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SOYA BASED FOOD PRODUCTS

PRODUCT CODE : NA

QUALITY AND STANDARDS : As per FSSAI Act, 2006

PRODUCTION CAPACITY : Flavored Soya Milk 60,000 kgs

Tofu (Paneer) 6000 kgs

Soya Curd 12000 kgs

Value : Rs. 24,00,000/-

MONTH AND YEAR : May, 2014

OF PREPARATION

PREPARED BY : Sh. Sandeep Agarwal

Assistant Director (Chemical)

1. INTRODUCTION

Soybeans possess a very high nutritional value. It contains about 20 per cent

oil and 40 per cent high quality protein (as against 7.0 per cent in rice, 12 per cent in

wheat, 10 per cent in maize and 20-25 per cent in other pulses). Soybean protein is

rich in valuable amino acid lycine (5%) in which most of the cereals are deficient. In

addition, it contains a good amount of minerals, salts and vitamins (thiamine and

riboflavin) and its sprouting grains contain a considerable amount of Vitamin C,

Vitamin A is present in the form of precursor carotene, which is converted into

vitamin A in the intestine. A large number of Indian and western dishes such as

bread, `chapati, milk, sweets, pastries etc., can be prepared with soybean. Wheat

flour fortified with soybean flour makes good quality and more nutritious `chapati.

Soybean oil is used for manufacturing vanaspati ghee and several other industrial

products. Soybean is used for making high protein food for children. It is widely

used in the industrial production of different antibiotics. Soybean builds up the soil

fertility by fixing large amounts of atmospheric nitrogen through the root nodules,

and also through leaf fall on the ground at maturity. It can be used as fodder; forage

can be made into hay, silage etc. Its forage and cake are excellent nutritive foods for

livestock and poultry. Soybean being the richest, cheapest and easiest source of best

quality proteins and fats and having a vast multiplicity of uses as food and industrial

products is sometimes called a wonder crop.

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The protein content of soybean is about 40%. Nutritionally, soy protein is the most balanced plant protein for human consumption. It is high in protein, low in fat and carbohydrate and contains no cholesterol. It is an excellent food for babies, children, elderly people and pregnant and lactating women since it contains vegetable protein which is very nutritious and easy to digest. Besides possessing high nutritional values, Soya milk is best for people suffering from diabetes and lactose-intolerance. It can be said that Soyabean is a valuable gift of Mother Nature to human beings.

2. MARKET POTENTIAL With the increasing health consciousness among the general people, the use of

Soyabean is getting acceptance in the form of textured vegetable protein (popularly known as Soya badi or Soya nuggets), Soya fortified wheat flour, Soya milk, Tofu and Soya curd etc. Being mainly the country of vegetarians, India has indeed a very great potential for Soya products. Soy biscuits made from blends of soybean and wheat flour are also available in the market. These products are penetrating in the diet of the Indians. Here it is important to mention that adding soy protein with cereal protein in any form, improves the quality of the protein in the resulted product by increasing its biological value.

Because of the non-availability of soyamilk and tofu everywhere in the country, this product is confined only to its local area of production. It requires extensive promotional activities on the national level to make it popular.

Being mainly the country of vegetarian people, India has indeed a very great potential for soy products. Its higher nutritional as well as medicinal value within an affordable price has increased the demand of this product.

3. MARKETING STRATEGY There are many established national as well as regional brands but they have

captured mainly the urban and elite markets and for a quality product, there is a vast market which can be penetrated by offering competitive prices. Apart from a growing household market, other lucrative segment is gyms, schools, eateries, restaurants, food joints etc. Marketing would play a crucial role and placement, publicity, commission to retailers etc. are important aspects.

4. BASIS AND PRESUMPTIONS

i. It is presumed that the unit will run single shift per day and 300 days in a year.

ii. The rate of interest has been taken 14% on an average both for fixed investment and working capital.

iii. It is presumed that 1 kg. of Soyabean may yield 7.5 litres of Soyamilk. 1 litre Soyamilk can be converted into two litres of flavoured Soya milk or 1 kg of Soya curd or 200 gms of Soya Paneer (Tofu).

iv. The rates of machinery and equipments and raw materials are those prevailing at the time of preparation of Project Profile. They are likely to vary from place to place and supplier to supplier and necessary changes are to be made as and when required.

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5. IMPLEMENTATION SCHEDULE

The approximate time required for various activities is given below.

However, it may vary from place to place depending upon the local circumstances

and enthusiasm of the entrepreneur:

S. No. Activity Period (in Months)

1. Scheme Preparation and Approval 0-1 Month

2. SSI Provisional Registration & Preparation of Project Report

1-2 Months

3. Sanction of loan 2-5 Months

4. Clearance from State Pollution Control Board

3-4 Months

5. Placement of order for machinery and delivery

4-5 Months

6. Installation of machines 6-7 Months

7. Power connection 6-7 Months

8. Trial Run 7-8 Months

9. Commercial Production 9 Months onwards

Due to overlapping of some activities, normally 6-9 months are required to implement the project.

6. TECHNICAL ASPECTS

6.1. Process of Manufacturing

The initial stage involves the cleaning, sorting of the Soyabean followed by

dehulling and soaking at room temperature in 0.5 1% sodium bicarbonate solution

in 1:3 ratio (soya: solution). After soaking the weight of original soyabean becomes

double, the split (dehulled beans) are ground in hot water in 1:7 and filtered to get

milk. The residue is known as okra. The milk is then cooled to 70C and 0.1 molar

calcium sulphate/magnesium chloride or 2% citric acid solution is added with slow

stirring. These chemicals precipitate/coagulate the proteins of soya milk. The muslin

cloth containing Soya protein is pressed in paneer making boxes for 3 to 5 mts. And

then cut into pieces of approx. desired size and put in cold water for another 30

minutes. Vacuum packed tofu should always be kept in the fridge and after

unpacking, immersed in water.

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The various products which can be manufactured are mentioned in the Chart

below:

6.2. Quality Control and Standards

Product should conform to the FSSAI Act, 2006.

6.3. Production Capacity

S. No. Item Qty. (kg)

1 Flavored Soya Milk 60,000

2 Tofu (Soya Paneer) 6,000

3 Soya Curd 12,000

6.4. Pollution Control

Though no industrial effluent is released in the manufacturing process even

then a NOC from State Pollution Control Board is to be obtained before commercial

production.

6.5. Energy Conservation

Suitable measures should be used for the appropriate use of fuel and

electricity.

Clean & Soak Soyabeans in water

Grind & cook in water

Extract Soya Milk (7.5Lt Soya milk) + (1.4kg Okara)

Okara, Add Salts, Spices, Flour veggies

Bake or Fry or Add to Foods & cook

Add Water, Flavor

Sweetener,

Add Coagulant

or citric

Add Sweetner, Salt

& Yoghurt

Homogenize or mix well soya milk

Extract curd & Press in a

forming Box Tofu (Paneer)

Incubate Yoghurt

optionally add fruits

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7. FINANCIAL ASPECT

7.1. Fixed Capital

Building: Land & Building 1200sq ft. on rent.

7.1.1. Machinery and Equipments

S. No. Description Qty. Amount

(Rs.)

1 Soya Machine for Soya Milk & Paneer (Tofu) consisting of Grinder Cooker, Manual Boiler, Filter Press, Tofu box, Tofu Press

1 No. 2,30,000

2 Deodizer 1 No. 1,00,000

3 Vacuum Packaging Machine 1 No. 1,30,000

4 Freezer 2 No. 60,000

5 Pouch Sealing Machine 1 No. 11,000

6 Tables with AL Top 3 No. 30,000

7 Plastics Trays/ Tubes & other misc. items L.S. 20,000

8 Water Storage Tank 1 No. 10,000

Total 5,91,000

iii Packaging, Forwarding, Tax etc @ 10% 59,100

iv Electrification & Installation @ 10% 59,100

v Office Furniture & Equipments 50,000

vi Preoperative Expenses 20,000

Total Fixed Investment 7,79,200

7.2. Working Capital (per month)

7.2.1. Personnel

S. No. Designation No Rate Total (Rs.)

1 Supervisor 1 10,000 10,000

2 Skilled Workers 1 9,000 9,000

3 Unskilled Workers 1 8,000 8,000

4 Salesman 1 8,000 8,000

Total 35,000

Perquisites @ 10% 3,500

Total 38,500

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7.2.2. Raw Material

S. No. Item Qty. Rate (Rs.) Value (Rs.)

1 Soyabean 1,100 kgs

34/-kg 37,400

2 Chemicals, Flavors, Color & other Materials

L.S. - 15,000

3 Packaging Material for Milk, Curd & Paneer @ Rs. 10/kg

L.S. - 11,000

Total 63,400

7.2.3. Utilities

S. No. Description Value (Rs.)

1 Power(25 unit /day; 1000 units @ Rs. 7/- per unit) 7,000

2 Fuel/ LPG (19kg/cylinder) 5 Nos. @ Rs. 2000/- 10,000

3 Water 1,000

Total 18,000

7.2.4. Other Contingent Expenses

S. No. Description Value (Rs.)

1 Rent 8,000

2 Postage & Stationary 1,000

3 Consumable Store 1,000

4 Repairs & Maintenance 1,000

5 Advertisement & Publicity 3,000

6 Transportation 2,000

7 Telephone/ Mobile 1,000

8 Miscellaneous Expenses 2,000

Total 19,000

7.2.5. Total Recurring Expenditure (per month)

S. No. Description Value (Rs.)

1 Raw Materials 63,400

2 Salary & wages 38,500

3 Utilities 18,000

4 Other Contingent Expenses 19,000

Total 1,38,900

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7.3. Total Capital Investment

Total Fixed Capital Rs. 7,79,200

Total Working Capital (for 2 months) Rs. 2,77,800

Total Rs. 10,57,000

8. FINANCIAL ANALYSIS

8.1. Cost of Production (per annum)

S.No. Description Amount (Rs.)

1 Total Recurring Cost per year 16,66,800

2 Depreciation on Machinery & Equipment @ 10% 59,100

3 Depreciation on Furniture @ 20% 10,000

4 Interest on Total Capital Investment @ 14% 1,47,980

Total 18,83,880

8.2. Turnover (per annum)

S.No. Description Amount (Rs.)

1 Flavored Soya Milk 60,000 kgs @ Rs. 25 per kg 15,00,000

2 Tofu (Paneer) 6000kgs @ 90 per kg 5,40,000

3 Soya Curd 12000 kgs @ Rs. 30 per kg. 3,60,000

Net Turn Over 24,00,000

8.3. Net Profit (per annum)

= Turnover cost of production

= Rs. 24,00,000 18,83,880

= Rs. 5,16,120

8.4. Net Profit Ratio

= Net profit per year

X 100 Turnover per year

= 5,16,120

X 100 24,00,000

= 21.5 %

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8.5. Rate of Return

= Net profit per year

X 100 Total Capital Investment

= 5,16,120

X 100 10,57,000

= 48.8 %

8.6. Break-even Point

Fixed Cost per Annum

S. No Description Amount (Rs.)

1 Depreciation on Machinery 59,100

2 Depreciation on Furniture 10,000

3 Rent 96,000

4 40% of other Expenses excluding LPG/Rent/Transport 81,600

5 40% of Salary & Wages 1,84,800

6 Interest on Total Investment @ 14% per annum 1,47,980

Total 5,79,480

B.E.P

= Fixed Cost

X 100 Fixed Cost + Net Profit

= 5,79,480

X 100 5,79,480 + 5,16,120

= 52.89 %

ADDRESSES OF MACHINERY SUPPLIERS

S. No. Name of the Supplier Address of the Supplier

1 M/s SSP Limited, 19, DLF Industrial Area IV, 13/4, Mathura Road, Faridaabad 121003 Phone: 0129 527544, 5277730 Fax: 91 129 527744

2 M/s. Pristine Plants India Pvt. Ltd.

16, Gurukual Industrial Area,12/6, Mathura Road, Faridabad 121003 Phone: 91 0129 4136901 05 Fax: 91 129 4136901