Appendix l-A—A Case Study of Acetaminophen Production • 271 
\1* \l’ in\ ()l\ ('s two The product of tlie indi\ id- 
ual reactions for each step represents the oxerall 
lom ersion efficiency. ,\ molar conversion efficiency 
of [)ercent was assumed for each step. This value 
is based on a multitude of reports demonstrating 
similar molar conversion efficiencies for analogous 
hiochemical reactions under actual fermentation 
conditions. 
PKOniCT VIELI) 
I'he yield of \l’ \l’ |)rojected in table 1 -.\-l is based 
on estimating a ratio of 40 percent w eight to v olume 
ti e.. 40 lb ()er 100 gallons (gal) of fermentation broth) 
[trior to 90 [tercent recov ery. Such a high yield is per- 
mitted because of the poor solubility of .\P.AP under 
o[)erating conditions. \s a result, high levels of .\P.\P 
would bav e no atlv er.se effect on the host micro-orga- 
nism. Use of insoluble systems in fei iiientation has in 
fact been reported in recent years— e.g., in certain 
microbial transformations of steroids, yields of 40 
percent may result due to the insolubility of the 
product. 
“It J Vhholl immohill/cd ( CIK. " In \niw;il Reports on h'rrmcn- 
liilion PriHvssrs, \nl. I I) I’ci lman ((‘d.l I.Vi-w Vork: Vcadriiiic 
Pi rsN. I!)77). |)|) 
Economics 
PRODUCTION REQUIREMENTS 
How the various production requirements would 
be met during the microbial transformation of ani- 
line to APAP is summarized in tables I-A-1 and 2. Ani- 
line and acetic acid would not be added to the fer- 
mentation broth all at once but rather step-wise ac- 
cording to their rates of conversion. The plant would 
contain two 50, 000-gal fermenters, which in the 
course of a year would yield 10 million lb of APAP. 
PRODUCTION COSTS 
The costs for the annual production are summa- 
rized in table l-A-3. I’hey are broken down into their 
majoi' components and are expressed both as annual 
costs and as unit costs. Detailed budgets for the vari- 
ous cost centers are shown in tables I-A-4 through 
l-,\-10. Materials and supplies are described in table 
I-.A-4; labor distribution in table I-A-5; utility require- 
ments in tables l-A-6 through I-A-8; equipment in 
table l-A-9; and space requirements in table I-A-10. 
This analysis reveals a unit cost of APAP equal to 
$ 1.05/lb. 
Table l-A-2.— Summary of Production Conditions 
of APAP 
Table I-A-4.— Materials and Supplies for 
Production of APAP 
Number of fermenters 
Size of fermenters ... 
Operating volume ... 
Cycle 
Batches 
^day fermentation. 1-day turn around. 
SOURCE: Cenex Corp. 
Table l-A-3.— Summary of Costs of 
Production of APAP 
Annual cost 
Cost/lb 
Materials and supplies . . . . 
... $ 6,133,802 
$0.6091 
Labor 
. .. 2,012,140 
0.1998 
Utilities 
630,200 
0.0626 
Equipment 
. .. 1,377,590 
0.1368 
Building 
439,399 
0.0436 
Total 
$10,593,131 
$1.05/lb 
Annual production = 10,070,1001b 
SOURCE: Cenex Corp. 
Materials 
Cost/batch 
Cost/year 
Fermentation 
Fishmeal (1.5% @ $0.155) 
$ 648.68 
$ 
64,868 
Glucose (1.5% @ $0.1535) 
Lard oil (2.5% @ $0.325) 
Mineral salts (4,215 lb @ $0.05074) 
Aniline (76,250 lb @ $0.42) 
642.40 
2,266.88 
213.77 
32,027.52 
64,240 
226,888 
21,377 
3,202,752 
Acetic acid (46,680 lb @ $0,245) . . 
11,436.60 
1 
,143,660 
Miscellaneous (10% of basic 
materials) 
Subtotal 
377.17 
$47,613.02 
37,717 
$4,761,302 
Recovery 
Filter aid (0.2 Ib/gal @ $13) 
$ 871.00 
$ 
87,100 
Other chemicals and supplies. .. . 
1,600.00 
$ 
160,000 
Subtotal 
$ 2,471.00 
$ 
247,100 
Finishing 
Packaging (1,255 bag units 
at $0.80) 
$ 1,004.00 
$ 
100,400 
Other (labels, stencils, etc.) 
1,004.00 
$ 
100,400 
Subtotal 
$ 2,008.00 
$ 
200,800 
General supplies 
Maintenance (4% of capital investment) 
$ 
425,900 
Other (laboratory office, plant miscellaneous) . 
Total 
498,700 
$6,133,802 
SOURCE: Cenex Corp. 
2 
50,000 gal 
33,500 gal 
7a 
100 
