- ≅ 15 kg Whole Plant
∴ IF, 25 kg Fine Roots needed for Extraction ----- ≅ 25 kg F.R × 15 kg Whole Plant
1 kg Fine Roots
≅ 375 kg Plant needed for getting
25 kg of Fine Roots for Extraction
COST: 1 kg Whole Plant ≅ RM 5.00
∴ 375 kg Whole Plant ≅ RM 1,875.00/Run
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2) SOLVENT (Acetone)
Raw Material: Solvent = 1: 10
∴ 25 kg Fine Roots : 250 L Acetone
ACETONE a) Industrial Grade – Volume = 209 L/Drum – RM 800.00
Therefore, we need : 250L/209L × RM 800.00 = RM 957.00/Run
3) UTILITIES
(Washing & Evaporation Process – Water & Electricity) = RM 50/Run
NEED TO BE CLARIFYING FURTHER IN TERMS OF ENERGY USAGE.
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3) FILTRATION PROCESS
(Membrane filter - STRAINER) = RM 30/Run
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2. INDUSTRIAL GRANT SCHEME (IGS) 2004 - SAIFUL IRWAN ZUBAIRI
DIRECT PRODUCTION COST (DPC) = RM 1,875 + RM 957 + RM 50
+ RM 30 = RM 2,912/Run
OPERATING LABOR (OL) = RM 0.02/g A.i × 666,431.09 mg of A.i =
RM 13.32/Run × No. of Workers (3) = ∴ RM 40.00/Run
LABORATORY CHARGES (LC)
= 10 % Operating Labor = RM 4.00/Run
TOTAL MANUFACTURING EXPENSES, AME = DPC + OL + LC =
RM 2,912 + RM 40.00 + RM 4.00 = 2,956.00/Run
DIRECT SCALE UP OF LAB SCALE PRODUCTION:
Maximum Capacity of Extraction Vessel: 300L/run: SEMI-PILOT
PLANT
Based on the result in the latest development of Rotenone extraction
process: 25 March 2004 using the Tuba Kota Johor Lama, Johor; the
Rotenone yield, concentration & volume of crude extract are:
Name of Samples Acetone Extract
Concentration (mg/ml)
(Unconcentrated)
Tuba Kota Johor Lama – Crude Extract 2.90
Name of Samples Acetone Extract Yield (mg)
(Unconcentrated)
Tuba Kota Johor Lama – Crude Extract 820.00
Name of Samples Acetone Extract
Volume of Crude Extract (ml)
(Unconcentrated)
Tuba Kota Johor Lama – Crude Extract 283/500
By up scaling the result from the laboratory to pilot plant process:
(A.i = Active Ingredient - Rotenone)
DATA FROM LAB SCALE: (50 g of raw material)
YIELD: 1.64% (w/w)
283.00 ml of crude extract solution ------------ 820.00 mg of A.i

3. INDUSTRIAL GRANT SCHEME (IGS) 2004 - SAIFUL IRWAN ZUBAIRI
DATA FOR SEMI-PILOT PLANT SCALE: (25,000 g of raw material)
YIELD: 2.66% (w/w)
If, 230,000 ml (230 L) of crude extract solution ----------? mg of A.i
820.00 mg of A.i ______ × 230,000 ml of crude extract
283.00 ml of crude extract
= 666,431.09 mg of A.i/Run contain in the 230 L of LIQUID CRUDE EXTRACT.
ASSUMING THAT THE CONCENTRATION OF CONCENTRATED LIQUID
CRUDE EXTRACT TO BE ACHIEVED IS 50 mg/ml AND THE ROTENONE
CONTENT IS RETAINED (666,431.09 mg) BEFORE AND AFTER THE
CONCENTRATION PROCESS.
(ROTENONE LOSSES IS NEGLECTED – ASSUMING TO BE 100% RECOVERY OF A.i)
2.90 mg/ml (Rotenone Conc.) ----------- 230 L of Liquid Crude Extract
(UNCONCENTRTED)/Run
50 mg/ml (Rotenone Conc.) ------------ 13.33 L of Liquid Crude Extract
(CONCENTRATED)/Run
CALCULATION:
50 mg/ml × Y (VOLUME OF CONCENTRATED LIQ) = 666,431.09 mg of Rotenone
So, Y (VOLUME OF CONCENTRATED LIQ) = 666,431.09 mg/50 mg × 1 ml
∴= 13.33 L/Run
13,328.62 ml (13.33 L) of Concentrated Liquid Crude Extract contains
666,431.09 mg of rotenone.
IF, 1 ml of Concentrated Liquid Crude Extract – 666,431.09 mg/13,328.62 ml ×
1ml
∴1 ml of Concentrated Liq. Crude Extract --- 50 mg of rotenone
50 mg of rotenone ------------- 1 ml of Concentrated Liq. Crude Extract
IF, 1g of A.i ------------ 1ml/50 mg × 1g = 20 ml
So, Cost per unit weight of Rotenone = AME / 666,431.09 mg of A.i/Run
RM 2,956.00/Run/666,431.09 mg of A.i/Run = RM 0.0044/mg A.i
COST OF SEMI PRODUCT/RUN:
∴RM 4.40/g A.i/20 ml of Concentrated Liquid Crude Extract
(1 g of A.i that contains in 20ml of Concentrated Liquid Crude Extract
(SEMI PRODUCT) per run = RM 4.40

4. INDUSTRIAL GRANT SCHEME (IGS) 2004 - SAIFUL IRWAN ZUBAIRI
PRODUCTION OF FORMULATED PRODUCT (3 % A.i) FROM 13.33 L OF
CONCENTRATED LIQUID CRUDE EXTRACT PRODUCT (SEMI PRODUCT)
ASSUMING THAT THE CONCENTRATION OF CONCENTRATED LIQUID
CRUDE EXTRACT TO BE ACHIEVED IS 50 mg/ml AND THE ROTENONE
CONTENT IS RETAINED (666,431.09 mg) BEFORE AND AFTER THE
CONCENTRATION PROCESS.
(ROTENONE LOSSES IS NEGLECTED – ASSUMING TO BE 100% RECOVERY OF A.i)
2.90 mg/ml (Rotenone Conc.) ----------- 230 L of Liquid Crude Extract
(UNCONCENTRTED)/Run
50 mg/ml (Rotenone Conc.) ------------ 13.33 L of Liquid Crude Extract
(CONCENTRATED)/Run
CALCULATION:
50 mg/ml × Y (VOLUME OF CONCENTRATED LIQ) = 666,431.09 mg of Rotenone
So, Y (VOLUME OF CONCENTRATED LIQ) = 666,431.09 mg/50 mg × 1 ml
∴= 13.33 L/Run
13,328.62 ml (13.33 L) of Concentrated Liquid Crude Extract contains
666,431.09 mg of rotenone.
IF, 1 ml of Concentrated Liquid Crude Extract – 666,431.09 mg/13,328.62 ml ×
1ml
1 ml of Concentrated Liq. Crude Extract --- 50 mg of Rotenone
Production ratio of 1000 ml formulated product:
ASSUMING 3 % A.i (w/v)
1. 3 % Active Ingredient (Rotenone) : 600 ml
0.03 × 1000 ml = 30 g A.i needed.
IF, 0.05 g (50 mg) -- 1 ml of Concentrated Liq. Crude Extract
So, 30 g A.i needed --- 1 ml/0.05 g × 30 g = 600 ml
600 ml of Concentrated Liquid Crude Extract is needed for
obtaining the 30 g A.i (Rotenone)
2. Surfactant : 80 ml
3. Water : 320 ml

5. INDUSTRIAL GRANT SCHEME (IGS) 2004 - SAIFUL IRWAN ZUBAIRI
In order to produce 13,328.62 ml, we need:
1. Active Ingredient : 13.3 L × 0.6 L × 30 g × RM 4.40/g A.i
= RM 1,053.36/Run
2. Surfactant : 13.3 L × 0.08 L × RM 800/209 L (209 L/Drum)
= RM 4.07/Run
3. Water : 13.3 L × 0.32 L × RM 1.50/0.5 L Water
= RM 12.77/Run
∴ Direct Cost : (RM 1,053.36 + RM 4.07 + RM 12.77)/Run
: RM 1,070.20/Run
OPERATING LABOR (OL) = RM 0.02/g A.i × 666,431.09 mg of A.i =
RM 13.32/Run × No. of Workers (2) = ∴ RM 26.64/Run
LABORATORY CHARGES (LC)
= 10 % Operating Labor = RM 2.66/Run
∴ TOTAL PRODUCTION COST:
= (RM 1,070 + RM 26.64 + RM 2.66)/Run
= RM 1,099.30/Run
= RM 1,099.30/Run/13.33 L
= RM 82.46/L Formulated Product (3 % A.i)/Run
AMOUNT OF FORMULATED PRODUCT CAN BE PRODUCED /RUN:
600 ml (0.6 L) of SEMI PRODUCT contains with 30 g (3 % A.i) is
needed to produce 1 L of Formulated Product.
The amount of SEMI PRODUCT/RUN = 13.33 L.
So, THE AMOUNT OF FORMULATED PRODUCT CAN BE
PRODUCED/RUN:
13.33 L/0.6 L ≅ 22 BOTTLES OF FORMULATED PRODUCT/RUN
COST OF FORMULATED PRODUCT (3 % A.i)/RUN:
∴RM 82.46/L Formulated Product (3 % A.i)