After Vietnam and Nigeria, India ranks globally as the third-largest producer and processor of cashew shells. These cashews compose of 32.5% nuts and 67.5% shells. The shell undergoes processing to extract cashew nut shell liquid (CNSL) and the residue, known as cashew deoiled cake (Cashew DOC). Cashew DOC is transform into a high-quality fuel called “Astillas” through intricate processes.

The Transformation Process: From Cashew DOC to Astillas

• Initial Extraction: The first step involves extracting cashew kernels from the cashew nutshells, which consist of a high amount of Cashew Nut Shell Oil (15-25%) and anacardic acid.
• Oil Extraction: The shells undergo an oil extraction process, reducing the oil content in the shell to less than 5%.
• Acid Reduction: Despite the oil extraction, the deoiled cake still contains high levels of anacardic acid, making it challenging to use as fuel. It then undergoes further processing to lower the acid content.
• Blending with Biomass: The deoiled cake is mix with locally available biomass like dry sawdust and wood chips. This blending helps absorb excessive oil.
• Screening and Packaging: The mixture is then process further and screen to ensure quality before being packed in bags as per requirements.

Technical Aspects of Astillas: How Does It Differ from Cashew DOC?

• Reduced Acidity: Astillas have an oil content below 5%, compared to Cashew DOC, which contains about 10-20% oil. This reduction in oil content is crucial as the acidic nature of the oil can pose severe threats to worker safety, the environment, and the furnace linings of the combustion chamber.
• Clean Combustion: Astillas burns wholly and cleanly, leaving no black or acidic smoke traces.
• Enhanced Safety: The reduced acidity in Astillas enhances worker safety and prolongs the life of the equipment. Unlike Cashew DOC, Astillas is much safer to handle with bare hands.

Hear from Our Clients

1. Mahadev Foods

“Mahadev Poha Mill, based in Bhatapara, manufactures poha. We installed a Renewable Energy Combustor (REC) from Steamax, and the results have been excellent. With their burner and fuel, we’ve successfully eliminated excess fumes and reduced fuel consumption by 20-25%. Steamax’s fuel feeding and combustion system are so efficient that we now have uniform heating throughout the roaster.”

2. Diamond Beverage Limited

“We have been associated with Steamax since 2017. Steamax has been managing our fuel and steam requirements in the Kolkata region. With their support, we successfully shifted to clean fuel Astillas, a biomass fuel that aligns with pollution control norms. Its high calorific value and negligible ash content make it the perfect fuel for our system. We are delighted with the company’s commitment and look forward to continuing our association.”

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