aamchur (dried mango powder)

1

AAMCHUR (DRIED MANGO POWDER)

1. Introduction

Aamchur is dried raw mango powder. It is used as a tastemaker in many

foods and as a substitute to tamarind or lime to give the sour taste. “Chaat

Masala” “Curry Masala” and other spice mixtures have Aamchur as an

ingredient.

2. Market

The major market outlets are the “ A” class outlets. The product also

finds placement in self-service counters and departmental stores. Food

processing industries purchase the product in bulk quantities. The dehydrated

powder also has a good export potential.

3. Packaging

Aamchur powder is packed in tins for bulk packaging. In retail packaging,

50 grams and 100 grams are the unit weights.

4. Production capacity

• The plant will be in continuous operation. It will operate to two shifts per day,

each of twelve hours duration.

• The plant will process 1000 kgs of raw mango per day.

• The yield of aamchur powder will be 25% of the weight of raw material used.

The total quantity of finished product available per annum would be 75 metric

tonnes.

• The time period required for achieving full capacity utilization is one year.

5. Sales revenue

• With an ex-factory selling price at Rs. 150 per kilogram for dehydrated

aamchur powder the total sales revenue will be Rs. 112.50 lakhs per annum.

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6. Production process outline.

Raw mango is taken and the skin peeled. The fruit is slit to remove the

seed. The resulting pulp is grated. The gratings are blanched for a few seconds

in bisulphite solution and then dried in a fluidized bed drier. The dried mass is

ground in a pin mill and the powder to the desired mesh size is obtained,

7. Quality specifications

• The product should be free from mold and fungal growth.

• It should be free from any fermented odour, coliforms, salmonella and

streptococci bacteria.

• The moisture content in the product should not normally exceed 8 to 10%

• It shall not contain any added flavours or colours.

8. Pollution control measures

Not necessary as there are no pollutants or effluents.

9. Energy conservation measures

Common measures will do.

10. Land and construction cost for the proposed unit

The unit is proposed to be set up in a leased area. The area required is

4000 square feet as detailed below.

Sl Description Sq. feet 1 Processing area 500 2 Raw material store 400 3 Washing area 200 4 Dehydration area 500 5 Grinding area 500 6 Packing area 400 7 Quality control laboratory 200 8 Packaging material store room 200 9 Finished goods store 400

10 Machinery spares store room 100 11 Administration office 200 12 Boiler area 200 13 Toilet space 200 14 Total 4000

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• Lease rent – Rs. 6.00 per square foot

• Total rent per month – Rs. 24000

•••• Lease advance – Rs. 1,00,000

11. Costing of machinery and equipment

Sl Description Rs. lakhs 1 Precooling facility at + 10 degrees centigrade

for raw fruit 3.500

2 Stacking trays for raw mango - 500 trays @ Rs. 200 each with each tray holding 10 kgs of raw material

1.000

3 Preparatory section consisting of washing tank, slicers and graters

2.500

4 Blanching tank with thermostat control, solenoid valves, and circulation pump to keep blanching solution in circulation

1.850

5 Vibratory shaker in stainless steel to remove excess water after blanching

0.600

6 Fluidized bed dryers for dehydrating gratings at a capacity of 1000 kilograms in a span of 8 to 10 hours complete with heat exchanger, blower fans and accessories

4.840

7 Pin mill with accessories at a grinding capacity of 50 kilograms per hour

5.500

8 Hot water boiler and accessories 1.850 9 Form fill and seal packing machine with

augur weighers and fillers 2.750

10 Total 24.390 11 Laboratory equipment 1.000 12 Grand total machinery and equipment 25.390

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12. Project cost Sl Description Rs. lakhs 1 Land On lease 2 Civil works On lease 3 Plant machinery 24.390 4 Laboratory equipment 1.000 5 Transport vehicle 0.000 6 Pollution control equipment 0.000 7 Energy conservation equipment 0.000 8 Cost of power connection 1.000 9 Cost of electrification 1.000

10 Erection and commissioning 2.500 11 Cost of machinery spares 0.500 12 Cost of office equipment 0.500 13 Deposits if any 1.050 14 Company formation expenses 0.100 15 Gestation period expenses 1.500 16 Sales tax registration expenses 0.100 17 Initial advertisement and publicity 2.000 18 Contingencies 0.150 19 Working capital margin money 2.000 20 Total 37.790

13. Working capital requirements per month

a. Salaries and wages

Sl Description No of persons

Total salary / month

(Rs. lakhs) 1 Production Manager 1 0.150 2 Production supervisor cum

chemist 2 0.200

3 Skilled workers 4 0.240 4 Unskilled workers 8 0.240 5 Packing workers 4 0.120 6 Administrative staff 2 0.200 7 Total 21 1.150

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b. Raw material requirement per month Sl Description Qty

(kgs) Rate / kg

(Rs) Value

(Rs. lakhs) 1 Raw mango 25000 15.00 3.750

2 Total raw material 25000 3.750 c. Packaging material requirement per month

Sl Description Qty Rate / unit Rs)

Value (Rs. lakhs)

1 Primary packaging material – metallized polyester – poly film

25 kgs 250 0.0625

2 Cartons and straps 1000 nos 20 0.2000

3 Total 0.2625 Total raw + packaging material = Rs. 4.0125 lakhs d. Utilities per month

Sl Description Rs. lakhs 1 Power 6000 kwh @ Rs. 6.00 per unit 0.360 2 Water 0.050 3 Boiler fuel 0.250 4 Total utilities 0.660

e. Contingent expenses per month

Sl Description Rs. lakhs 1 Rent for processing shed 0.240 2 Postage and stationery 0.010 3 Telephones, fax etc. 0.025 4 Consumable stores 0.010 5 Repairs and maintenance 0.281 6 Local transports, loading and unloading 0.010 7 Advertisement and publicity @ 5% of sales 0.469 8 Insurance 0.018 9 Sales expenses @ 1% of sales 0.094

10 Miscellaneous expenses @ 1% of sales 0.094 11 Trade incentives @ 2% of sales 0.188 12 Taxes @ 4% 0.376 13 Total contingent expenses 1.815

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f. Total working capital requirement per month

Sl Description Rs. lakhs 1 Salaries and wages 1.150 2 Raw material and packaging material 4.013 3 Utilities 0.660 4 Contingent expenses 1.815 5 Total 7.638

14. Means of finance

Sl Description Rs. lakhs 1 Total Project Cost 37.790 2 Equity 12.263 3 Debt 25.527 4 Working capital margin money 2.000

15. Financial analysis

Sl Description Rs. lakhs 1 Total recurring cost per year 91.656 2 Depreciation on land and building 0.000 3 Depreciation on machinery 2.539 4 Depreciation on furnaces 0.000 5 Depreciation on moulds and fixtures 0.010 6 Depreciation on office equipment 0.050 7 Interest on long term loan @ 12% 3.063 8 Interest on short term borrowings@ 12% 0.676 9 Total cost of production 97.994

16. Turnover per year

Sl Item Qty Rate/unit (Rs)

Total Rs. lakhs

1 Aamchur 75000 kgs 150 112.50

1

AMLA SYRUP 1. Introduction

Amla syrup is a concentrated form of fruit beverage made from Amla or

Emblica officianalis. It is normally consumed after reconstitution with water to

the extent of 5 to 7 times. It is preferred because it is ready to use and needs no

terminal processing except dilution with water to form a ready to serve beverage.

It has also a good nutritive value and therefore liked by one and all. It is a very

good source of Vitamin C.

2. Market

The major market outlets are the “ A” and “B” class stores. The product

also finds placement in self-service counters and departmental stores.

3. Packaging

Amla syrup is bottled in 200 ml capacities.


• The plant will be in operation for one shift a day.

• The production capacity is estimated at 100 litres per day.

• The yield of Amla syrup will be 2500 litres per month and 30000 litres per

annum.


5. Sales revenue

• With an ex-factory selling price at Rs. 60.00 per bottle of 200 ml., or Rs. 300

per litre, the sales realization will be Rs. 90 lakhs on full capacity utilization.


Mature round fruits of amla are taken, washed and steamed to make it

soft. The seed is removed by slitting, and the fruit pressed to extract the juice.

The yield of juice can range between 10 to 12 percent. Sugar is melted

separately and mixed in equal proportions. The mixture is warmed slowly till the

sugar concentration reads 65 degrees brix. The resulting squash is bottled.

. The product keeps well for over a year without change in colour or taste.

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• A certificate of approval for production has to be obtained under the Fruit

Products Order (FPO)

• The minimum total soluble solids shall be 40%.

• The minimum fruit pulp content shall be 25%.

• Only sugar, dextrose, invert sugar, liquid glucose, either singly or in

combination can be used as sweetening agents.

• Amla syrup shall not contain tartaric acid, agar or gelatin.









The proposed unit is to be set up in a leased area. The total area required

is 2200 square feet as described below:

Sl Description Sq. feet 1 Processing area 600 2 Raw material store 200 3 Washing area 200 4 Packing material store 200 5 Finished goods store 200 6 Laboratory space 100 7 Boiler area 200 8 Administrative area 200 9 Machinery spares room 100

10 Toilets 200 11 Total 2200

• Rental value – Rs. 5.00 per square foot • Total rent per month – Rs. 11000

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Sl Description Rs. lakhs 1 Fruit washing tank 0.100 2 Juice extractor 0.450 3 Steam jacketed kettle – tilting type 0.833 4 Stirrer 0.250 5 Bottle washing machine 0.356 6 Stainless steel working tables 0.888 7 Baby boiler and accessories 1.250 8 Working tools 0.100 9 Total 4.227

10 Laboratory equipment 0.500 11 Grand total machinery and equipment 4.727

12. Project cost

Sl Description Rs. lakhs 1 Land On lease 2 Civil works On lease 3 Plant machinery 4.227 4 Laboratory equipment 0.500 5 Transport vehicle – Tata Ace 3.600 6 Pollution control equipment 0.000 7 Energy conservation equipment 0.000 8 Cost of power connection 0.050 9 Cost of electrification 0.200


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chemist 1 0.060

3 Skilled workers 1 0.050 4 Unskilled workers 2 0.060 5 Packing workers 2 0.060 6 Van driver 1 0.040 7 Administrative staff 1 0.060 8 Total 9 0.430 b. Raw material requirement per month

Sl Description Qty (kgs)

Rate / kg (Rs)

Value (Rs. lakhs)

1 Amla 12500 40.00 3.750

2 Sugar 1300 17.00 0.221



Value (Rs. lakhs)

1 Primary packaging material – PET bottles of 200 ml capacity

12625 nos 4.00 0.505




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15. Financial analysis Sl Description Rs. lakhs 1 Total recurring cost per year 81.252 2 Depreciation on land and building 0.000 3 Depreciation on machinery and vehicle 0.830 4 Depreciation on furnaces 0.000 5 Depreciation on moulds and fixtures 0.050 6 Depreciation on office equipment 0.100 7 Interest on long term loan @ 12% 1.214 8 Interest on short term borrowings@ 12% 0.500 9 Total cost of production 83.946



Total Rs. lakhs

1 Amla syrup 30,000 litres 300 90.00 17. Viability analysis

Sl Description Value 1 Net profit before income tax (Rs. lakhs) 6.054 2 Net profit ratio 6.7% 3 Internal rate of return 30.3% 4 Break even percentage 40% 5 Debt service coverage ratio 2.102

List of machinery suppliers for Amla syrup 1. Geeta Food Engineering, Plot No. C - 7 / 1, TTC Industrial Area, Pawana

MIDC, Thane - Belapur Road, Behind Savita Chemicals, Navi Mumbai 400705. Maharashtra.; Tel: 022 - 27906450; Fax: 022 - 27906451

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17. Viability analysis Sl Description Value 1 Net profit before income tax (Rs. lakhs) 14.506 2 Net profit ratio 12.9% 3 Internal rate of return 23.4% 4 Break even percentage 48% 5 Debt service coverage ratio 2.106

List of machinery suppliers for Aamchur 1. Sri Valsa Engineering Works, 36, Nanda Nagar, Singanallur, Coimbatore

641005. Tamil Nadu.; Tel: 0422 - 2574268; Fax: 0422 – 2574268 2. Geeta Food Engineering, Plot No. C - 7 / 1, TTC Industrial Area, Pawana


1

ASEPTIC PACKAGING OF FRUIT PULPS AND PUREES 1. Introduction

Fruits and vegetables have a very short shelf life after harvest. In order to

prevent post harvest losses, they have to be processed immediately or stored

under refrigerated conditions. Aseptic packaging of fruit and vegetable pulp is

currently adopted by many processing industries, as the process does not affect

the product cost largely. Moreover, there are no chemical preservatives added

and this is preferred by foreign buyers. The present profile considers tomatoes

for processing as an example.

2. Market

The market for aseptically packed pulps and purees of mango, guava,

banana and tomato is both domestic and abroad. Manufacturers of jams, juices,

ketchup and ice-creams are the potential buyers.

3. Packaging

Mango and tomato purees are packed in aseptic cartons of varying

capacities according to the specification of the buyer.


• The plant will be in operation for three shifts a day.

• The production capacity is estimated at 5000 kilograms per hour or 100

metric tonnes per day or 2500 metric tonnes per month or 30000 tonnes per

annum

• The yield of mango and tomato purees will be approximately 50%. The total

yield per day would be 50 metric tonnes and that per annum would be 15000

metric tonnes.

• The time period required for achieving full capacity utilisation is one year.

5. Sales revenue

• With an ex-factory selling price at Rs. 50.00 per kilogram inclusive of taxes,

the net sales revenue will be Rs. 7500 lakhs on full capacity utilisation.

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Ripe fruits are taken. Green and unripe ones are avoided as it would

discolour the final product and increase the acidity. The fruits are first washed.

Mere rinsing of fruits is not enough because mold filaments and other micro-

organisms found in their cracks and wrinkle folds and stem cavities are not easily

dislodged. For thorough cleaning, they should be washed in running water. In the

washing tank, water is circulated and a jet of air bubbled for agitation.

After washing, the tomatoes are conveyed by a belt conveyer for pulping.

In the belt conveyer, excess water adhering to the surface of tomatoes is drained

off by a jet of cold air. In addition, segregation also takes place on the conveyer

to remove unripe and damaged ones. The tomatoes pass through a chopper

wherein they are cut into small pieces. The pieces are then softened by the hot

break method wherein they are subjected to a temperature of 90 degrees

centigrade for a few seconds. The softened mass pass through a superfine

pulper and the juice and pulp are separated from the seeds. The extracted juice

and pulp are taken to a vacuum concentrator where they are concentrated under

jacketed steam and vacuum to nearly 50% of its original volume. From the

vacuum concentrator, the puree is pumped to a steriliser where it is pastuerised

and then pumped to the head of the aseptic filling machine for packaging. The

container is also sterilized simultaneously by dry steam. The puree is then

packed aseptically.


• The manufacturer has to obtain an FPO license (Fruit Products Order

license) in order to manufacture the product.

• It shall test negative for coliforms, salmonella and streptococci bacteria.





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Land 5.0 acre - Rs.10.0 lakhs.

Processing area is 35000 square feet as detailed below.

Sl Description Sq. feet 1 Pre cooling area for fruits 5000 2 Preparatory section 5000 3 Processing section 10000 4 Cold store area for finished products 2000 5 Laboratory 500 6 Administrative section 1000 7 Boiler area 1000 8 Refrigeration compressor room 1000 9 Raw material store room 5000

10 Toilet space 1000 11 First aid and canteen 3000 12 Security office 500 13 Total 35000

Construction cost – Rs. 800 per square foot

Total cost of civil works – Rs. 280.00 lakhs

Total cost of land and civil works = Rs. 290.00 lakhs


• Preparatory section a) Primary washing tank wherein the fruits are unloaded. The system consists of

a centrifugal circulation pump which sucks the water from the tank, filters and recycles the filtered water to the tank.

b) Elevator for conveying the fruits to the secondary washing tank. c) Washing machine with nozzles for water spray. d) Belt conveyer for sorting and inspection of the fruit and removing surface

moisture e) Feed and discharge hoppers. f) Chopper for chopping of tomato and other fruits together with stainless steel

chamber, rotor blades, feed and discharge hopper.

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• Processing section g) The hot break system for softening the fruit by thermal treatment for

conversion to pulp / juices. Unit consists of receiving tank, high speed centrifugal pump for recirculation, heat exchangers with thermostat control for heating the fruit mass.

h) Super pulper for extraction of pulp. i) Juice and pulp collection tank. j) Screw type waste conveyer for removal of waste such as seed and skin from

the pulper. k) Vacuum concentrator l) Steriliser m) Sterilizing and aseptic packaging line for complete sterilization of puree and

tetrabrik packing bags with heat exchangers and chillers complete with all accessories and controls; aseptic filler etc.

• Additional equipment n) Additional preparatory section equipment for processing, papaya, guava,

mango and banana. o) Accessories such as pipelines, flanges, motors, valves, etc. • Total cost of processing equipment inclusive of duties and taxes - Rs.

1180.407 lakhs. • Accessory machinery p) Boiler - 5 Tons / hour capacity - Rs.36.00 lakhs q) Air compressor - Rs. 1.60 lakhs r) Tube wells for continuous water supply - Rs. 20.00 lakhs s) Cooling tower - Rs. 3.50 lakhs t) Weigh bridge - Rs. 12.00 lakhs u) Generator - 500 KVA along with accessories - Rs.26.00 lakhs v) Effluent treatment plant - Rs.30.00 lakhs w) Air conditioning plant - Rs.30.00 lakhs x) Water softening plant - Rs. 3.00 lakhs y) Laboratory equipment - Rs. 2.00 lakhs • Total cost of machinery and equipment - Rs. 1344.51 lakhs

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12. Project cost Sl Description Rs. lakhs 1 Land 10.000 2 Civil works 280.000 3 Plant machinery 1342.510 4 Laboratory equipment 2.000 5 Transport vehicle ( 2 LCV) 15.000 6 Pollution control equipment Included 7 Energy conservation equipment Included 8 Cost of power connection 1.500 9 Cost of electrification 5.000


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(Rs. lakhs) 1 Managing Director 1 0.300 2 General Manager (Technical) 1 0.200 3 General Manager (Finance) 1 0.200 4 General Manager (Marketing) 1 0.200 5 Production Manager 1 0.100 6 Production Supervisors 3 0.180 7 Maintenance Engineers 3 0.300 8 Maintenance Supervisors 3 0.180 9 Quality Control Chemists 3 0.180 10 Boiler Operators 3 0.180 11 Refrigeration Mechanics 3 0.180 12 Sales Staff 5 0.300 13 Skilled Workers 10 0.600 14 Unskilled workers 40 1.200 15 Administrative staff 5 0.400 16 Security staff 10 0.300 17 Total 93 5.000


(kgs) Rate / kg

(Rs) Value

(Rs. lakhs) 1 Tomatoes 2750,000 10.00 275.00

2 Total raw material 2750,000 275.00

c. Packaging material requirement per month Sl Description Qty Rate / unit

Rs) Value

(Rs. lakhs) 1 Primary packaging

material – polyethylene pouches or film

100.000

2 Cartons and straps 125000 nos

20 25.000

3 Total 125.000 Total raw + packaging material = Rs. 400.00 lakhs

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d. Utilities per month

Sl Description Rs. lakhs 1 Power 200000 kwh @ Rs. 6.00 per unit 12.000 2 Water 2.250 3 Boiler fuel 1.000 4 Refrigeration gas 0.250 5 Total utilities 15.500






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Total Rs. lakhs

1 Fruit Purees Aseptically

Packed

15000 MT 50,000 7500.00


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List of machinery suppliers for Aseptic packaging of fruit purees 1. Pennwalt Bertuzzi Limited, 507, Kakad Chambers, 132, Dr. Annie Besant

Road, Worli. Mumbai. 400018; Tel: 022 - 24932702; Fax: 022 - 24936255. 2. Abhay and Abhay Private Limited, B - 84 - 1; Okhla Industrial Estate - II; New

Delhi.110020.; Tel: 011 - 26831215; Fax: 011 - 26830190

1

BABY DOUGHNUTS 1. Introduction

Baby Doughnuts are small doughnuts weighing 20 to 25 grams each.

They are normally sweet but could be made sweet and sour, or salted or coated

with layers of chocolate. They could serve as alternatives to breakfast foods,

snacks, or as quick ready to eat foods. They are normally packed in units of four,

six, or ten and marketed through bakeries and departmental stores.

2. Market


also finds placement in self-service counters and departmental stores. Bakeries

also sell doughnuts.

3. Packaging

Baby Doughnuts are packed in polypropylene bags.



• The production capacity is estimated at 250 kilograms of the finished product

per day.

• The yield of doughnuts will be 6.25 tonnes per month and that per annum

would be 75 metric tonnes.

• The time period required for achieving full capacity utilization is six months.

5. Sales revenue

• The ex-factory selling price per piece of 25 grams is fixed at Rs. 2.00.

• The annual sales revenue would be Rs. 60 lakhs on full capacity utilization.


Raw material maida is kneaded into dough along with water, vanaspathi, salt,

sugar and yeast and allowed to mature for an hour. It is then kneaded once

again and cut into small size of desired shape and weight and allowed to further

proof for another half an hour. It is then baked to give raw doughnuts. They are

cooled and fried in oil for a few seconds. The excess oil is drained and the

doughnuts taken to the coating pan where they are enrobed with chocolate mass

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and dried by blowing hot air. They are then packed in polythene pouches in units

of four, six or ten as desired.


The maida used must conform to the following specifications:

• Moisture - 13.5% maximum

• Ash - 1% maximum

• Acid insoluble ash - 0.1% maximum

• Alcoholic acidity - 0.1% maximum

• Insect infestation - nil

• Rodent hair and excreta - absent

• Gluten - 7.5% minimum

The vanaspathi used should conform to the following specifications:

• Free fatty acids - 0.1% maximum as oleic acid

• Moisture 0.1% maximum

• Peroxide value - nil

• The doughnuts should be free from mold and fungal growth.



• If dried fruits are used, they shall be declared on the label.

• It cannot contain any added colours and flavours.





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Sl Description Sq. feet 1 Processing area 500 2 Raw material store 200 3 Packing material store 100 4 Finished goods store 100 5 Laboratory space 100 6 Machine spares area 100 7 Finished goods store 100 8 Administrative area 100 9 Toilet space 100

10 Miscellaneous space 100 11 Total 1500

Lease rent per square foot – Rs. 8.00 Total rental per month – Rs. 12000


Sl Description Rs. lakhs 1 Dough kneader 0.457 2 Forming machine 0.550 3 Proofing pans 0.250 4 Thermostat oven 35 to 250 degrees

centigrade 2.600

5 Thermostat fryer 0.390 6 Sugar coating pan 1.869 7 Sealing machines 0.300 8 Total 6.416 9 Laboratory equipment 0.500

10 Grand total machinery and equipment 6.916

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12. Project cost Rs. Lakhs

Sl Description Rs. lakhs 1 Land On lease 2 Civil works On lease 3 Plant machinery 6.416 4 Laboratory equipment 0.500 5 Transport vehicle – Tata Ace 3.600 6 Pollution control equipment 0.000 7 Energy conservation equipment 0.000 8 Cost of power connection 0.150 9 Cost of electrification 0.250







chemist 1 0.100

3 Skilled workers 2 0.120 4 Unskilled workers 3 0.090 5 Packing workers 2 0.060 6 Van driver 1 0.060 7 Administrative staff 1 0.080 8 Total 11 0.660

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(kgs) Rate / kg

(Rs) Value

(Rs. lakhs) 1 Maida 6250 18.00 1.125

2 Sugar 460 17.00 0.078

3 Vanaspathi 1065 75.00 0.799

4 Chocolate mass 80 150.00 0.120

5 Salt and spices 20 50.00 0.010



Value (Rs. lakhs)

1 Primary packaging material – polypropylene pouches

6300 nos 1.00 0.063




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10 Miscellaneous expenses @ 0.05% of sales 0.025 11 Trade incentives @ 2% of sales 0.100 12 Taxes @ 4% 0.200 13 Total contingent expenses 1.155





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15. Financial analysis Sl Description Rs. lakhs 1 Total recurring cost per year 49.812 2 Depreciation on land and building 0.000 3 Depreciation on machinery 0.106 4 Depreciation on furnaces 0.000 5 Depreciation on moulds and fixtures 0.010 6 Depreciation on office equipment 0.100 7 Interest on long term loan @ 12% 1.285 8 Interest on short term borrowings@ 12% 0.344 9 Total cost of production 51.657



Total Rs. lakhs

1 Baby doughnuts

75000 kgs 80 60.00

17. Viability analysis


List of machinery suppliers for baby doughnuts 1. Nagpal Brothers; C-127, Mayapuri Industrial Area Phase - II, (Opposite State

Bank of India), New Delhi. 110064; Tel: 011 - 28117631; Fax: 011 – 28116884

2. Arun Engineering Works, Leach and Webony Compound, 61, Off Haines Road, Worli, Mumbai. 400018. Tel: 022 – 23098629

3. Arun Engineering Works, SF No. 213, Site no. 4, Sitra Kalapatti Road, Near LMW Unit VIII, Kalapatti Post, Coimbatore 641035. Tamil Nadu. Tel: 0422-2665622; 0422-2669849

1

BANANA CHIPS 1. Introduction

Banana chips are gaining wide acceptance in numerous households as a

tasty snack food. Banana chips are prepared from two specific varieties viz.

“Mondan” and “Nendram”. The chips are predominantly consumed by people in

South India. The Nendram variety is fried in coconut oil while the Mondan variety

is fried in refined groundnut or sunflower oil. It is being consumed as an

alternative to potato chips.

2. Market

The major market outlets are the “A” and “ B” class outlets, departmental

stores, super markets and self service counters. The product also has a good

export potential. Although the product is conceptually new, its properties as a

ready to eat snack food are known among housewives.

3. Packaging

The processed product is packed in laminated polyester-poly pouches.

The product is packed in measures of 50 grams and 100 grams.


• The plant will be in operation for two shifts a day with each shift of 8 hours

duration.

• The plant will operate to a capacity of a raw material (Banana) input of 300

kilograms per shift or 600 kilograms per day. The end product yield will be

200 kilograms of chips per day.

• The estimated production per day is therefore 200 kilograms.

• The total production per month will be 5 M.T while the annual production is

estimated at 60 M.T


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5. Sales revenue

• The ex-factory selling price will be Rs. 130 per kilogram thereby yielding a

sales revenue of Rs. 78.00 lakhs on full capacity utilization.


The raw banana is first washed thoroughly to remove any adhering dirt or

sand. The skin is peeled manually and the fruit is sliced with slice thickness

ranging from 1.8 mm to 2.5 mm. The slices are dipped into a blanching tank to

remove surface starches and prevent browning at the time of frying. The slices

are subjected to centrifugal spinning in the spinner whereby excess moisture is

removed. The slices are fried in medium hot oil to give golden brown chips. The

excess oil from the chips is drained and the chips dusted with salt and spices in

the coating pan before being packed. The product is flushed with nitrogen gas in

the pouch so as to prevent development of rancidity.


• The product shall conform to standards laid down under the Bureau of Indian Standards and the Prevention of Food Adulteration Act.

• Outer residual skin - not exceeding 10% • Dirt and other suspended extraneous matter - should be absent. • Moisture - 2% maximum • Total ash - 0.4% maximum • Acid insoluble ash - 0.1% maximum • Free fatty acid of oil used - 0.1% • Peroxide value of oil used - nil





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The proposed unit is to be set up in a leased area. The total leased area

is 2700 square feet vide details given below.

Sl Description Sq. feet 1 Processing area 1000 2 Washing area 400 3 Raw material store 100 4 Other ingredients store room 100 5 Finished goods store room 100 6 Packaging material store room 100 7 Quality control laboratory 200 8 Office space 200 9 Machinery spares store room 100

10 Miscellaneous space 100 11 Toilet space 100 12 Total 2500

Lease rent – Rs. 8.00 per square foot Total lease rent per month = 20000


Sl Description Rs. lakhs 1 Washing tank 0.200 2 Peeling knives 0.010 3 Slicing machine 0.540 4 Rinsing and spinning machine 0.360 5 Batch frier – 2 nos 0.850 6 Spice coating pan 1.820 7 Sealing machine with inert gas flushing

arrangement 0.510

8 Total 4.290 9 Laboratory equipment 0.600


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12. Project cost Sl Description Rs. lakhs 1 Land On lease 2 Civil works On lease 3 Plant machinery 4.290 4 Laboratory equipment 0.600 5 Transport vehicle – 1 Tata Ace 3.600 6 Pollution control equipment 0.000 7 Energy conservation equipment 0.000 8 Cost of power connection 0.100 9 Cost of electrification 0.100






(Rs. lakhs) 1 Production Manager 1 0.150 2 Production supervisors 2 0.200 3 Skilled workers 2 0.120 4 Unskilled workers 4 0.120 5 Sales staff 1 0.100 6 Administrative staff 1 0.100 7 Van driver 1 0.060 8 Total 12 0.850

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(kgs) Rate / kg

(Rs) Value

(Rs. lakhs) 1 Raw banana 15000 12.00 1.800

2 Edible oil 1200 80.00 0.960

3 Salt 80 7.00 0.006

4 Spices 20 100.00 0.020



Value (Rs. lakhs)

1 Primary packaging material – pouches for chips

20000 nos 2.00 0.400

2 Cartons and straps 1350 20 0.270



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15. Financial analysis Sl Description Rs. lakhs 1 Total recurring cost per year 67.188 2 Depreciation on land and building 0.000 3 Depreciation on machinery and vehicle 0.850 4 Depreciation on furnaces 0.000 5 Depreciation on moulds and fixtures 0.010 6 Depreciation on office equipment 0.100 7 Interest on long term loan @ 12% 1.407 8 Interest on short term borrowings@ 12% 0.553 9 Total cost of production 70.108



Total Rs. lakhs

1 Banana chips

60000 kgs 130 78.00



List of machinery suppliers for banana chips 1. Hari Om Industries; Dhebar Road South, Atika Industrial Area, Street No. 3,

Near Jaydev Foundry, Rajkot 360002, Gujarat.; Tel: 0281 - 2363620; Fax: 0281 - 2371745.

2. Kanaka Lakshmi Machine Works, C-4, Industrial Estate, 100 feet road, Vijayawada. 520007, Andhra Pradesh. Tel: 0866-2555458; Fax: 0866- 2554134

3. Geeta Food Engineering, Plot No. C - 7 / 1, TTC Industrial Area, Pawana MIDC, Thane - Belapur Road, Behind Savita Chemicals, Navi Mumbai 400705. Maharashtra.; Tel: 022 - 56101973; Fax: 022 - 55906450

1

BISCUITS 1. Introduction

Biscuits are the most commonly consumed bakery products. The market

leaders for the product include Britannia, Parle, True, Real, Bakemans, Dukes

and a large number of national and local brands. There exists a lot of potential

for manufacture and sale of biscuits and value added products such as high

protein biscuits using vegetable protein isolates and concentrates or

hydrolysates; chocolate biscuits with the incorporation of chocolate mass;

biscuits with nuts and raisins etc.

2. Market

The product finds placement in all “A”, “B” and “C” class outlets, self

service, departmental stores and supermarkets. In addition biscuits from India

are exported to the neighbouring countries and the Gulf.

3. Packaging

Biscuits are best packed in metallized polyester-poly films. Alternatively a

BOPP laminate BOPP film would also be suited. They an be packed in weights

of 25, 50, 75, 100 150, 200 and 300 grams and thereafter in multiples of 100

grams.


• The plant operates to three shifts a day with each shift of eight hours

duration.

• The time period required for achieving full capacity utilization is three years.

• The plant will operate to a capacity of raw material (maida) input of 150

kilograms per hour or 3 M.T per day. The end product yield will be 2.5 metric

tonnes per day. The estimated production per annum of 300 working days will

be 750 tonnes of biscuits.

5. Sales revenue

• Considering the glucose variety as an example, the ex-factory price will be

Rs. 62.00 per kilogram thereby yielding a sales revenue of Rs. 465 lakhs on

full capacity utilization.

2


The ingredients consisting of refined wheat flour, sugar, liquid glucose,

hydrogenated fat, skimmed milk powder, emulsifiers such as lecithin, ammonium

bi-carbonate, traces of salt and preservatives are mixed in definite proportions

and kneaded into a dough by a mixer. The dough is put into a rotary moulding

machine for cutting biscuit designs. The cut dough traverses on a conveyer belt

through a baking oven at temperatures ranging between 180 and 220 degrees

centigrade. The speed of the belt can be varied for optimum baking and the

maximum time required is two and a half minutes. After baking, the biscuits are

cooled to less than two percent moisture on a cooling conveyer, connected with

the oven. It is then packed and readied for dispatch. The above mentioned

process is typical for glucose biscuits. Protein concentrates from a groundnut or

soya source can be added to the flour in small quantities not exceeding two to

fifteen percent to give high protein biscuits. In the process of manufacture of

salted varieties, liquid glucose and sugar are not added. After kneading,

moulding and baking, the biscuits are sprayed with hot oil, dusted with additional

salt and spices, cooled and packed.


• The ingredients used in the manufacture of biscuits should strictly conform to

standards laid down under the Prevention of Food Adulteration Act.

• Moisture content - maximum 2 percent.

• Acid insoluble ash - maximum 0.1 percent.

• Acidity of extracted fat as oleic acid - maximum 1.5 percent.

• The product should be free from coliforms, salmonella and streptococci

bacteria.





3


The proposed unit is to be set up in a leased area.

Sl Description Sq. feet 1 Processing area 3000 2 Raw material store for maida 500 3 Sugar storage room 200 4 Vanaspathi storage room 200 4 Other ingredients store room 400 5 Finished goods store room 500 6 Laboratory 200 7 Office space 300 8 Machinery spares room 200 9 Toilet space 200


Lease rentals – Rs. 5.00 per square foot

Total rent per month – Rs. 30000.

Lease advance – Rs. 2.00 lakhs


Sl Description Rs. lakhs 1 Flour sifter 2 Flour kneader 3 Molding unit 4 Baking oven 5 Cooling unit 6 Stacking unit 7 Oil spraying unit 8 Wrapping unit 9 Creaming unit

10 Weighing scales 11 Machinery spares 12 Total 24.000 13 Laboratory equipment 1.000 14 Grand total machinery and equipment 25.000

4

12. Project cost Sl Description Rs. lakhs 1 Land On lease 2 Civil works Onlease 3 Plant machinery 24.000 4 Laboratory equipment 1.000 5 Transport vehicle 2 LCV 10.000 6 Pollution control equipment 0.000 7 Energy conservation equipment 0.000 8 Cost of power connection 0.800 9 Cost of electrification 1.000







chemist 3 0.300

3 Skilled workers 3 0.180 4 Unskilled workers 30 0.900 5 Administrative staff 3 0.300 6 Security staff 3 0.120 7 Total 43 1.950

5


(kgs) Rate / kg

(Rs) Value

(Rs. lakhs) 1 Maida 50000 15.00 7.500

2 Vanaspathi 12500 65.00 8.125

3 Invert sugar 5000 16.00 0.800

4 Sugar 15500 17.00 2.635

5 Ammonium bi carbonate 335 10.00 0.035

6 Sodium bicarbonate 450 10.00 0.045

7 Skimmed milk powder 2750 120.00 3.300

8 Salt 500 5.00 0.025

9 Colours and flavours 50 200.00 1.000

10 Water 25000 0.025

11 Total raw material 23.490 c. Packaging material requirement per month


Value (Rs. lakhs)


450.kgs 250 1.125



d. Utilities per month Sl Description Rs. lakhs 1 Power 30000 kwh @ Rs. 6.00 per unit 1.800 2 Water 0.050 3 Boiler fuel 0.000 4 Total utilities 1.850

6




f. Total working capital requirement per month Sl Description Rs. lakhs 1 Salaries and wages 1.950 2 Raw material and packaging material 26.865 3 Utilities 1.850 4 Contingent expenses 5.538 5 Total 36.203



7


Sl Description Rs. lakhs 1 Total recurring cost per year 434.436 2 Depreciation on land and building 0.000 3 Depreciation on machinery and vehicles 3.600 4 Depreciation on furnaces 0.000 5 Depreciation on moulds and fixtures 0.100 6 Depreciation on office equipment 0.100 7 Interest on long term loan @ 12% 4.348 8 Interest on short term borrowings@ 12% 3.480 9 Total cost of production 446.064



Total Rs. lakhs

1 Biscuits 750,000 kgs 62 465 17. Viability analysis


List of machinery suppliers for biscuits 1. Nagpal Brothers; C-127, Mayapuri Industrial Area Phase - II, (Opositte State

Bank of India), New Delhi. 110064; Tel: 011 - 28117631; 011 – 28116407; Fax: 011 - 28116884

2. Gurunanak Engineering Corporation, No. 2-3-685/5, Amberpet, Hyderabad. 500013; Tel: 040 – 27408249; 040 – 27406978

3. Mangal Engineering Works, Factory Area, Patiala 147001, Punjab. Tel: 0175 - 2364702; Fax: 0175 – 2360652

4. Mangal Machines Private Limited, Factory Area, Patiala 147001, Punjab. Tel: 0175 – 2360180; 0175 – 2355486; ; Fax: 0175 – 2360652

5. Om Engineering Works, 222, Sector 6, Panchkula, Haryana 134109; Tel: 0172 - 2578525; Fax: 0172 - 2585850

1

BETEL NUTS 1. Introduction

Betel nuts are a commonly consumed commodity among people. For

many it is habit forming as it stimulates the nervous system while for many

others it is a pastime pleasure. Wide varieties of the product exist in the market.

The most prominent ones include an ad mixture of betelnut and other ingredients

like clove, menthol, catacheu, cardamom and other condiments, while others

contain tobacco as an added ingredient. Some manufacturers add saccharin as

a sweetening agent but it leaves a very unpleasant taste in the mouth.

2. Market


also finds placement in self service counters and departmental stores. Many “C”

class outlets and wayside shops also sell the product.

3. Packaging

Betel Nuts are packed in 50 grams and 100 grams pouches. Single use

sachets containing 5 grams of the product are also available.



• The production capacity is estimated at 200 kilograms per day.

• The yield of betel nuts will be 5 tonnes per month and that per annum would

be 60 metric tonnes.


5. Sales revenue

• With an ex-factory selling price at Rs. 400.00 per kilogram and with an unit

packaging of 100 grams, the total annual sales revenue on full capacity

utilisation would yield Rs. 240.00 lakhs.


For the production of sugar coated betelnuts, the raw nuts are taken and

cut into tiny pieces using a mechanical shredder. They are then soaked in sugar

syrup of 50 degrees brix for 72 hours. The sugar syrup is drained and the nuts

2

are once again soaked in sugar syrup of 70 degrees brix for 24 hours. The

excess sugar solution is drained and the betelnut dried in the drying chamber

and packed. For preparation of mentholated betelnuts, the raw nuts are first

shredded into tiny pieces using the shredder. To the desired quantity of nuts,

refined oil containing a paste of cloves, cardamom, menthol, and other

condiments is added and the mass mixed homogeneously. The mixed

ingredients are allowed to mature for 72 hours before being packed into sachets.



• The oil used should be free from rancidity.

• The oil used shall have a maximum F.F.A level of 0.1%

• The oil used shall be free from peroxides.

• No artificial colouring matter is permitted.





3




Sl Description Sq. feet 1 Processing area – pre preparation 600 2 Raw material store 200 3 Packing material store room 200 4 Finished goods store room 200 5 Laboratory space 100 6 Baby boiler area 200 7 Machinery spares room 100 8 Administration 100 9 Toilet space 200


Lease rent per month – Rs. 5.00 per square foot

Total rental value per month – Rs. 10000


Sl Description Rs. lakhs 1 Stainless steel soaking tanks – 40 nos 1.200 2 Shredder knives – 2 nos 0.010 3 Nut cracker 0.600 4 Form fill and seal packing machine 2.450 5 Packing machine for 2 gram sachets 1.700 6 Tray drier with two trolleys and 48 trays 2.000 7 Total 7.960 8 Laboratory equipment 0.500 9 Grand total machinery and equipment 8.460

4

12. Project cost Sl Description Rs. lakhs 1 Land On lease 2 Civil works On lease 3 Plant machinery 7.960 4 Laboratory equipment 0.500 5 Transport vehicle – Tata Ace 3.600 6 Pollution control equipment 0.000 7 Energy conservation equipment 0.000 8 Cost of power connection 0.100 9 Cost of electrification 0.500







chemist 1 0.080

3 Skilled workers 1 0.060 4 Unskilled workers 3 0.090 5 Packing workers 2 0.060 6 Sales coordinators 2 0.100 7 Vehicle drivers 2 0.080 8 Administrative staff 2 0.120 9 Total 14 0.690

5


(kgs) Rate / kg

(Rs) Value

(Rs. lakhs) 1 Arecanut 4600 240.00 11.040

2 Sugar 400 17.00 0.068

3 Orange oil 5 500.00 0.025

4 Condiments and spices 300 300.00 0.900

5 Refined oil 500 80.00 0.400



Value (Rs. lakhs)


500 kgs 200 1.000




6







7

15. Financial analysis Sl Description Rs. lakhs 1 Total recurring cost per year 222.216 2 Depreciation on land and building 0.000 3 Depreciation on machinery and vehicles 1.200 4 Depreciation on furnaces 0.000 5 Depreciation on moulds and fixtures 0.020 6 Depreciation on office equipment 0.100 7 Interest on long term loan @ 12% 2.194 8 Interest on short term borrowings@ 12% 1.584 9 Total cost of production 227.314



Total Rs. lakhs

1 Betelnuts 60000 kgs 400 240.00 17. Viability analysis


List of machinery suppliers for betel nuts Sri Valsa Engineering Works, 36, Nanda Nagar, Singanallur, Coimbatore 641005. Tamil Nadu.; Tel: 0422 - 2574268; Fax: 0422 - 2574268

1

BREAD AND BUNS 1. Introduction

Bread and Buns are a commodity consumed by many people daily at

breakfast or at snack times. They have become a staple food being very

convenient to use without any processing formalities. They are liked by one and

all because of their sweet taste and soft texture appealing to the palate. They are

also a very convenient food during travel and for convalescing people. Because

of their versatile nature, the acceptability is very common.

2. Market

The major market outlets are the “ A” and “B” class outlets. The product

also finds placement in self service counters and departmental stores. Some “C”

class outlets also stock the product. All bakery outlets manufacture and sell

bread and buns.

3. Packaging

Bread is packed in poly propylene wrappers in weights of 200 grams and

multiples of 100 grams. Buns normally weigh 100 grams.



• The plant operates to a production capacity of 1000 loaves of bread each

weighing 400 grams and 1000 buns each weighing 100 grams.


5. Sales revenue

• The ex-factory selling price of bread will be Rs. 14.00 per loaf and that of bun

at Rs. 3.50 per piece.

• The total sales revenue will be Rs. 52.50 lakhs on full capacity utilization and

300 working days in a year.

2


The required quantity of maida is first passed through the sieve to remove

any impurities present. It is then taken to the kneader, where it is mixed with the

desired quantities of water, sugar, salt, vanaspathi and yeast. After kneading, the

dough is cut into the required weights and placed in the proofing pans. The

dough is allowed to ferment at room temperature for 2 to 3 hours when it rises in

the pan. It is then baked in the oven at a set temperature of 180 degrees

centigrade. After baking, the bread is removed, cooled, sliced and wrapped in

poly propylene sheets before dispatch.


Maida

The maida used should have been extracted from hard wheat to get a

good bread volume. The specifications of maida to be used are:

Sl Description Value

1 Moisture Maximum 13.0%

2 Mold and fungal growth Absent

3 Ash Maximum 1.0%

4 Acid insoluble ash Maximum 0.1%

5 Gluten Minimum 7.5%

6 Alcoholic acidity Maximum 0.12% as sulphuric acid

7 Total plate count Maximum 30,000 per gram

8 Coliforms Absent

9 Salmonella Absent

10 Streptococci Absent

11 Insect infestation Absent

12 Rodent excreta Absent

13 Hair Absent

3

Vanaspathi

• It shall not contain any harmful colouring, flavouring or any other material

deleterious to health.

• No colour should be added to the vanaspathi unless authorized by the

Government.

• Moisture content - Maximum 0.25%

• Melting point as determined by the capillary slip method - 31 to 41 degrees

centigrade

• Butyro refractometer reading at 40 degrees centigrade - Minimum 40

• Unsaponifiable matter - maximum 2%

• Free fatty acids expressed as oleic acid - Maximum 0.25%

• The product on melting shall be clear in appearance and shall be free from

staleness or rancidity, and pleasant to taste and smell.

• It shall not contain less than 15 I.U. of Vitamin “A” at the time of use.

• No antioxidant synergist, emulsifier, or any other such substance shall be

present except in the case of shortenings wherein it may contain mono and di

glycerides as emulsifying agents.

• Bakery shortenings in use if aerated can contain only nitrogen gas or any

other inert gas to a maximum extent of 12% by volume.





4


The processing area is to be taken up on lease. The area required is 3000

square feet as described below.

Sl Description Sq. feet

1 Processing area 1000 2 Raw material store for maida 400 3 Raw material store for vanaspathi 200 4 Raw material store for other ingredients 200 5 Finished goods store 200 6 Packaging material store 100 7 Finished goods store room 200 8 Laboratory space 200 9 Office space 200

10 Toilet space 200 11 Miscellaneous space 100 12 Total 3000

Lease rent – Rs. 6.00 per square foot

Total rental value per month – Rs. 18,000


Sl Description Rs. lakhs

1 Flour sifter 0.350 2 Dough kneader 0.575 3 Proofing pans 0.300 4 Baking oven 2.000 5 Bread slicer 0.200 6 Bread sealing and wrapping machine 0.150 7 Total 3.575 8 Laboratory equipment 0.500 9 Grand total machinery and equipment 4.075

5

12. Project cost Sl Description Rs. lakhs

1 Land On lease 2 Civil works On lease 3 Plant machinery 3.575 4 Laboratory equipment 0.500 5 Transport vehicle – Tata Ace 3.600 6 Pollution control equipment 0.000 7 Energy conservation equipment 0.000 8 Cost of power connection 0.100 9 Cost of electrification 0.200






(Rs. lakhs) 1 Production Manager 1 0.150 2 Supervisor cum chemist 1 0.100 3 Skilled workers 1 0.060 4 Unskilled workers 2 0.060 5 Packing workers 2 0.060 6 Van driver 1 0.060 7 Administrative staff 1 0.100 8 Total 9 0.590

6


(kgs) Rate / kg

(Rs) Value

(Rs. lakhs) 1 Maida 8750 15.00 1.313

2 Vanaspathi 700 65 0.455

3 Yeast, salt, sugar and preservatives

1125 15.00 0.169

4 Total raw material 10575 1.937

c. Packaging material requirement per month


Value (Rs. lakhs)

1 Primary packaging material – polypropylene wrappers

50,000 nos 0.60 0.300


d. Utilities per month Sl Description Rs. lakhs

1 Power 1500 kwh @ Rs. 6.00 per unit 0.090 2 Water 0.010 3 Boiler fuel 0.000 4 Total utilities 0.100

e. Contingent expenses per month Sl Description Rs. lakhs

1 Rent for processing shed 0.180 2 Postage and stationery 0.010 3 Telephones, fax etc. 0.050 4 Consumable stores 0.020 5 Repairs and maintenance 0.042 6 Local transports, loading and unloading 0.060 7 Advertisement and publicity @ 5% of sales 0.212 8 Insurance 0.010 9 Sales expenses @ 1% of sales 0.043 10 Miscellaneous expenses @ 1% of sales 0.043 11 Trade incentives @ 2% of sales 0.086 12 Taxes @ 4% 0.172 13 Total contingent expenses 0.928

7

f. Total working capital requirement per month Sl Description Rs. lakhs

1 Salaries and wages 0.590 2 Raw material and packaging material 2.237 3 Utilities 0.100 4 Contingent expenses 0.928 5 Total 3.855



1 Total Project Cost 13.575 2 Equity 4.525 3 Debt 9.050 4 Working capital margin money 1.000

15. Financial analysis Sl Description Rs. lakhs

1 Total recurring cost per year 46.260 2 Depreciation on land and building 0.000 3 Depreciation on machinery 0.760 4 Depreciation on furnaces 0.000 5 Depreciation on moulds and fixtures 0.010 6 Depreciation on office equipment 0.100 7 Interest on long term loan @ 12% 1.086 8 Interest on short term borrowings@ 12% 0.343 9 Total cost of production 48.559



Total Rs. lakhs

1 Bread 300,000 loaves

14.00 42.00

2 Buns 300,000 pieces

3.50 10.50

3 Total 52.50

8

17. Viability analysis Sl Description Value

1 Net profit before income tax (Rs. lakhs) 3.941 2 Net profit ratio 7.56% 3 Internal rate of return 24.2% 4 Break even percentage 53% 5 Debt service coverage ratio 2.034

List of machinery suppliers for bread and buns 1. Nagpal Brothers; C-127, Mayapuri Industrial Area Phase - II, (Opposite State

Bank of India), New Delhi. 110064; Tel: 011 - 28117631; Fax: 011 – 28116884

2. Arun Engineering Works, Leach and Webony Compound, 61, Off Haines Road, Worli, Mumbai. 400018. Tel: 022 – 23098629

3. Arun Engineering Works, SF No. 213, Site no. 4, Sitra Kalapatti Road, Near LMW Unit VIII, Kalapatti Post, Coimbatore 641035. Tamil Nadu. Tel: 0422-2665622; 0422-2669849

4. Gurunanak Engineering Corporation, No. 2-3-685/5, Amberpet, Hyderabad. 500013; Tel: 040 – 27408249; 040 – 27406978

5. Mangal Engineering Works, Factory Area, Patiala 147001, Punjab. Tel: 0175 - 2364702; Fax: 0175 – 2360652

6. Mangal Machines Private Limited, Factory Area, Patiala 147001, Punjab. Tel: 0175 – 2360180; 0175 – 2355486; ; Fax: 0175 – 2360652

7. Om Engineering Works, 222, Sector 6, Panchkula, Haryana 134109; Tel: 0172 - 2578525; Fax: 0172 - 2585850

1

BUBBLE GUM 1. Introduction

Bubble gum or chewing gum is a favourite pastime chewee among

children and youth. Children like the product because of its minty or fruity flavour

which rolls constantly in the tongue. The youth prefer it as it is habit forming and

as well as a mouth freshner. Moreover, the manufacturers of these products

provide incentives for sale of this product by providing stickers or labels

pertaining to sports, film personalities and events or general awareness which

tempts the children to purchase the product.

2. Market

The major market outlets are the “ B” and “C” class outlets. The market is

oriented towards children and youth who buy the product as a pastime fun

chewee. The market though highly competitive is good and depends upon the

manufacturer’s promotional strategies to reach the product to the target clients.

3. Packaging

The processed product is packed in laminated paper wrappers. Each

bubble gum weighs 5 grams.


• The plant will be in operation for three shifts a day with each shift of 8 hours

duration.

• The plant operates to a production capacity of 25 kilograms per hour.

• The estimated production per day is 600 kilograms.


estimated at 180 M.T


5. Sales revenue

• The ex-factory selling price will be Rs. 0.65 per piece of 5 grams with an MRP

of Re.1.00. A carton of 200 pieces will weigh one kilogram and will cost Rs.

130 inclusive of taxes. The estimated annual sales revenue will be Rs. 234

lakhs.

2


Sugar is ground very fine in the grinder. It is then mixed with the required

quantities of edible gum, water, flavours, emulsifiers and then extruded in the

extruder. The resulting product emerges in the form of strips which is cut to

desired lengths and wrapped in the wax paper by the wrapping machine. The

product passes through a cooling tunnel wherein the product acquires a rigid

texture. The strips are then covered with a paper wrapper and then packed in

cartons for dispatch.


Sl Description Value 1 Edible gums Minimum 12.5% by weight 2 Moisture Maximum 3.5% by weight 3 Sulphated ash Maximum 9.5% by weight 4 Acid insoluble ash Maximum 2.0% by weight 5 Reducing sugars as dextrose Minimum 4.5% by weight 6 Total plate count Maximum 30,000 per gram 7 Coliforms Absent 8 Streptococci Absent 9 Salmonella Absent





3




Sl Description Sq. feet 1 Processing area 1600 2 Raw material store 100 3 Other ingredients store room 100 4 Finished goods store room 200 5 Packaging material store room 100 6 Laboratory 200 7 Office space 200 8 Machinery spares store room 200 9 Toilet space 200


Lease rentals – Rs. 8.00 per square foot Total rent per month – Rs. 24000 Lease advance – Rs. 150000


Sl Description Rs. lakhs 1 Sugar grinder with motor 0.400 2 Stainless steel sigma mixer 1.650 3 Gum extruder 1.850 4 Cooling conveyer 2.000 5 Cut and wrap machine 5.000 6 Total 10.900 7 Laboratory equipment 0.600 8 Grand total machinery and equipment 11.500

4


1 Land On lease 2 Civil works On lease 3 Plant machinery 10.900 4 Laboratory equipment 0.600 5 Transport vehicle (1 Tata Ace) 3.600 6 Pollution control equipment 0.000 7 Energy conservation equipment 0.000 8 Cost of power connection 0.500 9 Cost of electrification 0.500







chemist 3 0.300

3 Skilled workers 6 0.360 4 Unskilled workers 6 0.180 5 Administration staff 1 0.100 6 Sales staff 1 0.100 7 Van driver 1 0.060 8 Total 19 1.250

5

b. Raw material requirement per month


Rate / kg (Rs)

Value (Rs. lakhs)

1 Sugar 3000 17.00 0.510

2 Edible gums 750 120.00 0.900

3 Edible starches 11000 12.00 1.320

4 Fat 150 60.00 0.090

5 Emulsifiers 150 35.00 0.053



Value (Rs. lakhs)

1 Wax coated laminated paper

2.473

2 Wrapper 3.000





6



10 Miscellaneous expenses @ 1% of sales 0.195 11 Trade incentives @ 2% of sales 0.390 12 Taxes @ 12.5% 2.437 13 Total contingent expenses 6.759





7

15. Financial analysis Sl Description Rs. lakhs

1 Total recurring cost per year 213.660 2 Depreciation on land and building 0.000 3 Depreciation on machinery and vehicle 1.760 4 Depreciation on furnaces 0.000 5 Depreciation on moulds and fixtures 0.010 6 Depreciation on office equipment 0.050 7 Interest on long term loan @ 12% 2.692 8 Interest on short term borrowings@ 12% 1.396 9 Total cost of production 219.568



Total Rs. lakhs

1 Bubble gum 180,000 kgs 130 234.00 17. Viability analysis Sl Description Value


List of machinery suppliers for bubble gum 1. Bombay Industrial Engineers, 13, Crystal Apartments, Gulmohar Cross Road,

11, JVPD, Mumbai. 400049.; Tel: 022 – 26232810, 26201914; Fax: 022 – 26201914

2. Labh Group of Companies, 403-405, Time Square, Near Pariseema Complex, Ahmedabad 380006, Tel: 079-26569261,26442897, 30070400

3. Paresh Engineering Company, 74 / B, Sanjay Building No. 5, Mittal Industrial Estate, M. Vasanji Road, Marol Naka, Andheri East, Mumbai. 400059. ; Tel: 022 - 28501794; Fax: 022 - 28509193

1

CULTIVATION OF BUTTON MUSHROOMS (TINY SCALE)

1. Introduction

Button mushrooms are an edible non toxic fungus. They are considered a

delicacy in the continental variety of dishes. They make good ingredients in

soups and substitutes for chicken meat. They are cooked with vegetables or

meat or cooked and consumed per se. The mushrooms have a good demand in

urban towns and cities and in all restaurants serving Pizzas, Chinese and

Continental dishes. The mushroom soup in particular is very popular.

2. Market

The major market outlets are the “ A” class stores in major towns and

cities. Button mushrooms in frozen state are accepted in all restaurants

preparing Chinese, Continental and Western dishes. Fast food restaurants and

Pizza makers also buy mushrooms.

3. Packaging

Button mushrooms are packed in polypropylene bags.



• The production capacity is estimated at cultivating 25 kilograms of the

mushroom per day.

• The yield of mushrooms will be between 7.5 tonnes to 10.0 tonnes per

annum.


5. Sales revenue

• The ex-factory selling price of the mushroom is Rs. 120 per kilogram thereby

yielding a sales revenue of Rs. 12 lakhs on full capacity utilization.


Under the cultivation conditions, the spawn is grown on the compost under

regulated temperatures ranging between 16 to 20 degrees centigrade and a

relative humidity of 60%. The culture is inoculated on paddy or wheat straw

beds. These beds are first sterilized under steam to kill termites, beetles, insects

2

and bacteria. The straw is later mixed with some amount of compost and urea

before being inoculated. Fresh mushrooms on harvesting are frozen immediately

to temperatures less than zero degrees centigrade. Lower temperatures prevent

wilting, browning of colour, and retain freshness in the product. On freezing, they

are packed in polypropylene pouches.


• Protein - 3% minimum on wet weight basis.

• Fat - 0.8% on wet weight basis.

• Minerals - 1.4% on wet weight basis.

• Carbohydrates - 4.3% on wet weight basis.

• Moisture - 88.5%






The proposed unit is to be set up in a leased area in a two-storied building

with 2000 square feet of working space divided equally between the two floors.

The ground floor will house the raw material compost preparation and

pasteurization rooms. The upper floors will house the administrative office,

laboratory, cropping room and cold store room for finished goods. Both the floors

will be provided with adequate sanitation facilities. The lease rentals for the

premises are estimated at Rs. 6000 per month or Rs. 0.72 lakhs per annum.

3


Sl Description Rs. lakhs 1 Mushroom cultivation beds 0.500 2 Air conditioners for cropping room 0.500 3 Autoclaving unit for sterilization 0.350 4 Deep freezer 0.350 5 Weighing scales and miscellaneous items 0.250 6 Total 1.950 7 Laboratory equipment 0.300 8 Grand total machinery and equipment 2.250

12. Project cost Sl Description Rs. lakhs 1 Land On lease 2 Civil works On lease 3 Plant machinery 1.950 4 Laboratory equipment 0.300 5 Transport vehicle ( 1 auto rickshaw) 1.000 6 Pollution control equipment 0.000 7 Energy conservation equipment 0.000 8 Cost of power connection 0.050 9 Cost of electrification 0.150


4





(Rs. lakhs) 1 Manager (female) 1 0.080 2 Production supervisor (female) 1 0.060 3 Skilled workers (female) 1 0.050 4 Unskilled workers (female) 2 0.060 5 Administrative staff (female) 1 0.060 6 Driver 1 0.040 7 Total 7 0.350


(kgs) Rate / kg

(Rs) Value

(Rs. lakhs) 1 Paddy straw 3750 1.50 0.056

2 Rice bran 75 3.00 0.002

3 Urea 80 4.00 0.003

4 Gypsum 200 4.00 0.008

5 Cotton seed meal 100 4.00 0.004

6 Spawn bottles 125 8.00 0.010

7 Pesticides 0.010

8 Total raw material 0.093 9 Handling loss @ 10% 0.009

10 Grand Total 0.102


Rs) Value


material – Poly propylene pouches

3200 nos 1.00 0.032

2 Thermocole boxes 250 nos 20.00 0.050


5




10 Miscellaneous expenses @ 1% of sales 0.010 11 Trade incentives @ 2% of sales 0.020 12 Taxes 0.000 13 Total contingent expenses 0.202


6




Sl Description Rs. lakhs 1 Total recurring cost per year 9.552 2 Depreciation on land and building 0.000 3 Depreciation on machinery and vehicle 0.325 4 Depreciation on furnaces 0.000 5 Depreciation on moulds and fixtures 0.010 6 Depreciation on office equipment 0.050 7 Interest on long term loan @ 14% 0.603 8 Interest on short term borrowings@ 14% 0.076 9 Total cost of production 10.616



Total Rs. lakhs

1 Button mushrooms

10000 kgs 120 12.00


Cultivation of button mushrooms

Machinery not required. Small equipments to be procured locally

1

CASHEW APPLE PROCESSING 1. Introduction

Cashew apple is a fruit that is normally used for brewing alcoholic

beverages after separation of the nut. However, it can be processed to produce

titbits in sugar syrup, jams and pulp in honey. The project aims to produce

cashew apple bits in sugar syrup, cashew apple jam, and pulp in honey on a

small scale.

2. Market


also finds placement in self service counters and departmental stores.

3. Packaging

Cashew apple products are packed in weights of 200 grams, 400 grams

and 500 grams and multiples thereof.



• It would process cashew apples to produce 500 kilograms of the final product

with the following product mix.

a) Cashew apple in sugar syrup - 200 kilograms

b) Cashew apple jam - 200 kilograms

c) Cashew apple pulp in honey -100 kilograms

• The total quantity of products produced per month and annum are as follows:

Total production in kgs per (month) (annum) I. Cashew apple in sugar syrup 5000 60000 II. Cashew apple jam 5000 60000 III. Cashew apple pulp in honey 2500 30000 • Total 12500 150000


5. Sales revenue

• With an ex-factory selling price at Rs. 40 per bottle of 500 grams of each

variety, or Rs. 80 per kilogram, the total sales realisation will be Rs. 120 lakhs

on full capacity utilization.

2


The cashew apple received from farms must first be immediately stored

under refrigerated conditions failing which they would wilt. From the storage

chamber, they are taken for processing as and when required.

Three types of products are proposed to be produced and they include:

• Cashew apple in sugar syrup

• Cashew apple jam

• Cashew apple in honey

Cashew apple in sugar syrup

The fruit is washed, cut into cubes and kept separately. In the kettle,

sugar is converted into syrup and boiled to around 75 degrees brix. The cubes

are added to the sugar syrup and boiled for a few minutes. The syrup is cooled

and then transferred into bottles. Each bottle of 500 grams will contain 250

grams of cashew apples In 250 ml of sugar syrup. Necessary preservatives and

colours are added in the kettle at the time of cooking.

Cashew apple jam

The cashew apple after washing is passed through the pulper when the

pulp and juice are extracted. The extracted mass is taken to the kettle where it is

cooked under the influence of jacketed steam for ten minutes.

Sugar is then added in desired quantities and the mass further cooked

with constant stirring till a thick mass is formed with a reading of 65 to 70

degrees brix on the brix meter. After cooking, the required quantities of citric

acid, pectin, flavours and colours are added and the mass stirred thoroughly.

The mass after mixing is emptied into steel containers from where they are

poured into bottles of 400 grams capacity. On cooling the jam sets. The bottle is

capped after placing a foil paper at its top. The bottles are placed in cartons,

strapped and dispatched.

Cashew apple in honey

The cashew apple after washing is passed through the pulper when the

pulp and juice are extracted. The extracted mass is taken to the kettle where it is

cooked under jacketed steam to form a thick mass and almost all the water has

3

evaporated. The steam is switched off and the mass cooled. Honey is then

added to the desired extent and the contents mixed till a homogenous mass is

formed. Finally the desired quantities of powdered cardamom and preservatives

are added, stirred and the final product packed.


Cashew apple in sugar syrup

• The minimum fruit content shall be 45%.

• Mold and fungal growth should be absent.

• The product should be prepared under hygienic conditions and should be

free from coliforms, salmonella, and streptococci species of bacteria.

• It shall be free from fermented odour.

• No artificial sweetening agents are to be used. Only sugar, dextrose, liquid

glucose can be used either singly or in combination.

Cashew apple jam

• The minimum fruit content shall be 55%.

• Mold and fungal growth should be absent.

• The product should be prepared under hygienic conditions and should be

free from coliforms, salmonella, and streptococci species of bacteria.

• It shall be free from fermented odour.

• No artificial sweetening agents are to be used. Only sugar, dextrose, liquid

glucose can be used either singly or in combination.

• It can contain pectin derived from any fruit.

• It can also contain permitted preservatives, colours and emulsifying and

stabilising agents.


Not necessary as there are no pollutants or effluents. However waste

residues obtained after pulping have to be disposed off carefully failing which it

could pollute the surrounding area on fermentation, thereby yielding a foul odour.



4


The proposed unit is to be set up in a leased area. The total area required is 1800 square feet as described below:

Sl Description Sq. feet 1 Processing area 500 2 Raw material store 200 3 Washing area 200 4 Packing material store room 100 5 Finished goods store room 200 6 Laboratory space 100 7 Machinery spares room 100 8 Administrative office 100 9 Toilet space 200


Lease rentals – Rs. 6.00 per square foot Total rent per month – Rs. 10800 Lease advance – Rs. 75000


Sl Description Rs. lakhs 1 Fruit washing tank 0.047 2 Super pulper 0.353 3 Autoclave 0.330 4 Steam jacketed cooking kettle 0.373 5 Stainless steel stirrer 0.121 6 Bottle washing machine 0.206 7 Working tools 0.100 8 Baby boiler and accessories 1.250 9 Water softener 0.500

10 Stainless steel working tables 0.600 11 Gumming machine 0.060 12 Total 3.940 13 Laboratory equipment 0.500 14 Grand total machinery and equipment 4.440

5

12. Project cost Sl Description Rs. lakhs 1 Land On lease 2 Civil works On lease 3 Plant machinery 3.940 4 Laboratory equipment 0.600 5 Transport vehicle (1 Tata Ace) 3.600 6 Pollution control equipment 0.000 7 Energy conservation equipment 0.000 8 Cost of power connection 0.100 9 Cost of electrification 0.100







chemist 1 0.100

3 Skilled workers 2 0.120 4 Unskilled workers 4 0.120 5 Packing workers 2 0.060 6 Van driver 1 0.060 7 Administrative staff 1 0.060 8 Total 12 0.670

6


(kgs) Rate / kg

(Rs) Value

(Rs. lakhs) 1 Cashew apple in sugar syrup

A Cashew apple 7500 2.00 0.015

B Sugar 3200 17.00 0.544

C Citric acid, flavours, preservatives

150 100.00 0.150

D Total 10850 0.709 2 Cashew apple jam A Cashew apple 13200 2.00 0.264

B Sugar 2200 17.00 0.374

C Citric acid, flavours, preservatives

150 100.00 0.150

D Total 15550 0.788 3 Cashew apple pulp in honey A Cashew apple 7000 2.00 0.140

B Sugar 800 17.00 0.136

C Honey 1250 80.00 1.000

D Flavours, preservatives 75 150.00 0.113

E Total 9125 1.389 4 Grand Total Raw Material 35525 2.886

7


(Rs) Value

(Rs. lakhs) 1 Cashew apple in sugar syrup

A Glass bottles 10200 nos 8.00 0.816

B Cartons and straps 1000 nos 20.00 0.200

C Total 1.016 2 Cashew apple jam A Glass bottles 10200 nos 8.00 0.816


C Total 1.016 3 Cashew apple pulp in honey A Glass bottles 5100 nos 8.00 0.408


C Total 0.668 4 Grand Total Packaging

Material 2.700

Grand total Raw + Packaging Material - Rs. 5.586 lakhs


8


Sl Description Rs. lakhs 1 Rent for processing shed 0.108 2 Postage and stationery 0.010 3 Telephones, fax etc. 0.050 4 Consumable stores 0.020 5 Repairs and maintenance 0.036 6 Local transports, loading and unloading 0.100 7 Advertisement and publicity @15% of sales 1.500 8 Insurance 0.018 9 Sales expenses @ 1% of sales 0.100

10 Miscellaneous expenses @ 1% of sales 0.100 11 Trade incentives @ 2% of sales 0.200 12 Taxes @ 4% 0.400

13 Total contingent expenses 2.642




9





Total Rs. lakhs

1 Cashew apple tidbits 60000 kgs 80.00 48.00 2 Cashew apple jam 60000 kgs 80.00 48.00 3 Cashew apple pulp in

honey 30000 kgs 80.00 24.00

4 Total 150000 kgs 120.00 17. Viability analysis


List of machinery suppliers List of machinery suppliers for Amla syrup 1. Geeta Food Engineering, Plot No. C - 7 / 1, TTC Industrial Area, Pawana


1

CASHEW SNACKS 1. Introduction

Cashew kernels find a variety of uses in the daily cuisine of every Indian

household. However, the processed kernels are consumed as snacks, offered at

parties, and served on flights by airlines. They are also consumed in large

quantities during journeys, in theaters, and at home while watching the television.

The salted and peppered varieties offer a tasty combination with almost any

beverage.

2. Market

Cashew snacks have a good domestic and export market potential.

Roasted and salted cashews; paprika dusted cashews; pepper dusted cashews

and honey coated cashews are the most sought after both in the domestic and

export markets.

3. Packaging

The processed cashew is packed in metallized polyester-poly pouches in

the presence of an inert gas viz: nitrogen. The quantity packed per pouch is 50

grams. The pouches are placed in paperboard cartons and strapped prior to

dispatch.



• Estimated production per day - 250 kilograms.

• The total production per month will be 6.250 M.T while the annual production

is estimated at 75 M.T


5. Sales revenue

• The ex-factory selling price will be Rs. 25 per pouch of 50 grams or Rs. 500

per kilogram inclusive of taxes. The estimated annual sales revenue will be

Rs. 375 lakhs.

2


Cashew kernels are graded and roasted in a thermostat frier using

vegetable oil as the frying medium. They are then dusted with spices, salt etc

and packed automatically with the pouch flushed with nitrogen.


• Moisture content of roasted cashews - 2% maximum.

• Acidity of extracted fat - 1% maximum.

• Free fatty acids as oleic acid of oil used - 0.1% maximum.

• Mold and fungal growth should be absent. It should also test negative for

coliforms, salmonella and streptococci.

• Total plate count - 30,000 per gram - maximum.








Sl Description Sq. feet 1 Processing area 1500 2 Raw material store 400 3 Other ingredients storage room 100 4 Finished goods storage room 200 5 Packaging material storage room 200 6 Laboratory 100 7 Office space 100 8 Machinery spares room 100 9 Toilet space 200


Lease rent – Rs. 8.00 per square foot ; Total rent per month – Rs. 24000

Lease advance – Rs. 100000

3


Sl Description Rs. lakhs 1 Tray drier and accessories 1.600 2 Frying pans – 2 nos 0.560 3 Coating pan – Stainless steel 1.200 4 Form fill weighing and sealing machine 3.000 5 Weighing scales – bulk and fine 0.300 6 Total 6.660 7 Laboratory equipment 0.500 8 Grand total machinery and equipment 7.160

12. Project cost Sl Description Rs. lakhs 1 Land On lease 2 Civil works On lease 3 Plant machinery 6.660 4 Laboratory equipment 0.500 5 Transport vehicle (Tata Ace) 3.760 6 Pollution control equipment 0.000 7 Energy conservation equipment 0.000 8 Cost of power connection 0.200 9 Cost of electrification 0.500


4






chemist 1 0.100

3 Skilled workers 2 0.120 4 Unskilled workers 4 0.120 5 Packing workers 2 0.040 6 Administrative staff 1 0.100 7 Sales coordinator 1 0.100 8 Van driver 1 0.060 9 Total 13 0.790 b. Raw material requirement per month


Rate / kg (Rs)

Value (Rs. lakhs)

1 Cashew kernels 320 grade

6250 300.00 18.750

2 Vegetable oils 125 75 0.088

3 Salt and spices 150 30.00 0.045



Value (Rs. lakhs)


417 kgs 300 1.251



5






6







Total Rs. lakhs

1 Cashew snacks

75000 kgs 500.00 375.00



List of machinery suppliers for processing of Cashew snacks (roasted salted cashews) The machinery has to be fabricated locally in stainless steel as per drawings.

1

CATTLE FEED 1. Introduction

Cattle feed and poultry feed have a great demand in the local market

because of the increasing production in milk through milch cattle and increased

production and consumption of eggs through poults. With increased costs of

transportation, local sales of feeds have an added advantage. Cattle rearers are

increasingly becoming aware that scientifically produced and nutritionally

balanced cattle feed will give better yields in terms of milk and milk products

even though the cost may be marginally higher than the traditional feeds of grass

and hay. Similarly poults that are fed a scientifically manufactured diet are less

likely to contract diseases of different viruses and bacteria. The quality and

quantity of eggs is also increased considerably.

2. Market

The major market outlets are the cattle sheds and poultry farms in rural

and urban areas.

3. Packaging

Cattle feed is packed in gunny bags of 50 kilograms capacity.



• The production capacity is estimated at 25 metric tonnes per day or 7500

metric tonnes per annum.


5. Sales revenue

• With an ex-factory selling price at Rs. 10000 per metric tonne, the total sales

revenue would be Rs. 750 lakhs on full capacity utilization.


The raw material comprising wheat bran, rice bran, gram husk, deoiled

cakes and mineral mix are fed in the feed elevator in the desired proportions

and passed through the pulveriser wherein they are ground to the desired mesh

size. The ground material is pneumatically conveyed to the storage bin through a

2

cyclone and air lock. The material from the bin passes into the mixer where it is

mixed uniformly. Molasses is dosed in the desired quantities. The material after

mixing is discharged into the hopper below the mixer. From the hopper a bucket

elevator conveys the material to the tempering screw where open steam is

provided to soften the mass before pelletisation. The material from the tempering

screw passes into the pelletiser where it is formed by means of a screw and

then passes out of the die of desired diameter. The pellets emerging out of the

pelletiser are hot and are cooled in the pellet cooler where they harden slightly

and do not crumble on storage or transit. The cooled pellets are screened by

passing over a vibratory screen when the unpelletised material is removed. The

screened pellets are then bagged in gunny bags and stored prior to dispatch.


• Moisture - maximum - 12%

• Mold and fungal growth - absent.


Pollution control measures are necessary. The dust originating after

pelletisation should be collected properly and not allowed to be circulated in the

atmosphere. Molasses should not be allowed to ferment as it could become toxic

and pollute the feed ingredients.



3


The land required is one acre - Rs. 4.00 lakhs.

The constructed area required is 18000 square feet plus 500 cubic feet of

molasses tank as depicted in the following table:

Sl Description Sq. feet 1 Processing area 6000 2 Raw material store 5000 3 Finished goods area 4500 4 Molasses tank (cubic feet) 500 5 Administrative office 500 6 Laboratory 500 7 Security office 100 8 Packaging material store room 400 9 Machinery spares store 200

10 Boiler area 500 11 Toilet space 200 12 Miscellaneous space 100 13 Total 18000

At a construction cost of Rs. 750 per square foot, the cost of civil works amounts

to Rs. 135 lakhs. In addition the cost of construction of molasses tank would be

Rs. 2 lakh. Therefore the total cost of civil works is anticipated at Rs. 137 lakhs.

The total cost of land and civil works amounts to Rs. 141 lakhs.


• Feed elevator in mild steel construction with bucket link chain discharge chute complete with drive mechanism, comprising of 2 HP motor, gear box, chain wheel and chain. The elevator is also provided with a rotating magnetic drum at the boot of the elevator for separation of iron particles from the incoming raw material - one unit.

• Pulveriser mill complete with “V” Pulleys, “V” belts, cyclone collector and ducting, driven by a 7.5HP motor - one unit

• Suction fan having a capacity of sucking air at 1000 cubic meters per hour at normal atmospheric pressure and to convey pneumatically the ground material from the pulveriser mill to the cyclone collector. The system is provided with a “V” pulley, “V” belt, chain guard, tensioning device and driven by a 3HP motor - one unit.

4

• A rotary valve between cyclone and collection bin. • A storage bin made of mild steel construction of 500 litres capacity filled with

a rotary valve (air lock) for discharge into a horizontal mixer - one unit. • Horizontal mixer for mixing thoroughly all ingredients with facility of dosing

molasses by a metering pumping mechanism. The mixer made of mild steel is driven by a 7.5HP motor with a set of sprocket and wheels. - one unit.

• Platform and ladder for mixer and support for suction fan - one unit. • Dust collector with bags - one unit • Portable platform loose weighing scale of 300 kilograms capacity - one unit. • Receiving hopper below the horizontal mixer with 2 way chutes - one unit. • Elevator similar in item no.1 made of mild steel construction with bucket link

chain driven by a 2HP motor, gear box, chain wheel and chain. The elevator lifts the material from the receiving hopper and feeds the same to the tempering screw conveyer - one unit.

• Tempering screw conveyer for tempering the feed with open steam in order to soften the material for pelletisation and to convey the feed to the pelletiser. The screw conveyer is driven by a 25 HP motor and a reduction gear box - one unit.

• Pelletiser for converting the feed material received from the above screw conveyer into cylindrical pellets. The machine consists of special heat treated die plate and pressing rolls mounted on centrally located heavy vertical shaft driven by special worm gear and a 40 HP motor and complete with “V” Pulleys and “V” belts - 1 unit.

• Pellet cooler to cool the pellets coming out of the pelletiser complete with 2 HP motor for conveyer, blower, cyclone, and a 7.5HP motor for the blower - 1 unit.

• Screener comprising of a vibratory screen mesh for removal of unpelletised material before bagging. The system complete with a 5HP motor and necessary driving mechanism - 1 unit.

• Two way chute for bagging - 1 unit • Weighing scale - 100 kilograms - 2 nos. • Service tank for molasses for holding 300 kilograms of molasses with open

steaming arrangement. - 1 no. • Storage tank for molasses of 500 cubic feet capacity. • Molasses pump with 2 HP motor - 1 unit. • Electrical control panel consisting of starters, push buttons, intermediary

wiring and earthing material for connecting the equipment supplied. • Mild steel structure for supporting the equipment.

5

• Boiler and accessories for providing live steam into pelletiser and for heating molasses.

• Total cost of equipment inclusive of taxes and freight - 40.832 lakhs. • Testing equipment comprising hot air oven, ashing oven, precision weighing

scales, hot plate, soxhlet extractor, kjeldhal apparatus and distillation assembly, vortex stirrer, glassware, chemicals, distilled water apparatus - Rs. 1 lakh.

• Total cost of machinery and equipment - Rs. 41.832 lakhs

12. Project cost Sl Description Rs. lakhs 1 Land 4.000 2 Civil works 137.000 3 Plant machinery 40.832 4 Laboratory equipment 1.000 5 Transport vehicle (2 LCV) 14.000 6 Pollution control equipment 0.000 7 Energy conservation equipment 0.000 8 Cost of power connection 1.500 9 Cost of electrification 1.500


6





(Rs. lakhs) 1 Production Manager 1 0.150 2 Maintenance mechanic 1 0.100 3 Production supervisors 3 0.300 4 Laboratory chemist 1 0.100 5 Skilled workers 9 0.540 6 Unskilled workers 18 0.540 7 Packing workers 9 0.270 8 Van drivers 2 0.120 9 Administrative staff 3 0.300 10 Sales staff 3 0.300 11 Security staff 3 0.120 12 Total 53 2.840 b. Raw material requirement per month


Rate / kg (Rs)

Value (Rs. lakhs)

1 Wheat bran 206000 5.00 10.300

2 Rice bran 210000 5.00 10.500

3 Gram husk 50000 5.00 2.500

4 Deoiled cake 150000 9.00 13.500

5 Molasses 6000 21.00 1.260

6 Mineral mix 1000 12.00 0.120



Rs) Value

(Rs. lakhs) 1 Gunny bags 50 kg

capacity 13000 8.00 1.040

2 Total 1.040

Total raw + packaging material per month – Rs. 39.220 lakhs.

7









8





Total Rs. lakhs

1 Cattle feed 7500,000 kgs 10.00 750.00 17. Viability analysis


List of machinery suppliers for Cattle feed 1. Trumatic Engineers, 91 / 18, GIDC First Phase, Vatva, Ahmedabad. 382445,

Gujarat State; Tel: 079 – 25830353, 25892914 2. Do Well Oil Plants Private Limited, 306, Manish Commercial Centre, Dr. A,B.

Road, Worli, Mumbai. 400072.; Tel: 022 – 24224056, 24226350

1

CHAAT MASALAS 1. Introduction

Chaat Masala mixes comprise a mixture of spices in various

combinations in a powdered form. The typical taste of chaat comes with the

presence of red crystal salt or Lahori Namak. They are used in everyday

preparations with vegetables, pizzas, fruit juices, gol guppas etc,

2. Market



export potential.

3. Packaging

The processed product is packed in laminated polyester-poly pouches.

The product is packed in measures of 50 grams and 100 grams.



• The plant will operate to a capacity of a raw material input of 50 kilograms

per hour or 500 kilograms per day.

• The estimated production per month is therefore 12.50 MT.

• The total production per annum production is estimated at 150 M.T


5. Sales revenue


sales revenue of Rs. 180 lakhs on full capacity utilisation.


Individual spices are first cleaned to remove chaff and stones by passing

through sifter and destoner. They are roasted individually in definite proportions

in slow to moderate heat, cooled and ground to a fine powder, mixed and

packed. For example, a typical chaat masala has the following combination: non

pungent red chilli powder 42%; jeera - 22%; pepper -20%; namak - 4%; sugar

10% and mint - 2%.

2


Spices. • Moisture - 12% maximum • Total ash - 7% maximum • Acid insoluble ash - 1.5% maximum • Volatile oils - 3% maximum • Extraneous matter - not to exceed 3%. • Extraneous colouring matter - should be absent. Masala powder • Moisture - 14% maximum • Volatile oils - 0.25% maximum • Non volatile ether extract - 7.5% maximum • Edible common salt - 4% maximum • Acid insoluble ash - 2% maximum • Total ash - 7% maximum • Crude fibre - 15% maximum • Lead - 10 ppm maximum • Extraneous matter - should be absent • Mold and fungal growth - should be absent • Insect infestation - should be absent • Colouring matter - should be absent • Maximum percentage of starches and salt permitted - 15%





3




Sl Description Sq. feet 1 Processing area 1000 2 Raw material store 100 3 Other ingredients storage room 100 4 Finished goods storage room 100 5 Packaging material storage room 100 6 Laboratory 100 7 Office space 200 8 Machinery spares room 100 9 Toilet space 100


Lease rent – Rs. 8.00 per square foot Total rent per month – Rs. 16000 Lease advance – Rs. 100000


Sl Description Rs. lakhs 1 Sifter 0.250 2 Destoner 0.250 3 Hammer mill with accessories such as

blower, cyclone, airlock etc. 1.500

4 Roaster with thermostat 0.250 5 Stainless steel ribbon blender – 25 kg

capacity 0.500

6 Weighing scales – coarse and fine 0.220 7 Packing machine with augur 1.510 8 Total 4.480 9 Laboratory equipment 0.500


4








chemist 1 0.100

3 Skilled workers 1 0.060 4 Unskilled workers 4 0.120 5 Sales Representative 1 0.100 6 Administrative officer 1 0.100 7 Driver 1 0.060 8 Total 10 0.690

5


(kgs) Rate / kg

(Rs) Value

(Rs. lakhs) 1 Spices and salt 12750 60.00 7.650



Value (Rs. lakhs)


500 kgs 250 1.250




6







7





Total Rs. lakhs

1 Chaat Masala 150,000 kgs 120 180.00


List of machinery suppliers for chaat masala 1. Sri Valsa Engineering Works, 36, Nanda Nagar, Singanallur, Coimbatore

641005. Tamil Nadu.; Tel: 0422 - 2574268; Fax: 0422 - 2574268

1

CHICLETS

1. Introduction

Chiclets are small tablets of chewing gum. It is a favourite pastime

chewee among children and youth. Children like the product because of its minty

or fruity flavour which rolls constantly in the tongue. The youth prefer it as it is

habit forming and as well as a mouth freshner. Moreover, the manufacturers of

these products provide incentives for sale of this product by providing stickers or

labels pertaining to sports, film personalities and events or general awareness

which tempts the children to purchase the product.

2. Market

The major market outlets are the “ B” and “C” class outlets. The product

also finds placement in self service counters, departmental stores, fancy stores

and shops stocking confectionery products. The market is oriented towards

children and youth who buy the product as a pastime fun chewee. The market

though highly competitive is good and depends upon the manufacturer’s

promotional strategies to reach the product to the target clients.

3. Packaging

The processed product is packed in laminated paper board cartons. Each

box of chiclets has a net weight of 10 grams.


• The plant will be in operation for three shifts a day with each shift of 8 hours

duration.






2

5. Sales revenue

• The ex-factory selling price will be Rs. 1.20 per box of 10 grams. The MRP

per box shall be Rs. 2.00. A carton of 100 boxes will weigh one kilogram (net

weight) and will cost Rs. 120 inclusive of taxes. The estimated annual sales

revenue will be Rs. 216 lakhs.


Sugar is ground very fine in the grinder. It is then mixed with the required

quantities of edible gum, starches, emulsifiers, and peppermint flavour in the

desired proportions, and made into a dough in the kneading machine. The dough

is drawn into sheets and a roller cuts it into bits of desired size. These chiclets

are fed into the coating pan. Separately, some amount of sugar is dissolved in

water and a thick syrup is made in the kettle. This sugar syrup is coated over the

chiclets. Hot air is blown when the chiclet dries and is polished. They are then

placed in small paper board cartons and further in large boxes before being

strapped and dispatched.


Sl Description Value 1 Edible gums Minimum 14.5% by weight 2 Moisture Maximum 3.5% by weight 3 Sulphated ash Maximum 11.5% by weight 4 Acid insoluble ash Maximum 3.5% by weight 5 Reducing sugars as dextrose Minimum 5.5% by weight 6 Sucrose Minimum 60% by weight 7 Total plate count 30,000 per gram – maximum 8 Coliforms Absent 9 Streptococci Absent 10 Salmonella Absent 8. Pollution control measures




3




Sl Description Sq. feet 1 Processing area 1600 2 Raw material store for sugar 100 3 Raw material store – other ingredients 100 4 Finished goods store room 200 5 Packaging material storage room 100 6 Laboratory 200 7 Office room 200 8 Machinery spares room 200 9 Toilet space 200




Sl Description Rs. lakhs 1 Sugar grinder 0.200 2 Stainless steel sigma mixer 0.850 3 Sheeter and roller cutter 1.400 4 Sugar syrup kettle 0.500 5 Coating and polishing machine 4 nos 3.600 6 Packing machine 3.500 7 Total 10.050 8 Laboratory equipment 0.500 9 Grand total machinery and equipment 10.550

4








chemist 3 0.300

3 Skilled workers 6 0.360 4 Unskilled workers 6 0.180 5 Administrative staff 1 0.100 6 Sales coordinator 1 0.100 7 Van driver 1 0.060 8 Total 19 1.250

5


(kgs) Rate / kg

(Rs) Value

(Rs. lakhs) 1 Sugar 6000 17.00 1.020

2 Edible gums 750 120.00 0.900

3 Edible starches 8000 14.00 1.120

4 Fat 150 60.00 0.090

5 Flavours and colours 30 150.00 0.045

6 Emulsifiers 150 30.00 0.045



Rs) Value


material – laminated paper board cartons

30000 nos 1.50 4.500




6







7





Total Rs. lakhs

1 Chiclets 180,000 kgs 120 216.00 17. Viability analysis


List of machinery suppliers for chiclets 1. Bombay Industrial Engineers, 13, Crystal Apartments, Gulmohar Cross Road,

11, JVPD, Mumbai. 400049.; Tel: 022 – 26232810, 26201914; Fax: 022 – 26201914

2. Labh Group of Companies, 403-405, Time Square, Near Pariseema Complex, Ahmedabad 380006, Tel: 079-26569261,26442897, 30070400

3. Paresh Engineering Company, 74 / B, Sanjay Building No. 5, Mittal Industrial Estate, M. Vasanji Road, Marol Naka, Andheri East, Mumbai. 400059. ; Tel: 022 - 28501794; Fax: 022 - 28509193

1

CHIKKIES 1. Introduction

Chikkies are jaggery enrobed cashews, peanuts and sesame. They are

used as a pastime snack by children and adults as they enjoy the sweet taste. It

is also served during parties and festive occasions. People consume it while

traveling on picnics and therefore the product has a wide market potential.

2. Market


also finds placement in self service counters and departmental stores. Bakeries

sell chikkies. In addition “C” class outlets sell unbranded varieties of chikkies

made by cottage industries or by women at home.

3. Packaging

Chikkies are packed in weights of 100 grams. Polypropylene wrappers or

cellophane wrappers are used.



• The production capacity is estimated at 500 kilograms per shift or 1500

kilograms per day.

• The yield of chikkies will be 37.5 tonnes per month and that per annum would


• The time required for achieving full capacity utilisation is one year.

• Different types of chikkies are made from peanuts, sesame and cashew. The

present project considers use of peanuts as an example. The procedure for

manufacture of sesame and cashew chikkies is the same as that of peanuts.

5. Sales revenue

• With an ex-factory selling price at Rs. 80 per kilogram of peanut chikkies, the

total sales revenue will be Rs. 360 lakhs per annum on full capacity

utilisation.


2

Peanuts are first shelled to remove the outer skin. The kernels are roasted

in a roaster at 120 degrees centigrade to for 30 to 40 minutes till they turn golden

brown. They are removed and cooled. The outer seed coat is removed by

rubbing and the roasted kernels are removed by rubbing.

Separately jaggery is boiled in the kettle till a thick syrup is formed. The

syrup is filtered through a muslin cloth to remove mud, and other dust particles.

The hot syrup is mixed with the roasted kernels in the ratio of 40:60 by

weight respectively and then poured into the trays for drying. The trays are kept

in the trolley of the tray drier and dried in a blast of cold air.

The dried chikki is packed in cellophane paper and put into cartons for

dispatch.


• The product should be completely dry with the moisture content not

exceeding 5%.

• There should be no signs of mold and fungal growth when observed under

the microscope.

• Artificial sweeteners are prohibited from being added.

• Only sugar, jaggery, dextrose, invert sugar, liquid glucose, either singly or in




• It cannot contain any artificial flavours, colour and preservatives.





3




Sl Description Sq. feet 1 Processing area 1500 2 Raw material store 200 3 Packing material store 200 4 Finished goods store 200 5 Laboratory space 200 6 Machinery spares room 100 7 Administrative area 200 8 Toilet space 200 9 Miscellaneous space 200

10 Total 3000 Lease rent – Rs. 6.00 per square foot

Total rent per month – Rs. 18000



Sl Description Rs. lakhs 1 Thermostat controlled roaster for oilseeds 1.000 2 Tray drier with 2 trolleys each and 48 trays

each 3.200

3 Stainless steel working vessels and trays 0.333 4 Jaggery syrup preparation kettles – 2 nos 0.600 5 Electronic weighing scales of different

capacities – 5 nos 0.700

6 Total 5.833 7 Laboratory equipment 0.500


4

12. Project cost Sl Description Rs. lakhs 1 Land On lease 2 Civil works On lease 3 Plant machinery 5.833 4 Laboratory equipment 0.500 5 Transport vehicle ( Tata Ace) 3.760 6 Pollution control equipment 0.000 7 Energy conservation equipment 0.000 8 Cost of power connection 0.100 9 Cost of electrification 0.200







chemist 3 0.300

3 Skilled workers 3 0.180 4 Unskilled workers 12 0.360 5 Packing workers 6 0.120 6 Administrative staff 1 0.100 7 Van driver 1 0.060 8 Sales coordinator 1 0.100 9 Total 28 1.370

5


(kgs) Rate / kg

(Rs) Value

(Rs. lakhs) 1 Peanuts 23625 50.00 11.810

2 Jaggery 13150 18.00 2.367

3 Liquid glucose 2000 18.00 0.360



Value (Rs. lakhs)

1 Primary packaging material – polypropylene pouches

7.5 lakh nos

0.50 3.750




6








7





Total Rs. lakhs

1 Chikkies 450,000 kgs 80 360.00 17. Viability analysis


List of machinery suppliers for chikkies Machinery has to be fabricated to specifications. No ready-made machinery is available.

1

COLD STORAGE 1. Introduction

Fruits and vegetables have a very short shelf life after harvest. In order to

prevent post harvest losses, they have to be processed immediately or stored

under refrigerated conditions. Immediately after harvest, precooling to about 10

degrees centigrade is advantageous. Further cooling and storage at minus 8 to

minus 10 degrees centigrade enhances the shelf life of the product.

2. Market

Cold storage is a facility normally held by an individual to be provided to

users to store their raw materials. The market is therefore specific to users and

not wide as a consumer market.

3. Packaging

Material stored in the cold store is normally in crates.

4. Storage capacity

• The material to be kept under cold storage is received from the farms. It is

stacked and cooled to a temperature of 8 degrees centigrade. The plant will

be in continuous operation for three shifts a day with each shift of 8 hours

duration. The storage capacity of the unit is 500 tones.


5. Rental revenue

• At a rental value of Rs. 100 per ton per day the total sales revenue per

annum would be Rs. 182.500 lakhs on full capacity utilisation.

6. Storage process outline.

The material received from the farms will be weighed and placed in crates

with a customer and material code tag. The gross and net weights of the crate

will also be recorded. Stacking will be in pallets with a supporting frame.





2


Land 1.0 acres - Rs. 2.0 lakhs.

Storage area is 11000 square feet as detailed below.

Sl Description Sq. feet 1 Cold store for fruits and vegetables 8000 2 Administrative office 500 3 Machinery spares store 200 4 Refrigeration room 2000 5 Toilet space 200 6 Miscellaneous space 100 7 Total 11000


Total value of civil works – Rs. 99.00 lakhs

Total cost of land and civil works is Rs. 101.00 lakhs.


Sl Description Rs. lakhs 1 Refrigeration equipment for cooling 250 tons

of fruits and 250 tons of vegetables stored in 5500 square feet each and to provide a temperature of 2 to 8 degrees centigrade

20.000

2 Ducting and wall paneling 10.00 3 Stand by equipment 5.000 4 Total 35.000 5 Cost of pallets and stacking trays 2.000 6 Fork lift vehicle 10.000 7 Grand total machinery and equipment 47.000

3

12. Project cost Sl Description Rs. lakhs 1 Land 2.000 2 Civil works 99.000 3 Plant machinery 47.000 4 Laboratory equipment 0.000 5 Transport vehicle 0.000 6 Pollution control equipment 0.000 7 Energy conservation equipment 0.000 8 Cost of power connection 1.500 9 Cost of electrification 2.000






(Rs. lakhs) 1 Refrigeration Engineer 1 0.150 2 Refrigeration mechanics 3 0.300 3 Plant mechanics 3 0.300 4 Skilled workers 3 0.180 5 Unskilled workers 30 0.900 6 Administrative staff 2 0.200 7 Security staff 4 0.160 8 Total 36 2.190

4

b. Utilities per month Sl Description Rs. lakhs 1 Power 111500 kwh @ Rs. 5.50 per unit 6.133 2 Water 0.100 3 Refrigeration gas 1.000 4 Total utilities 7.233

c. Contingent expenses per month



d. Total working capital requirement per month Sl Description Rs. lakhs 1 Salaries and wages 2.190 2 Raw material and packaging material 0.000 3 Utilities 7.233 4 Contingent expenses 2.019 5 Total 11.442

5







Total Rs. lakhs

1 Cold store 500 MT 100 / MT/day 182.500


6

List of machinery suppliers for cold storage 1. Blue Star Limited, Commercial Equipment Division, 13, Community Centre,

New Friends Colony, New Delhi. 110065. ; Tel: 011 - 6834262; Fax: 011 - 6841845

2. Carrier Refrigeration Private Limited, C-7, Golden Enclave, Airport Road, Bangalore. 560017.; Tel: 080 - 5272688; Fax: 080 - 5262788

3. Freezeking Industries Private Limited, 7/17, Industrial Area, Kirti Nagar, New Delhi. 110015.; Tel: 011 - 5930681; Fax: 011 - 5447509

4. Frick India Limited, 7 / 15, Kirti Nagar Industrial Area, New Delhi. 110015; Tel: 011 - 5463706; Fax: 011 - 5275695

5. Voltas India Limited, Air Conditioning and Refrigeration Division, 19, J.N.Heredia Marg, Ballard Estate, Mumbai. 400001.; Tel: 022 - 2618131; Fax: 022 - 2615220

1

CRUDE EDIBLE OIL BY EXPELLER PROCESS 1. Introduction

Groundnut, coconut and sesame are the three major oilseeds grown in

the State of Tamil Nadu. The oil content is high in these oilseeds. The oil can be

obtained by crushing the seeds in an expeller and filtered to yield crude edible

oil. These oils can be packed for sale directly and can be sold as filtered oils.

Groundnut oil can also be sent to the refinery for refining which includes

neutralization, bleaching and deodorisation.

2. Market

For coconut and sesame oils, the major markets are the “ A” and “B”

class outlets. The products also find placement in self service counters and

departmental stores. Some “C” class outlets also stock the product. Edible oils

have always a ready market because the production of oilseeds and oil is lower

than the market demands of the consumer. For groundnut oil, the crude is sent

to the refinery for refining and packaging. Filtered groundnut oil is also sold in

very small quantities through oil stores.

3. Packaging

The expelled and filtered oil is packed in tins of 15 litre or 15 kilogram

capacity. Sesame and coconut oil is packed in pouches of 250 grams, 500

grams and one litre.



• The crushing capacity will be 5000 kilograms per shift.

• The crushing capacity will be 1500 M.T per annum.


2

5. Sales revenue

• Seed procurement price - 27500 per ton.

• Crude oil selling price - Rs. 65000 per ton.

• Deoiled cake selling price - Rs. 9000 per ton.

• Total sales revenue on full capacity utilization:

• a. By sale of oil - Rs. 458.25 lakhs

• b. By sale of deoiled cake - Rs. 71.55 lakhs.

• c. Total - Rs. 529.80 lakhs.


Bold varieties of groundnut seeds and gingelly seeds are taken and dried

in the sun to remove excess moisture. The seeds are crushed in the expeller,

filtered through the filter press and packed in tins or drums for sale. For

coconuts, the nuts after cracking into halves are dried and the copra obtained

subjected to oil extraction and filtration in the expeller and filter press. The

filtered oil is packed in tins or drums for sale.

The deoiled cakes of groundnut, gingelly and coconut can be used for

incorporation in cattle feed. Alternatively, deoiled groundnut and gingelly can be

used in the manufacture of candies in combination with jaggery or sugar.


• Filtered groundnut oil • Specific gravity - 0.910 • Butyro refractometer reading at 40 degrees centigrade - 54 to 57 • Iodine value - 94 • Saponification value - 191 • Unsaponifiable matter - 0.40% maximum • Free fatty acids as oleic acid - 0.10% maximum

3

7. Quality specifications ..... contd.

• Filtered Sesame oil • Specific gravity - 0.907 • Butyro refractometer reading at 40 degrees centigrade - 58 to 67 • Iodine value - 105 to 115 • Saponification value - 188 to 193 • Unsaponifiable matter - 0.40% maximum • Free fatty acids as oleic acid - 6% maximum • Filtered Coconut oil • Specific gravity - 0.9226 • Butyro refractometer reading at 40 degrees centigrade - 34 to 35 • Iodine value - 10 • Saponification value - 250 to 260 • Unsaponifiable matter - 1% maximum • Free fatty acids as oleic acid - 0.005% maximum






The proposed unit is to be set up in leased premises in rural areas only.

The area required is 3500 square feet as detailed below:

Sl Description Sq. feet 1 Processing area 1000 2 Raw material store 500 3 Finished goods storage room 500 4 Packaging material storage room 500 5 Laboratory 200 6 Office space 200 7 Machinery spares room 100 8 Toilet space 200 9 Miscellaneous space 300

10 Total 3500 Lease rent – Rs. 5.00 per square foot Total rent per month – Rs. 17500 Lease advance – Rs. 70000

4


Sl Description Rs. lakhs 1 Oil expeller – 33 X 6 with raw material bucket

elevator, feed hopper, conditioner and other accessories

5.016

2 Filter press, pump, underground storage tank etc

1.944

3 Motors and accessories; stainless steel storage tank etc

2.200


12. Project cost

Sl Description Rs. lakhs 1 Land On lease 2 Civil works On lease 3 Plant machinery 9.160 4 Laboratory equipment 0.600 5 Transport vehicle (1 LCV) 7.500 6 Pollution control equipment 0.000 7 Energy conservation equipment 0.000 8 Cost of power connection 0.600 9 Cost of electrification 1.000


5





(Rs. lakhs) 1 Production Manager 1 0.120 2 Skilled labour 1 0.060 3 Unskilled labour 2 0.060 4 Driver 1 0.060 5 Total 5 0.300


(kgs) Rate / kg

(Rs) Value

(Rs. lakhs) 1 Oilseeds 125000 27.500 34.375



Rs) Value

(Rs. lakhs) 1 Barrels 294 nos 400 1.176

2 Gunnies 1325 nos 10 0.133



6








7





Total Rs. lakhs

1 Oil 705 MT 65000 458.250 2 Deoiled cake 795 MT 9000 71.550 3 By recovery

of cost of barrels

14.110

4 Total 1500 MT 543.910


8

List of machinery suppliers for crude edible oil by expeller process 1. Brimco Engineering Works, M - 24 / 1, Street No. 9, Anand Parbat Industrial

Area, New Rohtak Road, New Delhi. 110005.; Tel: 011 - 25726347; Fax: 011 - 25761786

2. Goldin India Equipment Private Limited, F / 29, B.I.D.C. Industrial Estate, Gorwa, Vadodra, Gujarat. 390016. ; Tel: 0265 - 2380168; Fax: 0265 - 2380168

3. New Azad Oil Expeller Company, C - 82, Bulandsher Industrial Area, Ghaziabad, Uttar Pradesh.; Tel: 01204 – 2751003

4. Dhanalakshmi Industries, 204, Suramangalam main Road, Pallapatty, Salem. 636009; Tel: 0427-2350674

1

DEHYDRATED FRUITS (HOT AIR DRYING METHOD)

1. Introduction

Many fruits are seasonal in nature and due to their low shelf life after

harvest they are sold in the markets at very low prices. There is a considerable

surplus of these fruits which can be processed (dehydrated) for consumption

during lean months. The seasonal fruits that are in demand during lean periods

are mango, pineapples, sapota.

2. Market

The market for dehydrated fruits exists in India to a large extent with

dehydrated mangoes (aam papad or mango jelly) being the most sought after.

Dehydrated fruits are also common abroad with Israel and China being the

largest producers and marketers. Among the consumer markets, the product

finds placement in all departmental stores, self-service counters and “A” class

outlets in metropolitan towns and cities.

3. Packaging

Dehydrated fruit powders are packed in tins for bulk packaging. In retail

packaging, small dispensers are used.



• The plant will process 200 kgs of fruits per day.

• The yield of dehydrated fruits will be 40 % that includes 20% pulp and 20%

sugar used in the process of dehydration.

• The total quantity of dehydrated fruits produced per annum would be 180

M.T.


5. Sales revenue

• With an ex-factory selling price at Rs. 140 per kilogram for dehydrated fruits,

the total sales revenue per annum works out to Rs. 252 lakhs. The MRP is

Rs. 200 per kilogram of the dehydrated product.

2


The fruits received from the farms are directly taken to the cold store.

Storage of fruits at 10 degrees centigrade increases the shelf life of the product

after harvesting. The fruits are to be processed within one week after receipt

from the farms. The fruits are peeled, cubed or pulped as the case may be. They

are then blanched in cold water at 2 to 3 degrees centigrade with or without

blanching agents such as potassium meta-bi-sulphite. The excess water is

drained off in the product. Microfined sugar is dusted to the extent of 20% by

weight and later dehydrated in the fluidized bed dryers at temperatures ranging

between 50 to 55 degrees centigrade. The time taken to dry is 8 to 10 hours.

The dehydrated product is packed in the packing machine.






• An FPO license is required for processing.





3


Land required – 1.0 acres - Rs. 2.00 lakhs. The area required is 6700


Sl Description Sq. feet 1 Processing area – pre preparation 1000 2 Raw material store 800 3 Washing area 500 4 Dehydration area 1000 5 Grinding area 1000 6 Packing area 500 7 Quality control laboratory 400 8 Packaging material store room 400 9 Finished goods store 400


Cost of construction – Rs. 800 per square foot Total cost of civil works – 53.60 lakhs Total cost of land and civil works – Rs. 55.60 lakhs

4



for raw fruit 2.500

2 Stacking trays for fruits - 500 trays @ Rs. 150 each with each tray holding 10 kgs of raw material

0.750


2.500


1.850


0.600

6 Fluidized bed dryers for dehydrating fruits at a capacity of 1000 kilograms in a span of 8 to 10 hours complete with heat exchanger, blower fans and accessories

4.840


5.500




5

12. Project cost Sl Description Rs. lakhs 1 Land 2.000 2 Civil works 53.600 3 Plant machinery 23.140 4 Laboratory equipment 1.000 5 Transport vehicle ( 1 LCV) 7.500 6 Pollution control equipment 0.000 7 Energy conservation equipment 0.000 8 Cost of power connection 1.000 9 Cost of electrification 1.000







chemist 3 0.450

3 Skilled workers 3 0.180 4 Unskilled workers 9 0.270 5 Packing workers 9 0.270 6 Administrative staff 2 0.240 7 Driver 1 0.060 8 Sales coordinator 1 0.150 9 Total 29 1.820

6


(kgs) Rate / kg

(Rs) Value

(Rs. lakhs) 1 Fruits 60000 15.00 9.000

2 Sugar 3500 17.00 0.595



Rs) Value


material – metallized polyester – poly film

50 kgs 250 0.125




7








8





Total Rs. lakhs

1 Dehydrated fruits

180,000 kgs 140.00 252.00


List of machinery suppliers 1. Geeta Food Engineering, Plot No. C - 7 / 1, TTC Industrial Area, Pawana


1

DEHYDRATED VEGETABLES AND POWDERS 1. Introduction

Many vegetables are seasonal in nature and due to their low shelf life

after harvest they are sold in the markets at very low prices. There is a

considerable surplus of these vegetables which can be processed (dehydrated)

for consumption during lean months. The seasonal vegetables that are in

demand during lean periods are peas, cauliflower and carrots. Dehydrated

powders of spinach, onion and garlic find use in the spices and food processing

industries as well as in the consumer markets.

2. Market

The major market outlets are the “ A” class outlets. The product also

finds placement in self-service counters and departmental stores. Food

processing industries purchase the product in bulk quantities. The dehydrated

powders also have a good export potential.

3. Packaging

Dehydrated Vegetables and Powders are packed in tins for bulk

packaging. In retail packaging, small dispensers are used.



• The plant will process 1500 kgs of vegetables and 500 kgs of onions and

garlic per day.

• The yield of Dehydrated Vegetables and Powders will be 25% of the weight

of raw material used. The total quantity of finished product per annum would

be 112.5 metric tonnes of dehydrated vegetables and 37.5 metric tonnes of

dehydrated onion and garlic powders. .


5. Sales revenue


vegetable powders, the total sales revenue will be Rs. 225.00 lakhs per

annum.

2


Peas

Fresh mature pea pods are collected and the seeds separated. They are dried at

50 degrees centigrade in the dryers.

Cauliflower

The vegetable is chopped into small pieces and dried in a current of cold air.

Spinach

The leaves are separated from the stalk, washed in water to remove adhering

dirt and dried in the drier at 50 degrees centigrade.

Carrots

The roots are washed, scraped and cubed. The cubes are blanched and dried in

the drier at 50 to 55 degrees centigrade. They are ground to a fine powder along

with some edible starches and anti-caking agents.

Onion and garlic

The skin is peeled and the pods dried at temperatures ranging from 55 to 60

degrees centigrade. They are then ground after mixing with edible starches and

anti-caking agents.

Dehydrated potato and tapioca slices

The tubers are washed and the skin peeled. They are sliced to 2 to 3 mm

thickness and blanched immediately to prevent browning. After blanching, they

are soaked in brine solution for salting and removal of excess starches. They are

then dried in the tray drier at 50 to 55 degrees centigrade.










3



Land required – 1.0 acre - Rs. 2.00 lakhs. The area required is 6700


Sl Description Sq. feet 1 Processing area – pre preparation 1000 2 Raw material store 800 3 Washing area 500 4 Dehydration area 1000 5 Grinding area 1000 6 Packing area 500 7 Quality control laboratory 400 8 Packaging material store room 400 9 Finished goods store 400


Construction cost – Rs. 800 per square foot Total cost of civil works – Rs. 53.60 lakhs Total cost of land and civil works – Rs. 55.60 lakhs

4



for vegetables 2.500

2 Stacking trays for vegetables – 500 trays @ Rs. 150 each with each tray holding 10 kgs of raw material

0.750


2.500


1.850


0.600

6 Fluidized bed dryers for dehydrating vegetables at a capacity of 1000 kilograms in a span of 8 to 10 hours complete with heat exchanger, blower fans and accessories

4.840


5.500




5

12. Project cost Sl Description Rs. lakhs 1 Land 2.000 2 Civil works 53.600 3 Plant machinery 23.140 4 Laboratory equipment 1.000 5 Transport vehicle ( 1 LCV) 7.500 6 Pollution control equipment 0.000 7 Energy conservation equipment 0.000 8 Cost of power connection 1.000 9 Cost of electrification 1.000







chemist 3 0.300

3 Skilled workers 3 0.180 4 Unskilled workers 9 0.270 5 Packing workers 9 0.270 6 Administrative staff 2 0.200 7 Driver 1 0.060 8 Sales coordinator 1 0.100 9 Total 29 1.530

6


(kgs) Rate / kg

(Rs) Value

(Rs. lakhs) 1 Vegetables 40000 10.00 4.000

2 Onions 7000 12.00 0.840

3 Garlic 7000 40.00 2.800



Rs) Value



50 kgs 250 0.125


3 Total 0.525 Total value of raw and packing materials – Rs. 8.165 lakhs


7


Sl Description Rs. lakhs 1 Rent for processing shed 0.000 2 Postage and stationery 0.020 3 Telephones, fax etc. 0.050 4 Consumable stores 0.020 5 Repairs and maintenance 0.281 6 Local transports, loading and unloading 0.150 7 Advertisement and publicity @10 of sales 1.875 8 Insurance 0.020 9 Sales expenses @ 1% of sales 0.187





8





Total Rs. lakhs

1 Dehydrated vegetables

112500 kgs 150.00 168.75

2 Dehydrated onion powder

37500 kgs 150.00 56.25

3 Total 150000 kgs 225.00


List of machinery suppliers 1. Geeta Food Engineering, Plot No. C - 7 / 1, TTC Industrial Area, Pawana


1

DEHYDRATED DRUMSTICK POWDER 1. Introduction

Drumstick is grown in large quantities in the State and especially in the

southern districts. Drumstick forms an important ingredient in sambhar prepared

traditionally at home or in restaurants and eating-houses. The flavour is most

preferred. Being messy to use, the powder is finding a lot of acceptability both in

India and abroad. There is a considerable surplus of this vegetable that can be

processed (dehydrated) for consumption throughout the year.

2. Market

The major market outlets are the “ A” class outlets. The product also finds

placement in self-service counters and departmental stores. Food processing

industries purchase the product in bulk quantities. The dehydrated powder also

has a good export potential.

3. Packaging

Dehydrated drumstick powder can be packed in metallised or foil pouches

for retail packaging. Bulk packaging can be in tins.



• The plant will process 1500 kgs of drumstick per day.

• The edible portion of drumstick is 83% and it has a moisture content of 86%.

• The yield of dehydrated drumstick powder will be 15% of the weight of raw

material used. The total quantity of finished product per annum would be 67.5

metric tones.

• The time period required for achieving full capacity utilization is five years.

5. Sales revenue


drumstick powder the total sales revenue will be Rs. 135 lakhs per annum.

2


Washing

Fresh mature drumsticks are selected for processing. They are washed to

remove adhering dirt.

Grading

The vegetable is graded to remove damaged and immature sticks.

Steaming and blanching

The sticks are steamed and blanched in huge tanks to facilitate pulp extraction.

Pressing

The soft sticks are pressed between rollers to extract the pulp.

Slurry preparation

Thick slurry is prepared with the pulp obtained.

Drying

The slurry is dried in a vacuum drier with the core drying temperature ranging

between 50 to 55 degrees centigrade.

Grinding

It is ground to a fine powder along with some edible starches and anti-caking

agents.











10. Fruit Products Order License

A FPO license is necessary for processing this vegetable

3


The unit is proposed to be set up in a leased area. The area required is

3600 square feet as described below


1 Processing area 1000 2 Raw material store 200 3 Washing area 200 4 Dehydration area 500 5 Grinding area 200 6 Packing area 200 7 Quality control laboratory 200 8 Packaging material store room 200 9 Finished goods store 200



4



1 Precooling facility at + 10 degrees centigrade for drumsticks

1.500

2 Stacking trays for drumsticks - 500 trays @ Rs. 150 each with each tray holding 10 kgs of raw material

0.750

3 Preparatory section consisting of washing tank

0.500

4 Steaming and blanching tank 1.850 5 Pulp extractor 0.600 6 Vacuum drier for dehydrating drumstick at a

capacity of 500 kilograms in a span of 8 to 10 hours, complete with vacuum pump, heat exchangers and accessories

4.840

7 Form fill and seal machine with augur weigher and filler

2.750


5.500

9 Boiler and accessories 3.850 10 Total 22.140 11 Laboratory equipment 1.000 12 Grand total machinery and equipment 23.140

5


1 Land On lease 2 Civil works On lease 3 Plant machinery 22.140 4 Laboratory equipment 1.000 5 Transport vehicle ( Tata Ace) 3.760 6 Pollution control equipment 0.000 7 Energy conservation equipment 0.000 8 Cost of power connection 1.000 9 Cost of electrification 1.000







chemist 3 0.300

3 Skilled workers 3 0.180 4 Unskilled workers 9 0.270 5 Packing workers 9 0.270 6 Administrative staff 2 0.200 7 Van driver 1 0.060 8 Total 28 1.430

6


(kgs) Rate / kg

(Rs) Value

(Rs. lakhs) 1 Drumsticks 40000 8.00 3.200




Value (Rs. lakhs)


40 kgs 250 1.000

2 Cartons and straps 2000 20 0.400

3 Total 1.400

Total raw + packaging material = Rs. 4.600 lakhs d. Utilities per month Sl Description Rs. lakhs




1 Rent for processing shed 0.216 2 Postage and stationery 0.010 3 Telephones, fax etc. 0.050 4 Consumable stores 0.020 5 Repairs and maintenance 0.281 6 Local transports, loading and unloading 0.100 7 Advertisement and publicity @ 10% of sales 1.124 8 Insurance 0.018 9 Sales expenses @ 1% of sales 0.113


7









8



Total Rs. lakhs

1 Dehydrated Drumstick

powder

67500 200 135.00

17. Viability analysis Sl Description Value


List of machinery suppliers 1. Sri Valsa Engineering Works, 36, Nanda Nagar, Singanallur, Coimbatore

641005. Tamil Nadu.; Tel: 0422 - 2574268; Fax: 0422 – 2574268 2. Geeta Food Engineering, Plot No. C - 7 / 1, TTC Industrial Area, Pawana


1

DESICCATED COCONUT 1. Introduction

Desiccated coconut is used commonly in sweetmeat preparations, as

toppings in desserts, ice creams, puddings, etc., as a filler in betel leaves and a

variety of products. The present production of desiccated coconut is around

5600 tonnes per annum and is concentrated in Karnataka where a number of

small units are located. The present production is absorbed by the food

processing industries for various end uses. Market surveys have shown that

desiccated coconut powder in consumer packs is widely accepted by the middle

class segments in preference to raw nuts.

2. Market



buy desiccated coconut in bulk quantities for use in different products.

3. Packaging

Desiccated coconut is packed in laminated foil or polyester-poly pouches

in weights of 50 grams, 100 grams, 250 grams, 500 grams and 1 kg.


• The plant will be in operation for two shifts a day.

• The plant will operate to a processing capacity to crack 250 nuts per shift or

500 nuts per day.

• The yield of desiccated coconut will be 50 kilograms per day.

• The production of desiccated coconut powder per month will be 1250

kilograms and that per annum would be 15 metric tonnes.


5. Sales revenue

• With an ex-factory selling price at Rs. 240 per kilogram, the total sales

revenue will be Rs. 36.00 lakhs. MRP is fixed at Rs. 300 per kilogram.

• In addition, coconut milk would yield Rs. 5.00 lakhs, fibre - Rs. 0.50 lakhs,

and coconut shell - Rs. 2.50 lakhs, making the total sales revenue to Rs.

44.00 lakhs.

2


Mature coconuts are taken. They are shredded and the fibre removed.

The nuts are cracked into two halves manually. The kernel is grated manually

into a fine mesh. The kernel gratings are blanched in hot water, milk extracted

and dried in a fluidized bed drier at 50 to 55 degrees centigrade for 8 to 10

hours.

The coconut husk is used for the manufacture of ropes and is also used

as a fuel.

The coconut milk is concentrated in the jacketed vessel to yield coconut

cream. The shell can be used for manufacture of shell powder and activated

carbon.


• The desiccated coconut powder should be free from mold and fungal growth.

• It should test negative for coliforms, streptococci and salmonella bacteria.


Not necessary as there are no pollutants or effluents. However, the peel

and seeds of fruits processed have to be disposed off carefully failing which it

could pollute the surrounding areas on fermentation, yielding a foul odour.



3


The unit is proposed to be set up in a leased area.

The processing area required is 2000 square feet as detailed below:

Sl Description Sq. feet 1 Processing area 500 2 Raw material store 200 3 Packing material store 200 4 Finished goods store 200 5 Laboratory space 200 6 Baby boiler area 200 7 Machinery spares room 100 8 Administration office 100 9 Toilet space 200






Sl Description Rs. lakhs 1 Tools for nut cracking 0.060 2 Coconut milk extractor 0.350 3 Steam jacketed kettle 0.333 4 Baby boiler and accessories 1.250 5 Fluidized bed drier 5.000 6 Total cost of machinery 6.993 7 Laboratory equipment 0.500 8 Grand total machinery and equipment 7.493

4

12. Project cost Sl Description Rs. lakhs 1 Land On lease 2 Civil works On lease 3 Plant machinery 6.993 4 Laboratory equipment 0.500 5 Transport vehicle (1 Tata ace) 3.760 6 Pollution control equipment 0.000 7 Energy conservation equipment 0.000 8 Cost of power connection 0.100 9 Cost of electrification 0.250







chemist 1 0.080

3 Skilled workers 1 0.050 4 Unskilled workers 3 0.150 5 Packing workers (female) 3 0.060 6 Administrative staff 1 0.080 7 Driver 1 0.050 8 Total 11 0.570

5

b. Raw material requirement per month


Rate / kg (Rs)

Value (Rs. lakhs)

1 Coconuts 12625 5.00 0.631



Rs) Value

(Rs. lakhs) 1 Packaging material –

poly propylene pouches 12500 nos 0.50 0.063

2 Primary cartons 12500 nos 1.50 0.187


4 Total 0.502 Total raw + packaging material – Rs. 1.133 lakhs





6








Total Rs. lakhs

1 Desiccated coconut

15000 kgs 240 36.00

2 Coconut milk 12500 litres 40 5.00 3 Coconut

shell, fibre 3.00

4 Total 44.00

7


List of machinery suppliers for Desiccated coconut powder 1. Sidvin Machineries Private Limited, 10, 3rd Stage, Industrial Suburb, Mysore,

570008, Karnataka.; Tel: 0821-2485822; Fax: 0821 - 2489564

1

DHAL MILL 1. Introduction

The dhal mill is a process industry to dehull the pulses and split them into

halves or dhal and make it available to the consumer, ready for use. There are

various pulses like red gram (tur), black gram (udad), Bengal gram (chana),

masoor (lentils) etc and all these need dehulling before being made available in

the market.

2. Market

Since there is always a constant demand in the consumer market, the

demand for dhals is always present and on the increase. The products find

placement in all retail outlets in the consumer market.

3. Packaging

Dhals being primarily traded by wholesalers, are packed in 50 kg gunny

bags. In the retail consumer market, they are packed in 500 grams and 1000

grams units.



duration.

• The total raw material input will be 3 tonnes per shift of 8 hours or 9 tonnes

per day. With refraction losses at 2%; hulls at 11%; and bran at 1%, the

recovery will be 14% less than the input raw material.


5. Sales revenue

• The sales revenue will entirely depend upon the procurement price of raw

material used for milling. Gram is considered as a representative sample in

this profile.


The gram is first passed through the sieves of the preparatory section to

remove chaff and twigs, followed by the destoner to remove stones. The cleaned

gram is then passed through the mill where it is cracked, split into two halves and

2

the hulls separated from the dhal with the help of sieves. The hulls are disposed

off to cattle feed manufacturers and the dhal packed in 50 kg gunnies.


• The dhals should be free from stones, hulls and other contaminant material.


On dehulling, there is a lot of dust which must be trapped and not allowed

to penetrate into the surroundings.




Land 1.0 acre - 2.0 lakhs. The total processing area required is 7900

square feet vide details given below.

Sl Description Sq. feet 1 Processing area – pre preparation 2000 2 Raw material store 2000 3 Finished goods store 2000 4 Office space 500 5 Panel board room 200 6 Machinery spares room 200 7 Quality control laboratory 200 8 Packaging material store room 200 9 General store room 200


Construction cost per square foot – Rs. 800.00


Total cost of land and civil works – 65.20 lakhs

3

11. Costing of machinery and equipment Rs. lakhs

Preparatory section • Destoner with accessories 0.45 • Chaff separator 0.40 • Elevators and conveyers 1.00 • Motors for above machines 0.60 Process section • Roller machine ( 1 no) 0.20 • Sieves (2 nos) 0.50 • Worm machine (2 nos) 0.15 • Bucket elevators (5 nos) 0.66 • Box fan or aspirator ( 1no) 0.15 • Accessories, bearings, shafts, counter shafts etc. 0.45 • Mild steel platforms for machinery 0.60 • Motors for above machines 0.60 • 20 HP A/C motor 0.35 • Tool kit, weighing scales and accessories 0.25 Total machinery 6.36 Laboratory equipment 0.50 Total cost of machinery and equipment 6.86

4








chemist 3 0.300

3 Skilled workers 6 0.360 4 Unskilled workers 12 0.360 5 Administrative staff 2 0.200 6 Drivers 2 0.120 7 Sales coordinator 1 0.100 8 Security staff on hire 3 0.120 9 Total 30 1.710

5


(kgs) Rate / kg

(Rs) Value

(Rs. lakhs) 1 Gram 189375 30.00 56.813

2 Water 0.100

3 Total raw material 56.913


Rs) Value

(Rs. lakhs) 1 Gunny bags 3786 nos 9.00 0.341






6








Total Rs. lakhs

1 Dhal 1954.350 MT 44,000 859.914

7

17. Viability analysis Sl Description Value 1 Net profit before income tax (Rs. lakhs) 41.514 2 Net profit ratio 5% 3 Internal rate of return 24.3% 4 Break even percentage 44% 5 Debt service coverage ratio 1.987

List of machinery suppliers for dhal mill 1. Sidvin Machineries Private Limited, 10, 3rd Stage, Industrial Suburb, Mysore,

570008, Karnataka.; Tel: 0821-2485822; Fax: 0821 - 2489564

1

DIGESTIVE CANDIES 1. Introduction

Digestive candies or sweets are prepared from sugar along with invert

sugar, extracts of tamarind, pepper, ajowan, jeera and lahori namak. It can also

contain some amounts of mint extracts. They are basically fun products used in

the event of indigestion. A common example is “Hajmola” candy prepared by

Dabur India Limited.

2. Market



class outlets and pharmacies also stock the product.

3. Packaging

The processed product is packed in twist and wrap cellophane wrapper.



duration.

• The plant operates to a production capacity of 500 kilograms per shift.


• The total production per month will be 25.0 M.T while the annual production is



2

5. Sales revenue


sales revenue of Rs. 210 lakhs on full capacity utilisation. The MRP is fixed at

Rs. 100 per kilogram.


Equal quantities of pepper, jeera and ajowan are ground fine in a

micropulveriser. The mixture is boiled in water till the extraction of their water

soluble constituents is complete. The solution is filtered and the filtrate

concentrated once again till a thick syrup like mass is obtained. This extract is

used for mixing with sugar in the preparation of digestive candy.

The required quantity of sugar and extracts of pepper, jeera and ajowan

per batch is taken in the candy cooker. Lahori Namak is also added in trace

quantities. The mixture is boiled with the required quantities of invert sugar and

citric acid. When the desired consistency is achieved, it is poured on to the

cooling tables and rolled to the desired sizes in the roller. The candy former

forms the candies to the desired shapes and sizes when it begins to harden. The

candies are further rolled on to the cooling conveyer wherein the product is

brought to room temperature before being twist wrapped in the wrapping

machine. They are then packed into weights of one kilogram in polypropylene

pouches before being dispatched into the market.


• Sulphated ash - Maximum 1.5% • Ash - Maximum 1.0% • Acid insoluble ash - Maximum 0.5% • Sulphur dioxide - Maximum 350 parts per million.





3


The proposed unit is to be set up in a leased area. The area required is

4600 square feet as detailed below:

Sl Description Sq. feet 1 Processing area 3000 2 Sugar storage room 300 3 Raw material (others) storage room 200 4 Finished goods storage room 200 5 Packaging material storage room 100 6 Laboratory 200 7 Office space 200 8 Machinery spares room 100 9 Toilet space 200


Lease rent per square foot – Rs. 8.00


Lease advance – Rs. 2.00 lakh


Sl Description Rs. lakhs 1 Baby boiler and accessories 1.850 2 Candy cooker 1.339 3 Cooling tables (2 nos) 0.600 4 Batch roller 1.386 5 Roto plant candy former 2.600 6 Cooling conveyer 0.928 7 Wrapping machines (2 nos) 6.440 8 Total Machinery 15.143 9 Laboratory equipment 0.600


4








chemist 2 0.300

3 Skilled workers 2 0.120 4 Unskilled workers 4 0.120 5 Packing workers 4 0.080 6 Administrative staff 2 0.200 7 Sales staff 2 0.200 8 Driver 1 0.060 7 Total 18 1.230

5


(kgs) Rate / kg

(Rs) Value

(Rs. lakhs) 1 Sugar 20000 17.00 3.400

2 Invert sugar syrup 6000 18.00 1.080

3 Citric acid 250 120.00 0.300

4 Jeera, pepper, rock salt, ajowan etc

250 150.00 0.375



Rs) Value

(Rs. lakhs) 1 Candy cellophane

wrapper film 1000 kgs 100 1.000

2 Polypropylene pouches 250 kgs 100 0.250




6







7





Total Rs. lakhs

1 Digestive candies

300,000 kgs 70 210


List of machinery suppliers for digestive candies 1. Mangal Engineering Works, Factory Area, Patiala 147001, Punjab. Tel: 0175

- 2364702; Fax: 0175 - 2360652 2. Emersion Engineering Enterprise, Near Gate Station, Surendarnagar,

363001, Gujarat.; Tel: 02752 -221940 3. The Ravalgoan Sugar Farm Limited, Factory - P.O. Ravalgoan 423108,

District Nashik, Maharashtra.

1

DRIED OYSTER MUSHROOMS 1. Introduction

Mushrooms are considered a delicacy the world over. They are a good

source of protein and minerals. There are two major varieties of mushrooms

grown i.e. the white button mushroom and the oyster mushroom. Of the two, the

oyster mushroom is relatively easy to grow and is sold in the domestic market.

The button mushrooms are grown, canned and mainly exported, although some

quantities find their place in the local market. Oyster mushrooms have a

tremendous local market potential. For the most part, they are being grown and

sold in the unorganized sector.

Mushrooms find their use in preparations of soups, mixed vegetables,

pickles and in combinations with eggs and meat. A variety of culinary treats can

be prepared with mushrooms.

2. Market

Mushrooms have a very short shelf life of just a few hours after harvesting

and therefore they are sold mainly in the fresh form locally in urban cities and

semi-urban towns. The present market potential in cities and towns varies from

100 kgs to 500 kgs per day.

The product finds placement in all “A” class outlets, self service,

departmental stores and supermarkets. The product has a lot of market potential

if it is very hygienically processed and dried. There is an increasing awareness

in the product because it blends well with both meat as well as vegetables.

3. Packaging

Mushrooms are best packed in polyethylene or polypropylene or BOPP

pouches as primary packing. The pouch is placed in cartons and strapped prior

to dispatch. The product is packed in weights of 50 and 100 grams.

2


• Eight hours per day and 300 days in a year.

• Estimated production per day is 100 kilograms.

• The estimated production per annum is 30,000 kilograms.

5. Sales revenue

• At an ex-factory selling price of Rs. 70 per kilogram of the product, the net

sales revenue per annum will be Rs. 21.0 lakhs on full capacity utilization.


• Dissolve 1.25 grams of Bavistin and 35 ml of formalin in 25 litres of water.

• Soak 2 kilograms of paddy straw for 30 minutes.

• Decant the water and recycle for use.

• Spread the straw in the open air on a concrete floor so that the surface

moisture from the straw is removed.

• Mix the spawn contents from one bottle thoroughly with the paddy straw and

fill it in five poly-propylene bags (30 cms X 45 cms) and tie the mouth with a

string. Punch a few holes in the bottom of the bag.

• Keep the bags in a dark and humid place in a room for 20 to 25 days till the

bags turn milky white.

• After the straw has turned milky white, cut open the bag. The beds are

obtained and watering has to be done three times a day without fail.

• The mushrooms start appearing four to five days after cutting open the bag.

• Since mushrooms grow in flushes, there will be three to four flushes in each

bed.

• Keep the bed for fifty days from the date of filling of the bags.

• Total produce from 2 kg of straw and one bottle of spawn will be 2 kg of

mushrooms.

3


• Moisture - 88.5%

• Protein - 3.0% on wet weight basis

• Fat - 0.8% on wet weight basis.

• Minerals - 1.4% on wet weight basis.

• Carbohydrates - 4.3% on wet weight basis.






The proposed unit is to be set up in a leased area. The area required is 3300

square feet vide details given below:

Sl Description Sq. feet 1 Straw preparation room – 1 400 2 Straw preparation room – 2 400 3 Cropping room – 1 400 4 Cropping room – 2 400 5 Harvesting and processing room 400 6 Raw material storage room 200 7 Other ingredients storage room 100 8 Finished goods storage room 200 9 Packaging material storage room 100

10 Laboratory 200 11 Office space 200 12 Toilet space 200 13 Miscellaneous space 100 14 Total 3300

Lease rent per square foot – Rs. 5.00



4


Sl Description Rs. lakhs 1 Tray drier with 36 trays 1.600 2 Stacking racks – 2 nos 0.600 3 Holding trays and vessels – 10 nos 0.500 4 Weighing scales – 3 nos 0.250 5 Pedal sealing machines – 3 nos 0.220 6 Machine spares 0.100 7 Total 3.270 8 Laboratory equipment 0.500




5





(Rs. lakhs) 1 Production Manager (female) 1 0.100 2 Production supervisor (female) 1 0.080 3 Administrative staff (female) 1 0.080 4 Unskilled workers 2 0.060 5 Total 5 0.320


(kgs) Rate / kg

(Rs) Value

(Rs. lakhs) 1 Paddy straw 3000 0.50 0.150

2 Chemicals and formalin 0.012

3 Spawn 0.015




Value (Rs. lakhs)

1 Polyethylene bags for straw

15000 nos 0.80 0.120

2 Pouches for finished goods

15000 nos 0.50 0.075

3 HDPE woven sacks 400 nos 6.00 0.024

3 Total 0.219

Total raw + packaging material = Rs. 0.396 lakhs d. Utilities per month


6








7





Total Rs. lakhs

1 Oyster mushrooms

30000 kgs 70 21.0



List of machinery suppliers for oyster mushrooms No machinery is required. Racks to be fabricated locally. Small instruments to be

procured locally.

1

ENROBED CHOCOLATES 1. Introduction

Enrobed Chocolates are a delicacy among the younger generations and is

consumed as a pastime fun product. It is served in parties, birthday functions,

airline flights, and also helps to pass time on long journeys. Being made from

milk, sugar and cocoa powder, it is harmless for consumption even if it becomes

habit forming. The addition of grated nuts and coconut make it more appealing

and tasty.

2. Market


also finds placement in self service counters and departmental stores.

3. Packaging

The processed product is packed in metallized film wrappers.



duration.






2

5. Sales revenue


sales revenue of Rs. 675 lakhs on full capacity utilization.


The chocolate mass is first prepared by melting milk fat, cocoa butter, milk

powder and cocoa mass in definite proportions. After tempering it is enrobed

over a nougat mass and the entire mass is passed through a cooling tunnel

wherein it hardens. The enrobed chocolate is packed in a metallized film in a

pillow pack machine.



1 Suphated ash Maximum 2.0%

2 Ash Maximum 1.0%

3 Acid insoluble ash Maximum 0.2%

4 Reducing sugars as dextrose Minimum 10%

5 Sucrose Minimum 60%

6 Fat Minimum 4%

7 Total protein Minimum 3%

8 Peroxide value of fat used Nil

9 Total plate count Maximum 10,000 per gram

10 Coliforms Absent

11 Streptococci Absent

12 Staphylococci Absent





3


The proposed unit is to be set up in a leased area. The area required is

4000 square feet as described below.


1 Processing area 2000 2 Milk and cocoa powder storage room 300 3 Sugar storage room 100 4 Vanaspathi storage room 100 5 Other raw materials storage room 200 6 Finished goods storage room 200 7 Packaging material storage room 100 8 Laboratory 200 9 Office space 200

10 Machinery spares store room 100 11 Administration office 200 12 Toilet space 200 13 Miscellaneous space 100 14 Total 4000

Lease rent – Rs. 8.00 per square foot Total rent per month – Rs. 32000 Lease advance – Rs. 2.00 lakhs



1 Chocolate melting kettle 1.505 2 Conch 1.326 3 Tempering machine 0.907 4 Enrober 2.402 5 Cooling tunnel 3.598 6 Pillow packing machine 4.196 7 Air conditioners 4 nos 1.400 8 Voltage stabilizer 1.000 9 Total 16.334


4


1 Land On lease 2 Civil works On lease 3 Plant machinery 16.334 4 Laboratory equipment 0.600 5 Transport vehicle ( 1 LCV) 7.500 6 Pollution control equipment 0.000 7 Energy conservation equipment 0.000 8 Cost of power connection 0.500 9 Cost of electrification 1.000






(Rs. lakhs) 1 Production Manager 1 0.200 2 Maintenance Engineer 1 0.150 3 Production supervisors / chemist 2 0.200 4 Skilled workers 2 0.120 5 Unskilled workers 8 0.240 6 Packing workers 8 0.240 7 Administrative staff 2 0.200 8 Sales staff 2 0.200 9 Driver 1 0.060 7 Total 27 1.610

5


(kgs) Rate / kg

(Rs) Value

(Rs. lakhs) 1 Milk powder 20625 120.00 24.750

2 Cocoa powder 1875 160.00 3.000

3 Sugar 7500 17.00 1.275

4 Cocoa butter 5625 100.00 5.625

5 Aerated shortening 1875 70.00 1.313

6 Emulsifier 375 50.00 0.188



Rs) Value



2250 kgs 250 5.625





6



1 Rent for processing shed 0.320 2 Postage and stationery 0.020 3 Telephones, fax etc. 0.050 4 Consumable stores 0.020 5 Repairs and maintenance 0.136 6 Local transports, loading and unloading 0.100 7 Advertisement and publicity @ 5% of sales 2.250 8 Insurance 0.034 9 Sales expenses @ 1% of sales 0.450








7






Total Rs. lakhs

1 Enrobed chocolates

450,000 150 675.00




List of machinery suppliers for Enrobed Chocolates 1. A.M.P Rose Private Limited, 38, Double Road, K.H.Circle, Bangalore 560027.

Tel: 080 – 28525092, 28525093, 28525094, 28525223; Fax: 080 - 28525223 2. Indian Foods Private Limited, 171, K.K.Nagar, Madurai 625020, Tamil Nadu. ;

Tel: 0452 - 2587776; Fax: 0452 - 2587511

1

EXTRUDED ENERGY FOOD 1. Introduction

Energy food is a commonly consumed commodity in all households both

in urban and rural areas. Traditionally the energy food is prepared by

germination and roasting of cereals and pulses. The product is cooked and

served with a little addition of milk and sugar. With the development of extrusion

technology, energy food in a cooked form can be produced which can be served

as a pap to infants, or as porridge or as a beverage. The product being already

cooked needs no further terminal processing. Further, it is already sweetened

and therefore ready to use by the addition of hot milk.

2. Market

The product finds placement in all “A”, and “B” class outlets, self service,


because it is very hygienically processed, reasonably priced and that it has a

very good nutritive value without any loss of nutrients during the process of

extrusion cooking.

3. Packaging

Extruded energy food is best packed in polyethylene or polypropylene or

BOPP pouches as primary packing. The pouch is placed in a paperboard carton,

which is the secondary packing. The product is packed in weights of 500 gms

and 1000 gms.



duration.

• The plant will operate to a capacity of raw material input of 150 kilograms per

hour or 3000 kilograms per day. The raw collet output will be 3000 kilograms

per day.

• After pulverization, the product would be mixed with sugar thus yielding 4

M.T. of the finished product per day.

• The estimated production per month would be 100 M.T and that per annum

of 300 working days would be 1200 M.T.

2


5. Sales revenue

• The ex-factory selling price of the product shall be Rs. 53 per kilogram

thereby yielding sales revenue of Rs. 636 lakhs on full capacity utilization.

The MRP is fixed at Rs. 80 per kilogram


The ingredients comprising corn grits, wheat semolina, defatted soya

flour, and skimmed milk powder are moistened with water and extruded. The

extruded collets obtained are dried to a moisture content of less than 6 percent

in a continuous drier and pulverized to a particle size of around 150 microns.

Sugar is also ground separately in the micropulveriser. The extruded product and

sugar are mixed in definite proportions and packed. A general formulation

comprises corn grits - 70%; wheat semolina - 10%; defatted soya flour - 10%;

and skimmed milk powder - 10%.


• Moisture - maximum 10 %.

• Protein - minimum 15%

• Fat - maximum 2%

• Crude fibre - maximum 5%

• Ash - maximum 1%

• Acid insoluble ash - maximum 0.1 %.

• Acidity of extracted fat as oleic acid - maximum 1.5 percent.


bacteria. The total plate count should not exceed 30,000 per gram.

• The product should be free from rodent excreta, human hair, and insect

infestation It should also not contain any added coal tar food colours,

preservatives, emulsifiers, stabilizers, and artificial flavouring agents.





3


Land required – 1.00 acre

Cost of land – Rs. 2.00 lakhs.

Total space required – 9200 square feet

Sl Description Sq. feet 1 Processing area 6000 2 Raw material store 1000 3 Other ingredients store room 500 4 Finished goods store room 200 5 Laboratory 300 6 Packing area 200 7 Office space 500 8 Machinery spares room 100 9 Toilet space 200


Cost of construction – Rs. 800 per square foot

Total cost of construction – Rs. 73.60 lakhs

Total cost of land and civil works – Rs. 75.60 lakhs


Sl Description Rs. lakhs 1 Flour sifter 0.350 2 Vertical screw mixer 1.500 3 Extruder and accessories 18.700 4 Continuous drier 6.000 5 Micropulveriser with all contact parts in SS 1.500 6 Stainless steel ribbon blender 1.250 7 Packing machine 2.450 8 Weighing scales bulk and fine – 2 nos 0.650 9 Machine spares 0.500


4

12. Project cost

Sl Description Rs. lakhs 1 Land 2.000 2 Civil works 73.600 3 Plant machinery 32.900 4 Laboratory equipment 1.000 5 Transport vehicle (1 LCV) 7.500 6 Pollution control equipment 0.000 7 Energy conservation equipment 0.000 8 Cost of power connection 1.000 9 Cost of electrification 1.500


5





(Rs. lakhs) 1 Production Manager 1 0.150 2 Production Supervisor 3 0.300 3 Maintenance Mechanic 1 0.080 4 Laboratory chemists 3 0.300 5 Skilled workers 6 0.360 6 Sales staff 3 0.300 7 Unskilled workers 15 0.450 8 Administrative staff 2 0.200 9 Driver 1 0.060 10 Security staff 3 0.120 11 Total 38 2.320


(kgs) Rate / kg

(Rs) Value

(Rs. lakhs) 1 Corn grits 55125 14.00 7.718

2 Wheat semolina 7875 20.00 1.575

3 Defatted soya flour 7875 16.00 1.260


5 Sugar 26250 17.00 4.463



Rs) Value



1000 kgs 250 2.500

2 Primary cartons 4.000


4 Total 7.700 Total raw material + packaging material per month – Rs. 32.166 lakhs

6








7





Total Rs. lakhs

1 Extruded Energy Food

1200 MT 53,000 636.00


List of machinery suppliers for Extruded Energy Food 1. F.M.C. Hongkong Limited, 2, Bhuvaneshwari Housing Society, Pashan Road,

Pune 411008, Maharashtra. ; Tel: 020 - 25893700; Fax: 020 - 25983701 2. Spectoms Engineering Private Limited, Purshottam Estate, Bahucharji Road,

Vadodra 390018, Gujarat.; Tel: 0265 - 2426920; Fax: 0265 - 2644592

1

EXTRUDED PUFFED SNACKS 1. Introduction

Extruded puffed snacks are made from degermed corn grits, wheat

semolina, rice and other cereals. There has been a remarkable growth in the

varieties of these products available in the market because the consumers find

these products easily affordable and ready to eat. The snacks are flavoured with

cheese, masala, onion, garlic, or chillies and pepper to suit local tastes.

2. Market

The market for the product is expanding considerably because these

foods are nutritive, tasty and inexpensive. In all metropolitan cities, such foods

are available for example: ‘Peppys” in all metros; Chennai - ‘Corn Puffs’; Pune -

‘Tasty Bites’; Delhi - ‘Crax’ etc.

3. Packaging

The snack food should preferably be packed in metallized polyester-poly

pouches and flushed with nitrogen before sealing. The quantity in each pouch

can be either 25 grams or 35 grams as is the general practice. The pouches are

placed in paperboard cartons and strapped prior to dispatch.


• The plant operates to two shifts a day, with each shift of 8 hours duration.

• Production is envisaged at 50 kilograms per hour or 800 kilograms per day.




5. Sales revenue

• The ex-factory selling price will be Rs. 3.00 per pack of 25 grams or Rs.120

per kilogram. The annual sales revenue is Rs.288 lakhs inclusive of taxes on

full capacity utilization.

2


The ingredients comprising of degermed corn grits and / or rice flour are

mixed with water so as to raise the moisture content to about 17%. The

moistened cereal grits are then fed manually into the hopper of the extruder. The

plant through a thermoplastic process, converts the natural starches in the cereal

to cold soluble starches in the machine. On cooking the cereals leave the

extruder as an expanded product.

. The product that leaves the extruder is termed as “collets”. The product

is cut to the desired shape and size with the help of a cutter fitted to the die

assembly. It has a moisture content of 6% and is immediately dried to a moisture

content of less than 2% in the drier. The raw dried collets are then fed into the

coating pan for enrobing with oil and spices. Oil is sprayed through a spray gun,

activated by a dried filtered air from a compressor. The oil used must be a

saturated fat in order to increase the shelf life of the product. The oil has to be

preserved with anti-oxidants. The coated snacks are fed directly into the hopper

of an automatic form and sealing machine. The product is weighed and packed

automatically in pouches by the hot bar sealing jaws of the machine. The

pouches are then packed in cartons for easy handling and distribution.


• Moisture content of the product at the time of packing should range between

1.0 to 1.2 percent.

• Free fatty acids of the oil used should not exceed 0.1%

• The oil used should also test negative for free peroxides.

• The cereal grits used should conform to the following specifications:

a. Moisture - 12% maximum

b. Ash - 0.5% maximum

c. Acid insoluble ash - 0.1% maximum

d. Alcoholic acidity - 0.1% maximum

• The cereal grits used should be free from insect infestation, rodent excreta

and hair.

3

• The end product shall not contain any harmful colouring, flavouring or any

other additive deleterious to health.

• The snack food should also show no signs of fungal growth. It should also

test negative for coliforms, salmonella and streptococci.






The unit is proposed to be located in a leased area. The total space required is

2500 square feet as detailed below

Sl Description Sq. feet 1 Processing area 1000 2 Raw material store 200 3 Other ingredients store room 200 4 Finished goods storage room 200 5 Packaging material storage room 100 6 Laboratory 200 7 Office space 200 8 Machinery spares room 100 9 Toilet space 200





4


Sl Description Rs. lakhs 1 Extruder with 30 HP motor for extrusion unit

and 1 HP motor for attached cutter assembly along with screws, barrel, dies etc.

4.240

2 Drier for collets 2.500 3 Blender with spray gun and compressor for

oil and spice coating of snacks and stainless steel oil heater

1.250

4 Automatic form fill and seal packing machine 2.540 5 Weighing scales, coarse and fine 0.250 6 Total 10.780


12. Project cost Sl Description Rs. lakhs 1 Land On lease 2 Civil works On lease 3 Plant machinery 10.780 4 Laboratory equipment 1.000 5 Transport vehicle ( 1 LCV) 7.500 6 Pollution control equipment 0.000 7 Energy conservation equipment 0.000 8 Cost of power connection 0.500 9 Cost of electrification 1.500


5






chemist 2 0.200

3 Skilled workers 4 0.240 4 Unskilled workers 6 0.180 5 Packing workers 4 0.120 6 Administrative staff 2 0.200 7 Sales coordinator 1 0.100 8 Driver 1 0.060 9 Security staff 3 0.120 10 Total 24 1.370


(kgs) Rate / kg

(Rs) Value

(Rs. lakhs) 1 Corn grits 20000 14.00 2.800

2 Vegetable oil 2500 70.00 1.750

3 Salt and spices 500 50.00 0.250



Rs) Value



3000 kgs 250 7.500



6





7






Sl Item Qty Rate/kg (Rs)

Total Rs. lakhs

1 Extruded corn snacks

240 MT 120 288


8

List of machinery suppliers for Extruded Snack Food 1. G.L. Extrusion System Private Limited, RZ - 172 / 12, Street no. 4, Durga

Park, Nasir Pur Dabri Road, New Delhi. 110045.; Tel: 011 - 25043182; Fax: 011 - 25043124

2. G.R. Engineering Works Limited, Poonam Chambers, Dr. Annie Besant Road, Worli, Mumbai 400018.; Tel: 022 - 24930404; Fax: 022 - 24925712

3. Fun Snacks Private Limited, B-134, DDA Sheds, Okhla Industrial Estate Phase -1, New Delhi. 110020

1

FLAKED CEREALS 1. Introduction

Flaked cereals consisting of corn and wheat flakes are a commonly

consumed commodity for breakfast in many households. They are consumed

with addition of little milk and sugar. Being easy to serve and use without any

terminal processing facility, it finds an easy acceptability among households.

Moreover, these breakfast foods are very nutritive, providing all the essential

nutrients for sustenance for an individual.

2. Market


also finds placement in self service counters and departmental stores. The

market is predominantly in all metros and major towns and almost all households

use the product.

3. Packaging

Flaked cereals are packed in 500 grams and 1 kg packaging.



• The production capacity is estimated at 100 kilograms per hour.

• The yield of flaked cereals will be 2.0 tonnes per day and that per annum

would be 600 metric tonnes.


5. Sales revenue

• With an ex-factory selling price at Rs. 80.00 per kilogram inclusive of taxes,

The net sales revenue will be Rs. 480.00 lakhs on full capacity utilisation.


Mature corn received from the farms is first cleaned by passing through

the sieves and destoner in the preparatory section. It is then conditioned in the

conditioner, degermed and flaked to the desired thickness in the flaker rolls. The

raw flakes are then toasted using the desired quantities of fat, sugar and malt.

2

The toasted flakes are cooled and packed in pouches with the aid of the packing

machine.


Corn flakes

• It shall be obtained from dehulled, degermed and cooked corn.

• It shall be in the form of crisp flakes of reasonably uniform size and golden

brown in colour.

• It shall be free from dirt, insects, larvae, and impurities and any other

extraneous matter.

• It shall have a maximum moisture content of 7%.

• Total ash shall not exceed 1% on dry weight basis.

• Acid insoluble ash - 0.1% maximum

• Alcoholic acidity - shall be equivalent to not more than 2.0 ml of 1 N NaOH

per 100 grams of dried substance.

• It shall test negative for coliforms, salmonella and streptococci bacteria.





3


Land 0.5 acres - Rs. 2.0 lakhs.

Processing area is 7000 square feet as detailed below.

Sl Description Sq. feet 1 Processing area 2000 2 Packing area 1000 3 Raw materials (cereals) store 1000 4 Raw materials (others) store 500 5 Packing material store 200 6 Finished goods store 400 7 Laboratory 400 8 Boiler area 500 9 Machinery spares store 200

10 Office space 200 11 Toilet space 200 12 Miscellaneous space 400 13 Total 7000



Total cost of land and civil works – Rs. 58.00 lakhs.


Sl Description Rs. lakhs 1 Boiler and accessories 1.650 2 Preparatory section for cleaning and

conditioning 8.400

3 Milling section with degermer unit; Flaking section with flaker rolls and accessories; and Processing section with toaster and accessories

5.200

4 Packing machine 2.850 5 Weighing scales – large and small 0.250 6 Working tools 0.100 7 Total 18.450 8 Laboratory equipment 0.500 9 Grand total machinery and equipment 18.950

4



5





(Rs. lakhs) 1 Production Manager 1 0.150 2 Production supervisor 3 0.300 3 Chemists 3 0.300 4 Skilled workers 3 0.180 5 Unskilled workers 6 0.180 6 Packing workers 6 0.180 7 Administrative staff 2 0.200 8 Driver 1 0.060 9 Sales Manager 1 0.150 10 Sales representatives 3 0.300 11 Security staff 4 0.160 12 Total 33 2.160


(kgs) Rate / kg

(Rs) Value

(Rs. lakhs) 1 Corn 60000 10.00 6.000

2 Malt, sugar, vanaspathi 1800 50.00 0.900



Rs) Value


material – primary carton – bag and box)

25000 nos 4.00 10.000


3 Total 12.000 Total raw + packaging material - Rs 18.900 lakhs

6









7





Total Rs. lakhs

1 Corn flakes 600,000 kgs 80 480.00


List of machinery suppliers for Flaked Cereals 1. Heat and Control Private Limited, 3, Anurag, G - 131, 1st main Road, Anna

Nagar East, Chennai 600102. ; Tel: 044 - 26631455; Fax: 044 - 6631466 2. M. Son Industries, D - 33, Sector - 2, Noida 201301, District Ghaziabad, Uttar

Pradesh.; Tel: 0118-24552197; Fax: 0118 - 24552197

1

FRIED NOODLES 1. Introduction

Fried noodles are a delicacy among children. It is consumed among most

households as a tea time snack. Being precooked it is very easy to use and

recipes can be prepared in a few minutes. Housewives find it very convenient to

use and prefer it as a tea time snack for children.

2. Market



export potential.

3. Packaging

The processed product is packed in laminated BOPP pouches. The

product is packed in measures of 100 grams.



duration.

• The plant will operate to a capacity of a raw material (maida) input of 50

kilograms per hour or 800 kilograms per day. The end product yield will be

920 kilograms per day.

• The estimated production per month is therefore 23 MT.

• The total production per annum production is estimated at 276 M.T


2

5. Sales revenue


sales revenue of Rs. 229.08 lakhs on full capacity utilization. The MRP is

fixed at Rs. 125 per kilogram.


Refined wheat flour (maida) is mixed with water in the mixer and kneaded

to form a dough. The dough is flattened into sheets of 2 millimeters thickness. It

is then slit into strands of 2 millimeters width and coiled. The coils are steamed

and then conveyed into the frier by the conveyer. After frying at temperatures

ranging between 160 to 180 degrees centigrade for about two to two and a half

minutes, the cakes are removed, excess oil drained and packed using the

machine. After packing, they are placed in cartons, strapped prior to dispatch.


• Moisture - 12% maximum • Total ash - 1.5% maximum • Acid insoluble ash - 0.1% maximum • Crude fibre - 2% maximum • Protein - 8% minimum • Fat - 15% maximum • Free fatty acids of the oil used as oleic acid - 0.1% maximum • Peroxide value of the oil used - nil 8. Pollution control measures




3




Sl Description Sq. feet 1 Processing area 1500 2 Raw material store 100 3 Raw material (oil) storage room 100 4 Finished goods storage room 200 5 Packaging material storage room 100 6 Laboratory 200 7 Office space 200 8 Machinery spares 100 9 Toilet space 200

10 Miscellaneous space 100 11 Boiler area 200 12 Total 3000





Sl Description Rs. lakhs 1 Stainless steel mixer 0.755 2 Sheeting and slitting machine 1.123 3 Steaming cabinet 0.755 4 Souping conveyer 0.656 5 Frier 0.952 6 Pillow pack machine 3.116 7 Weighing scales – coarse and fine 0.220 8 Steam boiler and accessories 3.120 9 Total 10.697


4

12. Project cost

Sl Description Rs. lakhs 1 Land On lease 2 Civil works On lease 3 Plant machinery 10.697 4 Laboratory equipment 1.000 5 Transport vehicle (1 LCV) 7.500 6 Pollution control equipment 0.000 7 Energy conservation equipment 0.000 8 Cost of power connection 0.500 9 Cost of electrification 1.000







chemist 2 0.200

3 Skilled workers 4 0.240 4 Unskilled workers 6 0.180 5 Packing workers 4 0.120 6 Administrative staff 2 0.200 7 Sales coordinator 1 0.100 8 Driver 1 0.060 9 Total 21 1.250

5


(kgs) Rate / kg

(Rs) Value

(Rs. lakhs) 1 Maida 20000 18.00 3.600

2 Vanaspathi 3400 75.00 2.550

3 Salt 500 7.00 0.035



Rs) Value


material – BOPP laminate BOPP film

1610 kgs 140 2.254




6

e. Contingent expenses per month Sl Description Rs. lakhs 1 Rent for processing shed 0.240 2 Postage and stationery 0.050 3 Telephones, fax etc. 0.050 4 Consumable stores 0.020 5 Repairs and maintenance 0.126 6 Local transports, loading and unloading 0.100 7 Advertisement and publicity @ 15% of sales 2.760 8 Insurance 0.025 9 Sales expenses @ 1% of sales 0.184





7





Total Rs. lakhs

1 Fried Noodles

276,000 kgs 83 229.08


List of equipment suppliers for fried noodles 1. F.M.C. Hongkong Limited, 2, Bhuvaneshwari Housing Society, Pashan Road,

Pune 411008, Maharashtra. ; Tel: 020 - 25893700; Fax: 020 - 25983701

1

FRIED SNACKS 1. Introduction

Fried Snacks such as “Samosas”, “Kachoris”, “Bhujiya” and “Karasev” are

the most commonly consumed tea time snack. They are also served during

parties, functions and as a pastime snack while watching the television.

However, the maximum offtake of the product is in theaters, cinema halls,

railway pantry cars, exhibitions, bakeries, tea stalls, and snack food joints. Being

a fried and spicy product, it finds easy acceptability in the market.

2. Market



class outlets also stock the product. All bakery outlets manufacture and sell fried

snacks.

3. Packaging

Fried snacks such as karasev and bhujiya are packed in metallized

polyester-poly pouches in weights of 50 grams and 100 grams. Samosas are

sold across the counter in individual units.



• Production of samosas is taken as a representative example.

• The plant operates to a production capacity of 2000 units of fried snacks e.g.

Samosas, each weighing 50 grams.


5. Sales revenue

• The ex-factory selling price would be Rs. 5.25 per piece thereby yielding a

sales revenue of Rs. 10500 per day or Rs. 2.500 lakhs per month or Rs.

31.50 lakhs per annum. The MRP is fixed at Rs. 6.00 per piece.

2


Maida and water are mixed in the kneader and formed into a dough. The

dough is transferred into the rolling machine where it is flattened, rolled into

sheets, and cut into the desired size. Separately, potatoes are cooked, skin

peeled, mashed and mixed with the required quantities of salt and spices. The

required quantities are placed on the sheets and the later folded to give a

triangular shape. They are then fried in the thermostat frier, cooled and packed.


Maida

The maida used should have been extracted from hard wheat to get a

good sheeting. The specifications of maida to be used are:

Sl Description Value 1 Moisture Maximum 13.0% 2 Mold and fungal growth Absent 3 Ash Maximum 1.0% 4 Acid insoluble ash Maximum 0.1% 5 Gluten Minimum 7.5% 6 Alcoholic acidity Maximum 0.12% as sulphuric acid 7 Total plate count Maximum 30,000 per gram 8 Coliforms Absent 9 Strptococci Absent 10 Salmonella Absent 11 Insect infestation Absent 12 Rodent excreta Absent 13 Hair Absent The refined oil used should be free from peroxides and the free fatty acid

value expressed as oleic acid should not exceed 0.1%.





3




Sl Description Sq. feet 1 Processing area 1000 2 Raw material store for maida 200 3 Raw material store for vanaspathi 100 4 Raw material (others) store 100 5 Finished goods store room 200 6 Packaging material store room 100 7 Quality control laboratory 100 8 Office space 100 9 Toilet space 100

10 Total 2000 Lease rentals – Rs. 8.00 per square foot Total rent per month – Rs. 16000 Lease advance – Rs. 100000 11. Costing of machinery and equipment

Sl Description Rs. lakhs 1 Stainless steel maida kneading machine –

tilting type with motor and gear box 1.100

2 Patta rolling machine 0.750 3 Thermostat fryers – 2 nos 0.360 4 Plastic trays – 100 nos 0.120 5 Utensils and miscellaneous items 0.300 6 Total 2.630 7 Laboratory equipment 0.300 8 Grand total machinery and equipment 2.930

4

12. Project cost Sl Description Rs. lakhs 1 Land On lease 2 Civil works On lease 3 Plant machinery 2.630 4 Laboratory equipment 0.300 5 Transport vehicle ( 1 Tata Ace) 3.760 6 Pollution control equipment 0.000 7 Energy conservation equipment 0.000 8 Cost of power connection 0.100 9 Cost of electrification 0.100






(Rs. lakhs) 1 Production Manager (female) 1 0.010 2 Production supervisor (female) 1 0.080 3 Skilled workers 1 0.060 4 Unskilled workers 2 0.040 5 Driver 1 0.060 8 Total 6 0.250

5


(kgs) Rate / kg

(Rs) Value

(Rs. lakhs) 1 Maida 2550 15.00 0.383

2 Refined oil 425 75.00 0.319

3 Spices and salt 80 50.00 0.040

4 Potatoes 1600 12.00 0.192



Value (Rs. lakhs)

1 Polypropylene wrappers 50000 nos 0.50 0.250






6








Total Rs. lakhs

1 Fried snacks (samosas)

600,000 nos 5.25 31.50

7

17. Viability analysis Sl Description Value 1 Net profit before income tax (Rs. L1khs) 2.835 2 Net profit ratio 9.0% 3 Internal rate of return 23.1% 4 Break even percentage 54%

5 Debt service coverage ratio 1.963

List of machinery suppliers for Fried Snacks R.M.Engineering Works, Gala no. 3, L.D’Souza Compound, Mohamadi Jama

Masjid Lane, Kherani Road, Saki Naka, Mumbai. 400072.; Tel: 022 - 25783484

1

GINGER TIDBITS 1. Introduction

Ginger tidbits is a product consumed along with betelnuts or fennel as a

tastemaker. It is a good digestive. It also finds place as a tastemaker in deep-

fried snacks, sweets and savories. It is also an ideal carrypack during travel and

picnics.

The product consists of tiny cubes of ginger soaked in concentrated sugar

syrup, dried and packed.

2. Market

The product finds placement in all “A” class and “B” class outlets, self

service, departmental stores and supermarkets.

3. Packaging

The product is packed in metallized poly-ester - poly pouches. Each

pouch contains 10 grams of the product.


• The plant operates to one shift of eight hours duration.



• The estimated production per annum is 30,000 kilograms.

5. Sales revenue

• Rs. 1.40 per pouch of 10 grams or Rs. 140 per kilogram. MRP per pouch is

Rs.2.00

• Total sales revenue per annum - Rs. 42.00 lakhs.


Pieces of ginger are first washed in water to remove adhering dirt. The

skin is scraped with the help of peelers. It is then cubed into small pieces of

around 2 millimeter cubes. The cubes are soaked in water.

A sugar syrup of 75 to 80 degrees brix is prepared in the sugar kettle. The

ginger cubes are soaked in the sugar syrup for about 10 to 12 hours. The excess

sugar is drained and the cubes dried in a tray drier and packed.

2


• The manufacturer must obtain a FPO license.

• In order to give a reasonable shelf life to the product, the following standards

may be maintained:

• Moisture - 6% to 8%

• Mold and fungus growth - absent


Not necessary as there are no pollutants or effluents




The proposed unit is to be taken up on lease. The total leased area is

1200 square feet vide details given below:

Sl Description Sq. feet 1 Processing area 500 2 Raw material store 100 3 Finished goods store 100 4 Boiler area 100 5 Quality control area 100 6 Spares stores 100 7 Office space 100 8 Toilet space 100 9 Total 1200




3


Sl Description Rs. lakhs 1 Baby boiler and accessories 1.800 2 Stainless steel soaking tanks 0.100 3 Stainless steel working tools 0.050 4 Sugar syrup preparation kettle – stainless

steel 0.350

5 Form fill and seal packing machine 1.200 6 Tray drier with 24 stainless steel trays 1.600 7 Weighing scales – 3 nos 0.240 8 Total 5.340 9 Laboratory equipment 0.300




4





(Rs. lakhs) 1 Production Manager (female) 1 0.100 2 Unskilled labour (female) 4 0.100 3 Accounts and administration 1 0.100 4 Driver 1 0.060 5 Total 7 0.360


Rate / kg (Rs)

Value (Rs. lakhs)

1 Ginger 2000 40.00 0.800

2 Sugar 1250 17.00 0.213



Value (Rs. lakhs)


25 kgs 250 0.063

2 Cartons and straps 350 nos 20 0.070 3 Total 0.133 Total raw + packaging material = Rs. 1.146 lakhs


5








6





Total Rs. lakhs

1 Ginger Tidbits

30000 kgs 140 42.00


List of machinery suppliers for Ginger Tidbits 1. Geeta Food Engineering, Plot No. C - 7 / 1, TTC Industrial Area, Pawana


1

HARD-BOILED CANDIES 1. Introduction

Hard-boiled candies or sweets are prepared from sugar along with invert

sugar, citric acid and flavours. Being available in different flavours like orange,

lemon, mango etc., and easily affordable children find it a delicacy. It is

consumed as a pastime fun product.

2. Market



class outlets also stock the product.

3. Packaging

The processed product is packed in twist and wrap cellophane wrapper.



duration.

• The plant operates to a production capacity of 500 kilograms per shift.





2

5. Sales revenue


sales revenue of Rs. 165 lakhs on full capacity utilization.


The required quantity of sugar per batch is taken in the candy cooker and

boiled with the required quantities of invert sugar and citric acid. When the

desired consistency is achieved, it is poured on to the cooling tables and rolled to

the desired sizes in the roller. The candy former forms the candies to the desired

shapes and sizes when it begins to harden. The candies are further rolled on to

the cooling conveyer wherein the product is brought to room temperature before

being twist wrapped in the wrapping machine. They are then packed into weights

of one kilogram in polypropylene pouches before being dispatched into the

market.


• Sulphated ash - Maximum 1.5% • Ash - Maximum 1.0% • Acid insoluble ash - Maximum 0.5% • Sulphur dioxide - Maximum 350 parts per million.





3


The unit is proposed to be set up in a leased area. The area required is 3500

square feet as detailed below:

Sl Description Sq. feet 1 Processing area 1500 2 Packing room 500 3 Sugar storage room 200 4 Other raw materials storage room 200 5 Finished goods storage room 200 6 Packaging material storage room 100 7 Laboratory 200 8 Office space 200 9 Machinery spares room 100






Sl Description Rs. lakhs 1 Baby boiler and accessories 1.850 2 Candy cooker 1.039 3 Cooling tables (2) 0.600 4 Roto plant candy former 2.600 5 Batch roller 1.086 6 Cooling conveyer 0.728 7 Wrapping machines (2 nos) 6.240 8 Total 14.143 9 Laboratory equipment 0.600


4








chemist 2 0.200

3 Skilled workers 2 0.120 4 Unskilled workers 4 0.120 5 Packing workers 4 0.080 6 Administrative staff 2 0.200 7 Sales staff 2 0.200 8 Driver 1 0.060 9 Total 18 1.130

5


(kgs) Rate / kg

(Rs) Value

(Rs. lakhs) 1 Sugar 20000 17.00 3.400

2 Invert sugar syrup 6000 16.00 0.960

3 Citric acid 250 120.00 0.300

4 Flavours and colours 50 500.00 0.250



Rs) Value


material – candy cellophane wrapper film

1000 kgs 100.00 1.000

2 Polypropylene pouches 25000 nos 1.00 0.250

3 Cartons and straps 1000 nos 20.00 0.200




6

e. Contingent expenses per month Sl Description Rs. lakhs 1 Rent for processing shed 0.210 2 Postage and stationery 0.020 3 Telephones, fax etc. 0.050 4 Consumable stores 0.020 5 Repairs and maintenance 0.156 6 Local transports, loading and unloading 0.100 7 Advertisement and publicity @ 15% of sales 2.063 8 Insurance 0.010 9 Sales expenses @ 1% of sales 0.138






7





Total Rs. lakhs

1 Hard Boiled Candies

300,000 kgs 550 165.00


List of machinery suppliers for Hard Boiled Candies 1. Mangal Engineering Works, Factory Area, Patiala 147001, Punjab. Tel: 0175

- 2364702; Fax: 0175 - 2360652 2. Emersion Engineering Enterprise, Near Gate Station, Surendarnagar,

363001, Gujarat.; Tel: 02752 - 221940 3. The Ravalgoan Sugar Farm Limited, Factory - P.O. Ravalgoan 423108,

District Nashik, Maharashtra.

1

ICE CREAMS 1. Introduction

Ice Creams a favorite among all children and a delicacy on all occasions.

They are highly nutritive because of the milk content and highly energizing

because of the fat. Especially in a warm climate like ours, ice creams can be

consumed right round the year.

2. Market

The major market outlets are the restaurants and ice cream parlours. It


also sell ice creams.

3. Packaging

Ice Creams are packed in cups of 50 ml and 100 ml capacity. In addition

carry packs of 500 ml and 1 litre are available.



• The total quantity of milk processed per day is 250 litres which on aeration

will yield 500 litres of ice cream.

• The yield of ice creams per annum will be 1.5 lakh litres.


5. Sales revenue

• With an ex-factory selling price at Rs. 85.00 per litre, the total sales revenue

will be Rs. 127.50 lakhs.


The milk received in cans is first chilled in the can cooler. It is then

pasteurized in the pasteurizer. The pasteurized milk is taken to the homogenizer,

where the required quantities of skimmed milk powder, whole milk powder,

sugar, flavours, emulsifiers, etc., are added and the mix prepared.

The mix is homogenized thoroughly and aerated till the homogenized

mass gives twice its volume. Simultaneously, the mass is chilled. It is then

transferred to a vat where it is allowed to mature and over run under chilled

2

conditions. It is then transferred to the batch freezer for freezing, followed by

storage under refrigerated conditions.


• It shall be prepared from cow or buffalo milk.

• Milk cream, whole milk powder, skimmed milk powder can be added.


combination can be used as sweetening agents. Artificial sweeteners are

prohibited from being added.

• It can also contain eggs, fruits, fruit juices, preserved fruits, nuts, chocolate,

edible flavours, and permitted food colours.

• Ice creams may contain stabilizing agents not exceeding 0.5% by weight.




• The mixture containing milk and other ingredients shall be suitably heated

before freezing.

• Ice cream shall contain a minimum of 10% milk fat, 3.5% protein and 36%

total solids.





3




Sl Description Sq. feet 1 Processing area 1000 2 Raw material store (milk store room) 200 3 Raw material (others store room) 100 4 Packing material store 100 5 Finished goods store 200 6 Laboratory space 200 7 Machinery spares room 100 8 Administration office 200 9 Toilet space 200




Sl Description Rs. lakhs 1 Can cooler for chilling milk cans received

from farms

2 Pastuerizer 3 Homogenizer 4 Chiller 5 Aging vat 6 Batch freezer 9 Total 10.240


4

12. Project cost Sl Description Rs. lakhs 1 Land On lease 2 Civil works On lease 3 Plant machinery 10.240 4 Laboratory equipment 0.600 5 Transport vehicle (refrigerated mini van) 7.500 6 Pollution control equipment 0.000 7 Energy conservation equipment 0.000 8 Cost of power connection 0.150 9 Cost of electrification 0.300







chemist 1 0.100

3 Skilled workers 2 0.120 4 Unskilled workers 4 0.120 5 Packing workers 2 0.060 6 Administrative staff 1 0.100 7 Driver 1 0.060 8 Total 12 0.710

5


(kgs) Rate / kg

(Rs) Value

(Rs. lakhs) 1 Milk 3750 14.00 0.525

2 Whole milk powder 500 180.00 0.900


4 Emulsifiers, stabilizers 30 200.00 0.060

5 Sugar 1500 17.00 0.255

6 Flavours 6 200.00 0.012



Rs) Value


material – cups with lid 125000

nos 1.50 1.875


3 Total 3.125 Total raw + packaging material - Rs. 5.577 lakhs d. Utilities per month

Sl Description Rs. lakhs 1 Power 6000 kwh @ Rs. 5.50 per unit 0.330 2 Water 0.050 3 Refrigerants 0.250 4 Total utilities 0.630

6







7





Total Rs. lakhs

1 Ice Cream 150,000 kgs 85 127.50 17. Viability analysis


8

List of machinery suppliers for Ice Creams 1. A.B. Industries, Shivaji Somajini Chawli, Near Agarwal Ice Factory,

Maherdikuva, Dudheshwar Road, Ahmedabad 380004. Gujarat.; Tel: 25625619

2. Akshay Industries, 107, Rajshree Industrial Estate - II, Chitalsar, Manpada, Ghodbunder Road, Thane West, Mumbai. 400607. ; Tel: 022 - 25435838; Fax 022 - 25335188

3. Dairy Den Limited, A - 29, GIDC Industrial Estate, Sector 25, Gandhinagar 382044, Gujarat.; Tel: 02712 - 232421; Fax: 02712 - 2227716

4. Heat and Control Private Limited, 3, Anurag, G - 131, 1st main Road, Anna Nagar East, Chennai 600102. ; Tel: 044 - 6631455; Fax: 044 - 26631466

5. Indian Dairy Equipment Company Limited, Plot No. 124 / 128, GIDC Estate, Vithal Udyognagar 388121, District Anand, Gujarat.; Tel: 02692 - 236148; Fax: 02692 - 236164

6. Indian Foods Private Limited, 171, K.K.Nagar, Madurai 625020, Tamil Nadu. ; Tel: 0452 - 2537776; Fax: 0452 - 2537511

7. P.W.S. Engineers Private Limited, Post Box No. 62, Anand Sojitra Road, Anand 388620, Gujarat. ; Tel: 02692 - 261948; Fax: 02692 - 261716

8. R.P.M. Engineers, 14 NP Developed Plots, Thiru - Vi - Ka Industrial Estate,

Ekkatuthangal, Chennai 600097.; Tel: 044 - 22325596; Fax: 044 - 22321639

1

IDIAPPAM 1. Introduction

Idiappam is a cooked rice product consumed commonly among

households in South India as rice is a staple food among them. Being

precooked, it is easy to digest and assimilate and therefore finds a very common

use in households. Both sweet and savory dishes can be made with idiappam.

The sweet preparations include the common “payasam”, while the savory dishes

include garnishing with lime, coconut, curds, gravies etc.

2. Market

The product finds placement in all “A”, and “B” class outlets, self service,


if it is very hygienically processed and dried, does not disintegrate on cooking

and if reasonably priced. South India forms the largest market for the product.

3. Packaging

Idiappam is best packed in polyethylene or polypropylene or BOPP

pouches as a primary packing. The pouch is placed in cartons and strapped prior

to dispatch. The product is packed in weights of 100, 200, 500 and 1000 gms.


• The plant operates to two shifts a day with each shift of eight hours duration.

• The plant will operate to a capacity of raw material (rice) input of 100

kilograms per hour. The anticipated production of idiappam is 1500

kilograms per day or 450 M.T per annum.


5. Sales revenue

• At an ex-factory selling price of Rs. 40 per kilogram of the product, the net

sales revenue per annum will be Rs. 180 lakhs on full capacity utilization.


Rice is first cleaned to remove stones and husk. It is then ground to about

400 micron particle size and then steamed in the cooking pan to a consistency

extrudable in nature. The product is then extruded in the form of strands, coiled,

2

steamed in the steaming trays till fully cooked. The product is then dried before

being packed.


• Moisture - maximum 10 %.

• Ash - maximum 0.5%.

• Acid insoluble ash - maximum 0.01%


bacteria. The total plate count should not exceed 30,000 per gram.

• The product should be free from rodent excreta, human hair, and insect

infestation It should also not contain any added coal tar food colours,

preservatives, emulsifiers, stabilizers, and artificial flavouring agents.






The proposed unit is to be set up on a leased shed. The total processing

area required is 2000 square feet vide details given below.

Sl Description Sq. feet 1 Processing area 1000 2 Raw material store 150 3 Other raw material storage room 100 4 Finished goods store 150 5 Laboratory 100 6 Office space 100 7 Machinery spares room 100 8 Boiler house 100 9 Toilet space 100


Lease rent – Rs. 6.00 per square foot; Total rent per month – Rs. 12000


3


Sl Description Rs. lakhs 1 Baby boiler and accessories 1.850 2 Flour sifter 0.250 3 Micropulveriser with a grinding capacity of

100 kgs per hour 0.500

4 Electrically operated screw press with die 1.000 5 Tray drier with 48 trays 1.600 6 Cooking vessels jacketed (2 nos) 1.000 7 Pedal sealing machine (5 nos) 0.380 8 Weighing scales 3 nos 0.250 9 Machine spares 0.100




4





(Rs. lakhs) 1 Production Manager (female) 1 0.100 2 Production supervisor (female) 1 0.080 3 Skilled workers (female) 4 0.200 4 Unskilled workers (female) 8 0.240 5 Packing workers (female) 4 0.080 6 Administrative staff (female) 2 0.160 7 Sales staff 2 0.200 8 Driver 1 0.060 9 Total 23 1.120


(kgs) Rate / kg

(Rs) Value

(Rs. lakhs) 1 Rice 40000 15.00 6.00



Rs) Value


material – polypropylene pouches

200000 nos

1.00 2.00


3 Total 2.500 Total raw + packaging material = Rs.8.500 lakhs d. Utilities per month


5







6





Total Rs. lakhs

1 Idiappam 450,000 kgs 40 180.00


List of machinery suppliers for Idiappam 1. Saraswathi Industries, 278, Sivasakthi Colony, Ganapathy P.O., Coimbatore

641006, Tamil Nadu.; Tel: 0422 - 2531536; Fax: 0422 - 2210252

1

INDIVIDUAL QUICK FREEZING OF FRUITS AND VEGETABLES 1. Introduction

Frozen fruits and vegetables are the most common forms of processed

fruits and vegetables preferred in the international market today. This is because

the product is easy to use and available right round the year even during off

seasons. Moreover, they are always available at a stable price. The product is

hygienically prepared, packed transported and stored under refrigerated

conditions till the use. Since almost every household has a refrigerator, storage

is easy and terminal processing is minimal. The product is also accepted

internationally because it is bacteria free without any contamination.

2. Market

The major market outlets are the “ A” class stores. The product also

finds placement in self service counters and departmental stores. The product

also has a good export potential.

3. Packaging

Frozen fruits and vegetables are packed in polyethylene pouches in 500

grams and 1 kilogram capacity. They are stored frozen, transported frozen and

sold to the consumer in the frozen state.



• The production capacity is estimated at 600 kilograms of raw material (cut

fruits and vegetables) per hour. In all the plant yields 4000 metric tonnes of

the product per annum.


5. Sales revenue

• With an ex-factory selling price at Rs. 50.00 per kilogram, the annual turnover

is Rs.2000 lakhs on full capacity utilisation.

2


The fruits and vegetables received from the farms are stored directly in

the cold room maintained at a temperature of + 10 degrees centigrade. They are

then processed within 5 to 7 days of the receipt of material.

The fruits and vegetables to be processed are taken to the processing

section. They are washed, peeled, cubed, diced or cut into the desired shapes

as may be by the various machinery in the preparatory section.

From the preparatory section it is steamed, blanched in cold water and

frozen in the freezer. The freezer has a temperature of minus 40 degrees

centigrade. The time taken for freezing is 30 minutes.

The frozen product emerges as a hard rock like mass and is immediately

taken to the packing machine. On packing it is stored in a refrigerated state at

minus 18 to minus 20 degrees centigrade. The product is transported cold and

stored under refrigerated conditions till use.












3


Land - 5 acres @ Rs. 2.00 lakhs per acre - Rs. 10.00 lakhs.

Sl Description Sq. feet 1 Preparatory section 5000 2 Processing section 10000 3 Cold storage room 2000 4 Laboratory 500 5 Administrative section 500 6 Boiler house 1000 7 Refrigeration compressor area 1000 8 Raw material store 5000 9 Machinery spares store 1000

10 Toilet space 1000 11 First aid and canteen space 3000 12 Total 30000

Cost of construction – Rs. 900 per square foot Total cost of civil works – Rs. 270.00 lakhs Total cost of land and civil works – Rs. 272.00 lakhs.


• Preparatory section machinery comprising washing machine, dicers, cubers, peelers etc. - Rs. 82.90 lakhs

• Processing machinery consisting of the following: a) Bulk hopper feeder to feed cut vegetables and fruits received from the

preparatory section to the next unit - viz: the transport conveyer. b) Transport conveyer conveying the material from hopper to the steam tunnel. c) Steam tunnel for injection of steam to cook the cut pieces of fruits and

vegetables. d) Belt conveyer to convey the material from the steam tunnel to the chilled

blanching tank. e) Blanching tank with chilled water at 4 degrees centigrade in circulation. f) Dew water shaker to remove excess surface moisture adhering to the fruits

and vegetables. g) Transport conveyer to convey the material from the vibratory shaker to the

spiral freezer.

4

h) The spiral freezer - It has a spiral flow bed for freezing the fruits and vegetables at a temperature of minus 40 degrees centigrade in about 30 minutes.

i) Flight conveyer - the unit that conveys the material from the freezer to the packing machine.

j) Packing conveyer - the unit is used to collect the pouched material from the packing machine for final packing of the finished products.

k) Cost of processing line - Rs. 150.70 lakhs l) Cost of packing line - Rs. 142.40 lakhs m) Cost of refrigeration unit - Rs. 138.50 lakhs n) Total cost of machinery - Rs. 514.50 lakhs o) Import duty @ 40% - Rs. 205.80 lakhs p) Grand total plant machinery - Rs. 720.30 lakhs

12. Project cost Sl Description Rs. lakhs 1 Land 10.000 2 Civil works 270.000 3 Plant machinery 720.300 4 Laboratory equipment 10.000 5 Boiler and accessories 22.000 6 Transport vehicle (2 LCV) 15.000 6 Pollution control equipment 0.000 7 Energy conservation equipment 0.000 8 Cost of power connection 10.000 9 Cost of electrification 10.000


5





(Rs. lakhs) 1 Managing Director 1 0.400 2 General Manager (Technical) 1 0.200 3 General Manager (Finance) 1 0.200 4 General Manager (marketing) 1 0.200 5 Production Manager 1 0.150 6 Van driver 2 0.120 7 Maintenance Supervisor 3 0.180 8 Maintenance Engineers 2 0.200 9 Quality Control Chemists 2 0.200 10 Boiler Operators 3 0.180 11 Refrigeration Mechanics 3 0.180 12 Sales staff 5 0.500 13 Skilled workers 6 0.360 14 Unskilled workers 30 0.900 14 Administrative staff 6 0.600 15 Security staff 10 0.400 16 Total 77 4.970


(kgs) Rate / kg

(Rs) Value

(Rs. lakhs) 1 Fruits 200,000 25.00 50.00

2 Vegetables 200,000 10.00 20.00

3 Total raw material 400,000 70.00


Rs) Value


material – Polyethylene pouches

400000 nos

0.50 2.000



6

d. Utilities per month Sl Description Rs. lakhs 1 Power 90000 kwh @ Rs. 5.50 per unit 4.950 2 Water 0.500 3 Boiler fuel 1.000 4 Ammonia refrigerant 0.500 5 Total utilities 6.950


Sl Description Rs. lakhs 1 Rent for processing shed 0.000 2 Postage and stationery 0.050 3 Telephones, fax etc. 0.100 4 Consumable stores 0.100 5 Repairs and maintenance 4.290 6 Local transports, loading and unloading 0.150 7 Refrigerated outward transport 6.750 7 Advertisement and publicity @ 5% of sales 8.333 8 Insurance 0.873 9 Sales expenses @ 1% of sales 1.666




7







Total Rs. lakhs

1 Frozen fruits and

vegetables

4000 MT 50.000 2000.00


8

List of machinery suppliers for Individual Quick Freezing of Fruits and Vegetables 1. F.M.C. Hongkong Limited, 2, Bhuvaneshwari Housing Society, Pashan Road,

Pune 411008, Maharashtra. ; Tel: 020 - 25893700; Fax: 020 - 25983701 2. Frigoscandia Winner Food Process Systems Limited, Shreesh Chambers,

3rd Floor, 25 / 1, Yeshwant Niwas Road, Indore 452003, Madhya Pradesh. ; Tel: 0731 - 2430527; Fax: 0731 - 2536815

1

INSTANT MIXES 1. Introduction

Instant mixes form a large range of convenience foods for housewives.

Being easy to use without much terminal processing, housewives find it very

convenient to use. It helps them to save time and effort and relieves them of the

tedious jobs of collecting various ingredients, cleaning and sorting them and

preparations. Modern households also do not offer the facilities necessary for

traditional processing and hence these products have gained instant acceptance.

Instant mixes can be used for preparation of various snack foods, sweets and

preparations with rice. For example, instant ‘dosa’ or ‘vadai’ mix can be used

conveniently as a tea time snack. Preparations of gulab jamun mix can be used

during festive occasions and ‘puliyogare mix’ as a change during supper.

2. Market

The major market outlets are the self service departmental stores, and “A”

and “B” class retail outlets. Moreover, export prospects are also good.

3. Packaging

The processed product is packed in metallized laminated polyester-poly

pouches. The quantity packed per pouch is 100 grams or 200 grams. The

pouches are placed in paperboard cartons and strapped prior to dispatch.



• Estimated production per day - 600 kilograms.




5. Sales revenue

• The ex-factory selling price will be Rs. 16 per pouch of 200 grams or Rs. 80

per kilogram inclusive of taxes. The estimated annual sales revenue will be

Rs. 144 lakhs.


2

The products considered for production are :

• Instant Gulab Jamun Mix

• Instant Rava Idli Mix

• Instant Puliyogare Mix

They have the maximum market demand among the instant mixes.

a. Instant Gulab Jamun Mix

It is a mixture of refined wheat flour; skimmed milk powder and sodium-

bicarbonate. The mix is kneaded into a dough and into small balls. They are then

fried in ghee or oil and soaked in sugar syrup before being served.

b. Instant Rava Idli Mix

It is a product comprising mainly of sooji or rava. The semolina is roasted

and seasoned with salt, curry leaves, mustard and asafoetida. The mix is added

to curd, whipped and steamed in an idli pan. The rava idlis obtained are served

hot with chutney.

c. Instant Puliyogare Mix

The product is a mixture of pre-gelatinised starch, tamarind powder, salt,

spices, roasted groundnuts, curry leaves and sesame seeds. The product is

mixed with rice and served.


a. Gulab Jamun Mix

• Moisture - 10% maximum • Ash - 2% maximum • Acid insoluble ash - 0.1% maximum • Mold and fungal growth - absent • Total plate count - 30,000 per gram • Coliforms - absent • Streptococci - absent • Salmonella - absent

3

b. Rava Idli Mix


c. Puliyogare Mix









Sl Description Sq. feet 1 Processing area 1000 2 Raw material store 400 3 Other ingredients store room 100 4 Finished goods store room 400 5 Packaging material storage room 100 6 Laboratory 100 7 Machinery spares room 100 8 Office space 100 9 Toilet and miscellaneous space 200

10 Total 2500

4



Sl Description Rs. lakhs 1 Tray drier and accessories 1.600 2 Hammer mill with accessories 1.560 3 Stainless steel sigma mixer 0.600 4 Weighing scales and working tools 0.200 5 Sealing machines 0.150 6 Total 4.110


12. Project cost Sl Description Rs. lakhs 1 Land On lease 2 Civil works On lease 3 Plant machinery 4.110 4 Laboratory equipment 0.500 5 Transport vehicle ( Tata Ace) 3.760 6 Pollution control equipment 0.000 7 Energy conservation equipment 0.000 8 Cost of power connection 0.200 9 Cost of electrification 0.300


5





(Rs. lakhs) 1 Production Manager (female) 1 0.100 2 Production supervisor (female) 1 0.080 3 Skilled workers (female) 1 0.050 4 Unskilled workers (female) 2 0.060 5 Packing workers (female) 2 0.040 6 Administrative staff (female) 1 0.080 7 Sales staff 1 0.100 8 Driver 1 0.060 9 Total 10 0.570


(kgs) Rate / kg

(Rs) Value

(Rs. lakhs) 1 Gulab Jamun Mix

A Maida 3060 14.00 0.428

B Skimmed milk powder 2040 120.00 2.448

2 Rava Idly Mix

A Semolina 5050 16.00 0.808

B Condiments and spices 252 150.00 0.378

C Vanaspathi 50 70.00 0.035

3 Puiliyogare mix

A Dextrin 5000 15.00 0.750

B Salt, spices, sugar 25 25.00 0.063

C Groundnuts 500 40.00 0.200

4 Total raw materials 15977 5.110

6


Rs) Value


material – metallized polyester – poly standee pouches

1,50,000 nos

1.50 2.250


3 Total 2.375 Total raw + packaging material = Rs. 7.485 d. Utilities per month





7








Total Rs. lakhs

1 Instant Mixes 180000 kgs 80 144.00

8


List of equipment for Instant Mixes 1. Sri Valsa Engineering Works, 36, Nanda Nagar, Singanallur, Coimbatore

641005. Tamil Nadu.; Tel: 0422 - 2574268; Fax: 0422 - 2574268

1

JAMS 1. Introduction

Jams are sweetened fruit preserves used commonly in households and

liked by all age groups. It is used basically as a bread spread or with pizzas and

pancakes. It finds wide acceptability as it is a fruit product; sweet and ready to

use without any terminal processing.

2. Market



buy jams in bulk quantities for use in different products.

3. Packaging

Jams are packed in 4 kg containers for bulk packaging. In retail

packaging, 200 grams or 450 grams are packed in bottles and sold.



• The production capacity is estimated at 500 kilograms per day.

• The yield of Jams will be 12.5 tonnes per month and that per annum would



5. Sales revenue

• With an ex-factory selling price at Rs. 18.00 per unit of 200 grams, or Rs.

90.00 per kilogram, the annual sales revenue on full capacity utilization would

yield Rs. 135.00 lakhs.


Ripe fruits comprising papaya, apples, pineapples, mangoes, bananas, grapes

are taken, washed and the skin peeled wherever applicable. The seeds are

removed, sliced and the pulp and juice extracted from the fruits. The extracted

mass is taken to the kettle where it is cooked under the influence of jacketed

steam for twenty to thirty minutes. Sugar is then added in desired quantities and

the mass further cooked with constant stirring till a fluid mass is formed with a

2

reading of 65 to 70 degrees brix on the brix meter. After cooking, the required

quantities of citric acid, pectin, flavours and colours are added and the mass

stirred thoroughly. The mass after homogenous mixing is emptied into steel

containers from where they are poured into containers of 200 grams capacity.

On cooling, the jam sets. The cup is sealed after placing a foil paper at its top.

The cup is covered with a lid and placed in cartons, strapped prior to dispatch.




• The minimum soluble solids shall be 68%.

• The minimum fruit pulp content shall be 45%.

• When raspberries and strawberries are used, the minimum quantities shall be

25%.



• Jams shall not contain tartaric acid, agar or gelatin.




• If dried fruits are used, they shall be declared on the label.

• It can contain permitted flavours , colours and preservatives.







3




Sl Description Sq. feet 1 Processing area 700 2 Raw material store 200 3 Packing material store 200 4 Finished goods store 200 5 Laboratory 100 6 Baby boiler area 100 7 Machinery spares area 100 8 Packing area 100 9 Administration office 200

10 Toilet space 100 11 Total 2000





Sl Description Rs. lakhs 1 Fruit washing tank 0.100 2 Juice extractor or pulper 0.350 3 Steam jacketed kettle 0.600 4 Stirrer 0.121 5 Bottle washing machine 0.206 6 Stainless steel working tables 0.667 7 Baby boiler and accessories 1.250 8 Working tools 0.100 9 Total 3.394


4







(Rs. lakhs) 1 Production Manager (female) 1 0.150 2 Production supervisor (female) 1 0.100 3 Skilled workers (female) 1 0.050 4 Unskilled workers (female) 2 0.060 5 Packing workers (female) 2 0.040 6 Administrative staff (female) 1 0.100 7 Driver 1 0.060 7 Total 9 0.560

5


(kgs) Rate / kg

(Rs) Value

(Rs. lakhs) 1 Mixed fruits 9375 20.00 1.875

2 Sugar 6875 17.00 1.168

3 Citric acid 63 120 0.076

4 Pectin, flavours, preservatives

125 200 0.250



Value (Rs. lakhs)

1 Primary packaging material – Plastic cups with foil and lid – 200 grams capacity

63000 nos 3.00 1.890




6








7





Total Rs. lakhs

1 Jams 150,000 kgs 90 135.00

17. Viability analysis Sl Description Value 1 Net profit before income tax (Rs. Lakhs) 6.825 2 Net profit ratio 5.1% 3 Internal rate of return 26.4% 4 Break even percentage 51% 5 Debt service coverage ratio 2.086

Jams 1. Geeta Food Engineering, Plot No. C - 7 / 1, TTC Industrial Area, Pawana


1

KHOA 1. Introduction

Khoa or condensed milk is used in all households during festive occasions

to prepare sweets. It is also used in many sweetmeat shops to prepare gulab

jamuns and other sweets. Khoa is a very versatile product. It can be used in

combination with various cereal and pulse flours; nuts like almonds, cashews,

pistachios, and fruit titbits. Sweetened khoa can be flavoured with cardamom,

pistachio, almonds, vanilla, and many more to suit individual tastes. Being a

versatile and commonly consumed product, it has a good market potential.

2. Market


also finds placement in self service counters and departmental stores. All

sweetmeat shops manufacture and sell Khoa.

3. Packaging

Khoa is packed in butter paper and enclosed in a carton. The packaging

weights are normally 50 grams and 100 grams.



• The plant will process 250 litres of milk per day.

• The yield of khoa will be 38 kilograms per day.


5. Sales revenue

• With the milk procurement price at Rs. 14.00 per litre and the resulting khoa

sold at Rs. 270 per kg., the annual sales revenue will be Rs. 30.78 lakhs on

full capacity utilization. The total quantity of milk processed will be 75000

litres per annum yielding 11400 kilograms of khoa.

2


Milk received from the dairies is collected in cans and stored in the can

cooler. Thirty litres of milk is poured into each pan and evaporated to dryness by

heating over a simmering flame lasting two hours and with constant stirring. On

attaining the desired consistency the product is removed, cooled and packed in

butter paper and cartons prior to dispatch.


• Only whole milk should be used.

• The minimum fat content of the dried mass should be 20%.

Citric acid can be used to a maximum extent of 0.1% of the dried mass.








Sl Description Sq. feet 1 Processing area 400 2 Milk store room 100 3 Finished goods store room 100 4 Packaging material store room 100 5 Washing area 100 6 Administrative office 100 7 Toilet space 100 8 Total 1000


3


Sl Description Rs. lakhs 1 Aluminum cans for storage of milk – 5 nos 0.250 2 Khoa machine with stainless steel parts and

covers. Pan with stainless steel scraper and driven by a 0.5 HP motor and reduction gear box. Heating by normal cooking gas. Number of units required – 2

1.000

3 Weighing scales – 3 nos 0.210 4 Can cooler – 1no 0.350 5 Total 1.810


12. Project cost Sl Description Rs. lakhs 1 Land On lease 2 Civil works On lease 3 Plant machinery 1.810 4 Laboratory equipment 0.100 5 Transport vehicle ( 1 Tata Ace) 3.760 6 Pollution control equipment 0.000 7 Energy conservation equipment 0.000 8 Cost of power connection 0.100 9 Cost of electrification 0.200


4





(Rs. lakhs) 1 Production Manager (female) 1 0.100 2 Skilled worker 1 0.060 3 Unskilled worker 1 0.030 4 Packing worker 1 0.030 5 Driver 1 0.060 6 Total 5 0.280


(kgs) Rate / kg

(Rs) Value

(Rs. lakhs) 1 Milk 6250 14.00 0.875

2 Sodium hypochlorite – disinfectant

25 15.00 0.004



Rs) Value


material – wax paper and cartons

9500 nos 2.00 0.190




Sl Description Rs. lakhs 1 Power 100 kwh @ Rs. 5.50 per unit 0.006 2 Water 0.010 3 Cooking gas 0.030 4 Total utilities 0.046

5








6





Total Rs. lakhs

1 Khoa 11400 270 30.78


List of machinery suppliers for Khoa 1. Ambika Engineering Works, Industrial Plot No. 6, Mahuva Road, Taloja

364140, Gujarat.; Tel: 02842 - 222141; Fax: 02842 - 222141 2. Varsha Machinery Corporation, C-6, Shivaji Stadium, Mangalwar Peth,

Kolhapur 416012, Maharashtra.; Tel: 0231 - 2640584; Fax: 0231 - 2642014

aamchur (dried mango powder)

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