Project Feasibility Report On Automatic Bread Making Plant Food Processing

MARKET SURVEY CUM DETAILED TECHNO ECONOMIC FEASIBILITY REPORT (PROJECT FEASIBILITY REPORT) ON

AUTOMATIC BREAD MAKING PLANT Published Date: 23 March 2014 For Latest Report – Visit www.eiriindia.org

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This project report has been prepared on the basis of information available with M/S. ENGINEERS INDIA RESEARCH INSTITUTE. The intention here is to provide preliminary information to the prospective entrepreneur. Prior to making a firm decision for investment in the project the entrepreneur must verify the various feasibility aspects together along with the addresses for the procurement of plant & machinery and raw materials independently. The information supplied in this report is obtained from the reliable sources but it is not guaranteed and the money once paid will not be refunded back in any case. Claims for incomprehensiveness of the project report will not be entertained and no legal action in this regard would be entertained in any case (Subject to Delhi Jurisdiction only). Any matter relating to our standard points covered in the report may be modified with in 5 days time only from the date of purchase. ENGINEERS INDIA RESEARCH INSTITUTE, 4449 NAI SARAK, DELHI-110006

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AUTOMATIC BREAD MAKING PLANT [EIRI/EDPR/1074] J.C.9718 CONTENTS INTRODUCTION BAKERY DEVELOPMENT PROPERTIES USES AND APPLICATIONS TEST OF BAKERY PRODUCTS DETERMINATION OF MOISTURE DETERMINATION OF ACID INSOLUBLE ASH DETERMINATION OF CRUDE FIBRE DETERMINATION OF ACID INSOLUBLE ASH DETERMINATION OF VOLUME/MASS RATIO FOR BREAD SAMPLING OF BAKERY PRODUCTS MARKET SURVEY OF BREAD INDUSTRY BREAD MANUFACTURERS/SUPPLIERS PROCESS OF MANUFACTURE WITH FORMULATION BREAD MAKING PROCESS WITH FORMULATION PROCESS FLOW SHEET FLOW CHART BREAD MANUFACTURING PROCESS PROCESSING BREAD BREAD INGREDIENTS BREAD MAKING FLOW CHART BREAD MAKING METHODS PRINCIPLES OF PLANT LAYOUT PLANT LOCATION FACTORS EXPLANATION OF TERMS USED IN THE PROJECT REPORT PROJECT IMPLEMENTATION SCHEDULES PLANT LAYOUT OF BREAD MAKING PLANT COMPLETE PLANT AND MACHINERY SUPPLIERS FOR BREAD MAKING UNIT SUPPLIERS OF RAW MATERIALS PLANT AND MACHINERY

5 7 17 18 21 22 23 25 27 29 31 32 41 44 46 49 51 52 54 55 68 71 78 84 89 92 95 96 100 120

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APPENDIX – A : 1. COST OF PLANT ECONOMICS 2. LAND & BUILDING 3. PLANT AND MACHINERY 4. FIXED CAPITAL INVESTMENT 5. RAW MATERIAL 6. SALARY AND WAGES 7. UTILITIES AND OVERHEADS 8. TOTAL WORKING CAPITAL 9. COST OF PRODUCTION 10. PROFITABILITY ANALYSIS 11. BREAK EVEN POINT 12. RESOURCES OF FINANCE 13. INTEREST CHART 14. DEPRECIATION CHART 15. CASH FLOW STATMENT 16. PROJECTED BALANCE SHEET

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AUTOMATIC BREAD MAKING PLANT [EDPR/1074] J.C.9718 INTRODUCTION Modern days are changes with the advance of scientific discovery. Due to the scarcity of time now human beings changes their food habits. No body can pay much more time for their preparation of food, every body wants to get ready made fresh food, such that human being can save their time. They do not want to loss their valuable time in the preparation of daily food. By this thiming now a days these different kind of food materials developed, like instant tea, instant coffee, instant milk, instant rice etc. On the above point of view bakery products are cheaper, largely accepted ready made food. Now the advancement of age use of bakery foods will gradually increases and utilization will be around the proportional of certain percentage of population increase.

Bread is most consumable wheat-based bakery product. It contains high nutritive value. They are easy to digest and compact in size, therefore, its consumption is increasing very fast.

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Indian bakery industry is spreaded over all small scale, large scale and houshold sectors. First bakery in India was set up in 19th century. At present there are 21 units in organized sector and many more in small scale, cottage and house-hold sectors. Breads are manufactured from flour, sugar, salt shortening (one type of fat), dried bakery yeast, vegetables, fruits etc. Bread is manufactured through fermentation and baking process. The manufacturing process and techniques are so simple that they can easily be adopted for production at any level. Recently Government has reserved production of bread for small scale sector.

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BAKERY DEVELOPMENT Discovery of grinding stones dating back to 75000 years has been taken to mean that even then man had begun to grind seed in order to prepare food in a form that has finally developed into today's. The history of human civilization is not much older. The history of development of today's leavened bread does, therefore, reflect, even though partially, man's march from prehistoric times into the modern day civilization. Though first traces of rubbing stones are available for a period dating back to 75000 years ago, their relatively common use has been established only to about 12000 years ago, in the Azilian Times in Europe. It is believed that it is only at this time that seeds had become an important part of man's diet and his search for a convenient form in which to consume grounded seed became intensified. perhaps this development process took about next 2000 years, because only about 10,000 years ago the oak grove Indians in Southern California are believed to have made use of grounded acorn and other seeds to produce a crude bread as food This bread might have been made of coarsely baked by covering with hot ashes. It is believed that at about the same times Swiss Lake dweller had also developed a primitive art of baking. The Swiss archaeological finds dated about 2500 B.C. establish that their art of baking was based on use of club wheat (a true bread wheat) as the predominant species. The first good picture of primitive baking, however, comes from the ancient tombs of Egypt. Scenes from the tomb of Ti, 2600 B.C. show the milling and bread making process from the removal of the grain from the granary through the grinding on stones and sifting to the mixing and kneading of the dough and subsequent baking of bread in large pots. The milled flour was separated into whiter (fine) flour and darker (coarse) four with the help of use of sieves. The white flour was used to bake bread for the elite and dark flour to bake bread for others. Egyptians are also credited with the first use of leavening. They maintained a stock of sour doughs, a crude culture of desirable fermentation organisms and mixed portions of this material to fresh doughs. This method continues to be in use ever since and a number of bakeries in Egypt as also in India continue to rely on this method of fermentation.

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The first over, to match the needs of baking was also developed with the help of baked Nile-clay. The oven, cylindrical in shape had two chambers, the lower one for fire and the upper one for baking. the pieces of dough were placed in the baking chamber through a hole provided at the top. Egypt thus can be truly described as the motherland of the present day bread since it is here that methods of baking similar in principle to those prevailing today we first developed. As the art of baking developed and spread across continents the bread forms also multiplied. The availability of the enclosed baking utensil or the oven made the baking of thicker loaves and cakes possible. At the same time development of knowledge of fermentation made it feasible to make the loaf structure lighter and more digestible. The next obvious development was addition of appealing flavours to cater to individual and class testes. The task of development of bread by addition of unique ingredients to dough was largely carried out in early Greece. When Roman legions took some Greeks to serve as slaves, the ancient art of baking received some further finishing touches in ancient Rome. Thus only through a series of developments did the bread from change from the ancient flat bread of which Mexican tortilla made of processed corn or Indian chapati usually made of wheat are more sophisticated versions, into the conventional form of leavened bread now in common use in most countries of the world. Early baked products were made of mixed seeds with perhaps predominance of barley. However, when it was observed that doughs or gurells made of different seeds held for several hours before baking exhibited different response to the puffing or leavening action of fermentation and wheat flour responded the best by producing a light porous structure in baked products, bakers naturally opted in favour of wheat flour for bakery products. It is believed that in early civilizations art of baking was closely connected with brewing. Both involved fermentation. The thicker dough was good for baking. The thinner mash produced beer. But when experience suggested that wheat was good for baking whereas barley was good for brewing, a kind of separation between the two trades started.

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Baking for a long time remained a domestic skill with few changes in equipment or processing methods. It is only when relatively large-scale milling developed that baking on a commercial scale came into being. Commercial baking first began in Rome where towards the first century B.C. well-to-do families wishing to avoid frequent and tedious bread making chores began to patronize professional bakers, at that time largely consisting of freed slaves. They baked loaves moulded by hand into a spheroid shape. These generally had a weight of about a pound each and were baked in behive shaped ovens fired by clay. Gradually guilds were formed by the miller-bakers of Rome. At the same time State introduced a food dole which initially consisted of free distribution of grain but was later converted to distribution of bread. This made miller-baker a very important link between the state and the people. It is possible because of this important role of miller-baker that in 2nd Century A.D. Emperor Trojan organized a "College" and defined the duties and obligations of the bakers. Thus reduced baker to a kind of civil servant with limited freedom of action. Here was the beginning of what later developed into a kind of industrial serfdom in Europe. This period also saw a relative stagnatio in the development of baking techniques. It is only towards the middle of middle ages that guilds were revived and expanded. Admission to a bakers guild needed several years of training. The rise of these guilds also reflected in a considerable improvement in baking techniques. Guild regulations strictly controlled size and quality. At outside the cities bread continued to be largely baked at home. But each country or more correctly each culture produced its own variety of bread since bread did lend itself to the manufacture of endless varieties. As the cultures intermigled so did the bread varieties. In Germany, USSR and Scandinavian countries rye bread gained predominance with some mixture of wheat flour to improve gluten content. In Mexico and latin America tortillas continue to remain popular. IN Middle East and India breads are dry and flat even f they are leavened as in most part of Middle East. In India and other Asian and African countries millet cakes are also favoured. In Ethiopia injerra bread is popular. Injerra is a flat leavened bread made of flour from teff, a high protein content grain grown in that country. Also popular is a bread variety prepared from ensete or "false banana". The ensete is ground, made into a dough and "cured" in the earth where it is also stored until needed. Ireland bread is leavened with baking soda and butter milk and contains no yeast.

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Although far eastern communities traditionally preferred riece the western variety of bread is becoming more popular here since the second half of the twentieth century. In particular in Japan bread making industry using U.S. process is expanding rapidly since World War II. Vienna and French breads are long, narrow and cursty. Other forms of raised breads include rolls and buns, chemically leavened quick breads and yeast leavened sweet products that are rich in sugar and shortenings. The leavened breads as thus produced had, however, an important limitation. These breads in all their various varieties had a limited shelf life. These breads were, therefore, not suitable for long journeys to be frequently undertaken in those days by sea. Those undertaking long sea voyages either for discovery, trade or warfare, therefore, demanded a bread form which had a much longer shelf life of more than a few weeks and even months. The answer to their problem was found in "Biscuits". "Bis" means twice and "cuit" means baked which suggests that the product was intended originally to be twice baked. If properly prepared, biscuits were observed to be capable of being kept for a long time and hence these came to be used as a common form of bread at sea. With the development of biscuits came the development of several other products based on unfermented dough, both saltish and sweet. This brought about a dichotomy in the bakery technology which was require to attend to rather different baking needs of fermented and unfermented doughs. The extensive pressures of urbanization, industrialization and wars further helped in considerable improvement of baking techniques. Although raised breads originally depended upon spontaneous fermentation, bakers gradually learned to produce and control fermentation with yeast. Specific strains have been developed with useful bread making qualities, including stability, rapid fermentation capacity and the ability to withstand high temperatures all permitting products of a uniform and consistent quality. Greater use was also made of ingredients other than flour such as milk, shortenings, salt, sugar, eggs, fruits etc.

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Technological improvements partly successfully carried out and partly under development include temperature control and improvements in handling method. Various mixing methods such as the straight dough method, the sponge dough method and never continuous mixing methods are also under development include temperature control and improvements in handling method. Various mixing methods such as the straight dough method, the eliminates several individual operations. An interesting new development in the area of bread making is that of bread fortification. Probably 95 percent of the white bread sold in U.S.A. receive a considerable portion of their calorie in take as well as much of their calcium, iron, thiamine and protein intake from bread. Feeding trials show that addition of 0.5 percent L. Lysine and 0.1 percent to 0.2 percent thiamine considerably improves the protein quality of bread. Both bread and biscuits have thus been identified as very useful carriers of nutrition supplementation. Within reasonable limits the input composition of both can be freely and frequently changed to meet nutrition requirements of specific target groups. These target groups; could be identified either by geographical location or by socio-economic and demographic groups and the nature and level of nutrition supplementation can be suitably altered in such manner as to precisely meet the pre-identified nutrition supplementation requirements of target groups at minimum cost per beneficiary. Bakery industry in India in the modern form developed largely to meet the needs of the British army. It is for this reason that a large part of this industry has its origin in Calcutta which can probably be traced back to the days of East India Co. For somewhat to meet the needs of foreign visitors who arrived in India through this gateway either for war or for trading. Biscuits appear to have been first manufactured in India more than three centureis ago to meet the needs of European travellers. The industry was then localized a important sea ports where European ships called more frequently. Perhaps the India bakers first learnt the art of making conventional biscuits from their European customers.

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Though the beginning towards the manufacture of conventional bread and biscuits of modern variety was made fairly early its development in the preindependence era has been very slow. The first organised factory for the production of biscuits was set up at Calcutta in 1897. Soon afterwards two other factories were set up one each at Bombay and Delhi. IN the next four decades i.e. till the beginning of the second world war only four more factories started production. These factories also produced bread and confectionary besides biscuits. However, when the war started and supplies from abroad were curtailed this industry, like several other industries, received a major stimulus for growth. The pre-Independence history of bakery industry in India in its modern commercial form is thus fairly brief and is largely limited to urban areas. Its impack on rural areas was nil or negligible. Whereas the growth of bakery industry in its modern form is largely a postindependence phenomenon a fairly large traditional bakery industry did exist and continues to exist in this country. The most popular products of this industry are buns, kulcha, nan, and such like items. Some of these are produced in cylindrical ovens popularly known as "tandoors". Others in manually operated bakeries.

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In particular in Jammu and Kashmir the traditional bakery industry continues to be very popular. The principal items of production here are: chauswhroo, Girdha, Kulcha and Bakerkhani. These items are produced in about 1000 tandoors in the State. It is estimated that current consumption of all bakery products in Jammu an Kashmir alone is about 60 tonnes per day of which over four-fifth takes place in the form of traditional bakery items. Jammu and Kashmir thus has the distinction of having highest per capita consumption level of bakery products among all the States in India. Also most of the bakery items used in this State are native to it and are not in use anywhere in the rest of the country or even rest of the world except perhaps for Girdha which finds some acceptance in Hyderabad and also in West Pakistan around Lahore. Each State, thus, has its own traditional bakery products which continue to be in use side-by-side with modern conventional arieties of bread and biscuits and other bakery products. A study of these varieties, State-wise, the quantity in which these are consumed, their recipes, their manner of production and also their manner of consumption (i.e. consumption alone or as a complementary food i.e. with tea or milk or some other complementary food can form an interesting subject of study for students of bakery industry both in India and abroad. The art of making yeast leavened baked grain products has been traced back to the ancient Egyptians is in 2000 B.C. Bread in its many forms continues to constitute an important part of the human diet in most cultures because it is both an energy food and source of valuable nutrients. At the present time, the bakery products industry represents a major portion of the food industry because of its high volume of production and large number of employees. Bakeries in the united states produce more thus, forty million pounds of bread daily and employ more workers than any other food industry. The character of the industry has changed over the years. In the past, because of the shortshelt life bread, each community had its bakery which produced bread on a daily basis and sold it directly to the consumer. With the introduction of preservatives and improved mechanical methods of making bread, these appeared increasing numbers of whole sale baking companies which produced bread in massive quantities and sold it to retails over a wide distribution area. The whole sale type of bakery dominantes the multibillion dollar baking industry today.

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The baking industry generally knew little or nothing about scientific control principles for another 50 years after the pioneer work had begun, but believed that only long and arduous experience would suffice for a knowledge of dough fermentation. Consequently, in spite of the development of new bread making machinery for almost every step in the process, those in charge of production were handicapped by each seasonal fluctuation or milling variation in the flours they used. With the advent of the machine age, all industries benefited by the application of new machine design, especially when steam power gave way to electric motive power that could be applied to individual machines. In the case of the baking process, practically every mechanical development designed to substitute the machine for hand work imposed modifications of the dough to some degree in order for the machine to handle it satisfactorily. Therefore the "almost" automatic baking factory of today has imposed many variations in the dough making process and consequently in the finished baked products. Because of, or inspite of these changes in mechanical handling, the present products of the baking industry are now much better than the old in uniformity, tastefulness, and nutritional value.

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Fortunately, consumer acceptance of the bakers' product during the early 1900's followed the convenience of more general distribution through the grocery stores. The added convenience of wrapped and sliced bread together with the practices of better sanitation, which followed by a few years the economic and social changes resulting from the first World War, speeded the growth of larger baking companies. Discovery of profit potentials by the bankers of the early 1920's led inevitably to financing of combinations of individual plants with the consequent formation of large corporations. These corporate entities, operating many centralized control and purchasing power, were soon to feed the competition of another form of organized baking group, the chain store bakeries. One large plant could produce and distributed breads to many chain store outlets in the surrounding marketing areas through their own established warehouse and trucking system, with a large saving over the regular sales and delivery cost of the independent or corporation bakers. Besides having the price advantage, the chain store organization was able to control more closely the sales of their baked products. A great fear of competition from both corporation bakeries and the chain stores caused the remaining independent bakers, who were limited to there own marketing areas, to seek such technical help as was available. This was found chiefly in the cooperative bakery service organizations an in the technical service personnel maintained by the larger allied distributors of machinery, flour shortenings, yeast and other ingredients. Men trained in cereal chemistry and in associated food sciences began to be sought to spread the word of technical baking knowledge and lead in the production of better products and in better production control. The stimulus of World War I to scientific knowledge brought new candidates in the sciences by the thousands to our colleges and universities. Of these, the relatively few advanced students in cereal chemistry and baking technology were absorbed it the baking and allied industries where they continued the study of baking science and the development of new products and better methods. The American Institute of Baking was organized by the American Bakers Association in 1919 to serve the industry and help teach the fundamental principles of baking.

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The American Institute of Baking was an addition to the several trade schools then offering short course of training in the baking field. Stimulation and more active support of research in cereal technology by the industry resulted in new knowledge for better control of the baking process and improvement of the products therefrom. Fundamental research was simultaneous in many other fields that contributed significantly to baked foods. The phenomenal advances in biochemistry, physical chemistry, food technology and nutrition during the years since 1900 have revolutionized the baking industry through application to the economics and controls of production. Wheat culture studies in the agricultural experiment station of many states paced the development of new strains of wheat better suited to special requirements of flours for a variety of cereal foods, from breads to macaroni. Mill chemist showed the way to blend and mill wheats from different growing areas and with somewhat diverse baking value into a flour that could be duplicated for more uniform baking use. Analytical and mechanical testing methods were worked out as an approach to specifications for and control of ingredients. There were only a few scientists in the bread making fiel in the early 1920's but they had a profound influence on the development of baking technology. Also influential were the few individuals whose engineering skill and imagination led the industry toward more modern automation in bakery production. And it is here that science must take over from the so-called practical operator to maintain control of the hysiochemical and biochemical processes that make up the mass production of baked products of uniformly high quality and nutritive values. A large part of the total production of land, shortening and certain other plastic fats is consumed in the manufacture of commercial baked goods. The average percentage of fat in some of the more popular bakery goods are approximately as follows: pie (rusk 35-50, Pound Cake 15.30, dough Nuts 15-20, Cookies and water 5-20, white and yellow layer cakes 12-15, soda crackers 8-12 pretzels 5 and white bread - 3.

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PROPERTIES

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USES AND APPLICATIONS Bakery products in India are now in common use and are no more exclusive to a few households or classes of performs. Even then, unlike advanced countries where breads are considered basic essentials of a household budget, in India the element of capacity to pay "continues to play a significant role. The outlay on bread, thus shares the character of "discreationary" expenditure rather than expenditure on basic necessities. This i more so in the case of biscuits than in the case of other bakery product. Variants of breads such as rusks have also found much acceptance among relatively poor households and workmen but other bakery products such as cakes, pastries, etc. specifically remain items of "class consumption".

Much attempt is being made to popularize bakery products among all because these products are considered easy, convenient and rather inexpensive means of taking food in hygienically prepared ready to eat form. A particular role in this direction is being played by use of both bread and biscuits as means of nutrition supplementation for large number of children, and locating and nursing mothers who are covered by various feeding programmes run by number of social welfare agencies operating both at the state and the central level.

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It is hoped that increased modernization, influence of urban consumption pattern, spread of industry and commerce and general change in eating habits shall gradually improve the share of rural consumption in the total market for bakery products. Indian consumption of bakery producers per capita basis in in table I and in table II showing the per capita consumption in different countries.

The family system and equally effection role played by everyone from a house be it male head, female partner or children contribute to this consumption. House-wives and continental cooking pattern also contribute to such consumption of bakery items. Cooking habits abroad are relatively. Simpler and therefore bread consumption is especially very high.

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FOR WHITE BREADS REQUIREMENT FOR WHITE BREAD

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TEST OF BAKERY PRODUCTS FOR BREADS Testing will be done by the following confideration: The bread shall be considered as having a good volume the volume/mass ratio is not less than 2.5 when tested. The bread shall be baked in the conventional form or any other form as agreed to between the purchaser and the vendor. The crust shall be free from blisters and shal be of uniform, golden to light brown colour. The crust shall not be burned and shall be free from blisters and shall be of a uniform, golden to light brown colour. The crust shall not be burned and shall be free from soot and any foreign matter. The loaf shall have a good volume. The crumb shall have small pores uniformly distributed throughout and with thin cell walls. It shall be free from non-porous mass, from splits and large holes, from lumps of flour or salt or any other evidence of in complete mixing or baking. There shall be no hollow between the crust and the crumb. The flavour shall be characteristics of fresh, well baked bread, free from bitterness or any other objectionable flavour or taste. The bread shall also be free from indication of rope "rope" or "mould".

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DETERMINATION OF MOISTURE APPARATUS

PROCEDURE

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CALCULATION

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DETERMINATION OF ACID INSOLUBLE ASH APPARATUS

REAGENT

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PROCEDURE Weigh accurately about 20 g of the biscuit power in the dish and ash in the muffle furnace at 600 + 20oC until light grey ash is obtained. Remove the dish from the furance and allow it to cool at room temperature. Add 25 ml of the hydrochloric acid to the dish, cover with a watch-glass and heat on the waterbath for 10 minutes. Mix the contents with the tip of a glass rod and filter through Whatman filter paper No. 42 or its equivalent. Wash the filter paper with water until the washings are free from acid when tested with a blue litmus paper. Return the washed filter paper to the dish for ashing in the muffle furance as above. Cool the dish in a desiccator and weigh. Again ignite the dish for half an hour in the furnace, cool and weigh. Repeat this operation until the difference between successive weighings is less than 1 mg. Filter 25ml of the hydrochloric acid through a blank filter paper, wash, ash and weigh it as in the case of acid insoluble ash. Subtract its mass from the mass of insoluble ash of the sample.

CALCULATION

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DETERMINATION OF CRUDE FIBRE REAGENTS Petroleum Ether Dilute Sulphuric Acid - 1.25 percent (m/v), accurately prepared. Sodium Hydroxide Solution - 1.25 percent (m/v), accurately prepared. Ethyl Alcohol - 95 percent by volume. PROCEDURE

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CALCULATION

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DETERMINATION OF ACID INSOLUBLE ASH REAGENT Dilute Hydrochloric Acid - 5 N, prepared from concentrated hydrochloric acid conforming to IS :265-1976*, by diluting 1 volume of hydrochloric acid with 2.5 volume of water. PROCEDURE Cut the slices of bread into fine pieces and accurately weigh about 10 g i a porcelain dish. Place the dish with the contents in an air-oven maintained at 105 + 2oC for about 4 hours. Cool in a desiccator. Ignite the material in the dish with the flame of a suitable burner for about one hour. Complete the ignitition by keeping in a muffle furnace at a temperature between 550 and 600oC for one hour. Cool the dish in a desiccator. To the ash contained in the porcelain dish, add 25 ml of dilute hydrochloric acid; cover with a watch-glass and heat on a water-bath for 10 minutes. Allow to cool and filter the contents of the dish through Whatman filter paper No 42 or its equivalent. Wash the filter paper with water until the washings are free from the acid. Return the filter paper and residue to the dish. Keep it in an electric airoven maintained at 135 + 2oC for about 3 hours. Keep the dish in a muffle furnace at a temperature between 550 and 600oC for one hour. Cool the dish in a desiccator and weigh. Heat the dish again at a temperature between 500 and 600oC for 30 minutes, cooling and weighing until the difference between the two successive weighings is less than one milligram. Record the lowest mass.

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CALCULATION

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DETERMINATION OF VOLUME/MASS RATIO FOR BREAD EQUIPMENT Wooden Box - Large enough to contain a loaf of bread in such a manner that the top surface of the loaf remains about 1.5 cm below the top level of the box, when the loaf is placed over a thin layer of rape seeds in the box. Graduated Cylinder -

500 ml capacity.

Rape Seeds. Weighing Scale. PROCEDURE Determination of Density of Rape Seeds - Weigh a 500 ml graduated cylinder on the weighing scale. Fill it to the 500 ml mark with rape seed and reweigh. Take the average of three readings. Calculate the density of the seeds in the following manner: Density of seeds (D), g/ml = (B - A) / 500 Where B

=

average mass in g of the cylinder filled with the seeds up to the 500 ml level, and

A

=

mass in g of the cylinder.

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Determination of Volume of Loaf - Weigh the loaf after it is cooled to room temperature and record the mass. Fill the wooden box place. Weigh the box with the seeds. Take two such reading and record the average. Empty out the seeds leaving a thin layer at the bottom of the box. Place the loaf on this layer of seeds and fill the rest of the space in the box with rape seeds. Level off the surface of the seeds b a wooden average. Note 1 - Precaution: Do no press the loaf while keeping in the box. It should be placed on the layer of the sees. The upper surface of the seeds should be leveled off with the sides of the box. Note 2 - Testing shall be done before slicing.

CALCULATION

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SAMPLING OF BAKERY PRODUCTS GENERAL REQUIREMENTS FOR BREAD The samples shall be placed in clean and dry bottles and shall be stored in such a manner that the material is not unduly affected. Each container containing the samples shall be sealed air-tight, and marked with full details of sampling, such as date and time of sampling, batch or code number, name of the manufacturer, and other relevant particulars. BREAD PACKING - The bread shall be wrapped or packed as such or in sliced form in clean waxed paper, or any other suitable non-toxic wrapper to preserve freshness. MARKING - The following particulars shall be clearly and indelibly marked on each pack of bread on the outer side of the wrapper; printing, if any, shall be done by non-toxic and non-transferable ink: a) Name of the material; b) Name and address of the manufacturer; c) Trade name, if any; d) Mass of the load when packed; and e) Any added ingredients, for example, Nutriments like vitamins or minerals. Each pack may also be marked with the ISI Certification Mark.

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MARKET SURVEY OF BREAD INDUSTRY The bread market

Major players The major players in the bread industry that hold about 90% of the market share are Britannia and Modern Industries Ltd. Bakery Products The Indian bakery industry is dominated by the small-scale sector with an estimated 50,000 small and medium-size producers, along with 15 units in the organized sector. Apart from the nature of the industry, which gravitates to the markets and caters to the local tastes, the industry is widely dispersed also due to the reservation policies (relating to the small scale industries) of the government.

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Biscuits and bread which are considered to be the major bakery product and they account for 82% of all bakery production. The unorganized sector accounts for about half of the total biscuit production estimated at 1.5 million tonnes. It also accounts for 85% of the total bread production and around 90% of the other bakery products estimated at 0.6 million tonnes. The last includes pastries, cakes, buns, rusks and others. Biscuits are estimated to enjoy around 37% share by volume and 75% by share by value of the bakery industry. The organized sector caters to the medium and premium segments, which are relatively less price-sensitive. The organized sector is unable to compete at the lower price range due to the excise advantage enjoyed by the informal sector. The organized segment in biscuits has witnessed a steady growth of about 7.5%, conforming broadly to the growth rate of GDP. Biscuits constitute about 7% of the Rs 878 billion FMCG markets in India. During 2009-10 biscuits market grew at double digit (about 11%) compared to a growth of 1.4% for the FMCG industry as a whole, and 4.4% average growth over last five years (2009-2010). Britannia has rationalized its product portfolio pruning the number of its brands. The company moved into the mass market for biscuits introducing lowpriced varieties under the umbrella brand, Tiger. The success of this brand has enabled Britannia to expand its market share in the glucose biscuit market. Its other major brands are 50:50, Mariegold, Bourbon, Pure Magic, Nice, Snax Coconut Crunchies, Glucose-D, Pure Magic, Good day. Its bread portfolio consists of Britannia, Britannia Premium Bake, Tiger and Chekkers.

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Britannia has a tie-up with Danone of France. Danone is one of the largest processed food producers of Europe - ranking seventh globally. It has a 22% equity stake in Britannia. Britannia has the option to draw from the product portfolio of Groupe Danone. Over the past couple of years, it has launched a number of dairy products (processed cheese, flavoured milk, butter, ghee and dairy whitener) and ethnic snack foods such as alloo bhujiya and chana choor. Although MNCs, like Nabisco, Arnotts and United Biscuits ventured into the market, Britannia enjoys a premium position. It has dispersed plants geared to the four metros, which account for a major slice of sales (65%). It also has 20 dedicated small units around the metros to help produce about 50% of biscuit production. Britannia Industries launched chocolate-based products and was exploring several variants in cheese, cakes and biscuits. The company has decided to enter into areas where it will have the potential of becoming number one operator. Britannia started selling lassi and cold coffee in tetrapak. Britannia was also extending its successful biscuit brand, Tiger, into categories like milk or milk powder. Britannia’s French partner, Danone, may consider taking the mass biscuit brand to its other Asian markets like Malaysia and China as well as Russia. Britannia Industries has acquired 49% stake in Kwality Biscuits. It has also acquired Kwality Chef and several other trademarks along with copyrights, designs in labels and packing material. The four group companies to be merged with Kwality Biscuits are Vajram Traders, Camilla Investments, Malakala Traders, Mytrayasa Traders. The domain of Kwality Biscuits includes baking, manufacture of biscuits, cakes, breads, buns, cornflakes and other breakfast foods, popcorn, wheat shreds, pastries and flour. Britannia is looking for more acquisitions in food business. Britania Industries has made an investment of Rs 600 million for its capacity expansion project at Pantnagar. Parle is the second largest producer of biscuits in the organized sector. In the popular brands segment, its Parle G remains a popular brand in the glucose biscuit segment. In the premium segment, its Hide and Seek is attracting competition due to the sway it holds in the market place. In the saltish biscuits, Monaco has been quite popular, especially in the cocktail circuit. Parle's, however, derives a major part of its revenues from the lowpriced products. The company has, nevertheless, outpaced the industry growth in 36 latest Formulations, Books and Visit https://www.eiriindia.org for Bankable Project Reports

step with the market leader Britannia. Parle Products is setting up a new biscuit manufacturing unit at Pantnagar, Uttaranchal. Kellogg's, known worldwide for breakfast cereals, entered a new product segment - biscuits. It has launched Kellogg's choco-biscuits, an extension of its Chocos cereal. Kellogg's found that there was an opportunity to carve out a niche for itself in the market by leveraging the core equity of some of its large cereal brands. SmithKline has succeeded with the launch of Horlicks (a healthfood brand) biscuits. Nestle has recently taken over the biscuit manufacturing joint venture with Dabur, Excelsia and converted it into a wholly-owned subsidiary. Dabur India has divested its entire 40% stake in the controversial joint venture Excelcia Foods with Swiss major, Nestle SA, thus exiting the biscuit business altogether. Lancer Foods is launching cookies, biscuits and namkeens. Vita Gold is positioned against Parle's Glucose brand. Lancer Food Products, a late entrant in the biscuit market, had planned to set up two additional manufacturing plants at Noida, UP. The new plants of Lancer have a biscuit manufacturing capacity of 150 tonnes a day. Some 85% of the company's total production is exported to countries in Africa and the Middle East. Priya Food Products set up with an investment of Rs 26 mn had a capacity to produce 5 tonnes of biscuits per day. In the past near two decades, it has come a long way and today commands a significant share of the biscuit market. A study has shown that Bakeman's market share has remained stagnant. In contrast, older players like Britannia, Parle and SmithKline Beecham and a host of new players like Kellogg's have seen their shares expand. On the other hand, Bakeman is planning a major expansion which is expected to make it the largest biscuit plant under one roof in Asia and the third largest in the world. The size of the bread market is estimated at Rs 15 bn. There are a number of producers in both sectors, organized and unorganized. Modern Foods, a Central public sector undertaking, and a leader in the bread segment was privatized by the government in a strategic sale to Hindustan Lever at a price of Rs. 1054 mn. 37 latest Formulations, Books and Visit https://www.eiriindia.org for Bankable Project Reports

The later was to induct a fresh equity of Rs 200 mn into the company, while the government retained 26% equity, giving it the right to block special resolutions. The deal marks HLL's entry into bread making, having already forayed into ice creams and marketing of flour under the brand name Annapurna. This was its first foray into baking business. Modern Foods had nearly half of the organized market to itself. Britannia’s bread market share declined sharply in 2008-2009 and continued till 2010-2011 mainly because of the competition from Modern Foods. However with the takeover of Modern Foods and the time spent in restructuring has enabled Britannia to have a major share of the bread market. Earlier, Britannia introduced Premium Bake, premium bread. The brand created a high-end segment for the daily staple item used by all segments. Britannia has since been joined by other bread manufacturers like Candico (India), Elite Breads and a host of others with small market presence. From a low priced commodity, bread has graduated into a branded product with discriminating prices. Barring Premium Bake, the others are priced high almost double the standard bread brands. Premium Bake comes closer to the 'normal' price, a mid-way pricing strategy. INCREASING CONSUMPTION OF BAKERY PRODUCTS IN INDIA Bread

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Market Structure

Lead Players Modern Foods,Britannia Inds are the lead players in biscuit in the market. Market Growth Rates 1990-91 1996-97 2001-02 2004-05 2009-10

-

1996-97 2001-02 2006-07 2009-10 2014-15

5.4% 7.9% 6.9% 6.0% 5.0%

Sensitivity Coefficient 5.6% Product Variation Segment Milk Bread Brown Bread Fruity Nutritional and other specialty

Share (%) 85 10 3 2

Leading Brands

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Britannia, Modern, Bakeman Sujana, Premium Bake, Whyte Kollar, Ovenfresh, Premium Bake, Gardema are the leading brands in biscuits. Are you looking for a large market ? Stop looking. There is no bigger market than in India. India has a population of one billion and more. In terms of population India is likely to overtake China and soon will become the largest populated country in the world. Here are some more facts for you to consider.

*

One out of six persons in the world is now an Indian

*

India is a mature democracy and business climate is very good.

*

Indian economy is third largest in Asia after Japan and China.

*

Indian economy is sixth largest in the world and with the present growth rate; it soon will be the fourth largest economy in the world.

*

With inflation under control, lower interest rates and comfortable forex reserves, the Indian economy is projected to grow by 8 to 8.5 per cent during the current fiscal year (2009-10). (One of the fastest growing economies in the world.)

There are certain demongraphic changes that are happening through out the world and India in particular that you need to know. This will 4 guide you to the age group of people you can target to market your products. *

In the first stage, the proportion of young people in the population rises.

*

In the second stage, the proportion of young people declines, that of the old increases modestly, and that of adults of working age increases significantly.

*

India is just entering the second stage and its share of the working age population is expected to increase until 2035 and beyong.

*

In the third stage, the proportion of working age adults falls while that of old people rises.

Where will your customers be living? Throughout the world people are migrating to cities to seek employment, new opportunities and new life styles. The number of people engaged in rural agriculture is declining due to 40 latest Formulations, Books and Visit https://www.eiriindia.org for Bankable Project Reports

migration to cities. This has resulted in the growth of big, small and mega cities that act like magnet to rural youngsters and even to whole families. Cities provide immense economic opportunities to migrants. * The urban population has been growing more rapidly than the rural population. Within the urban areas, the population of mega cities has been growing even more rapidly. * Added to the natural increase is migration of people from rural areas, towns and smaller cities. * It is projected that by the year 2015, five Indian cities will be among the 30 largest cities in the world. These are Mumbai, Kolkata, Delhi, Hyderabad and Chennai, Mumbai will be the second largest city in the world, next only to Tokyo. What kind of purchasing power the people India have. Can they afford to buy high quality bakery products ? Sure they can. The disposable income of most people have gone up and there is new affluence every where. People have become quality consicious and also demand and buy a great variety of products to consume and own from quality foods, cell phones, garments, motorbikes, cars to homes. India annually produces 120 million tones of wheat and is one of the largest producers in the world. India also has a large and under utilized milling capacity to mill products like flour etc needed by the bakery Industry. The milling industry has become quality conscious due to modernization, competition and demanding customers. *

According to the estimate made by the Ministry of Food Processing Industries (2003), the total market of bakery product, bread and biscuit is estimated at 1.5mn ton and 1.1mn ton respectively.

*

The cake market is estimated at 0.4mn ton. Bread market is estimated to be growing at around 7% pa in volume terms.

*

The organized segment of the biscuit market is estimated to be 0.44 mn tons whereas the unorganized sector accounts for the balance 0.66mn tons.

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*

Biscuit market in the recent years has witnessed a little higher growth at around 8-10% pa. Within the biscuit category, cream and specially biscuits are growing at faster pace at 20% pa, while the popular segment is growing.

Large joint family system has given way to compact nuclear families. These days, a household may even consist of one person or a double income no-kids (DINK) family, Often both husband and wives goes to work. Number of meals cooked at home is declining dramatically and consuming convenience foods such as bakery foods and eating out are increasing. The per capita consumption of bakery product like bread, biscuits, cakes and other baker's speciality products are very low by world standards. It is expected that with increase in nuclear families, rise in standard of living and rapid urbanization, the demand and consumption of bakery products will go up many folds. Bank loans are easily available from banks at low interest rates. The ministry of food processing as well as state government encourages starting of bakery units and gives subsidies and tax holidays in select places. Every kind of bakery equipment, both domestically made and imported, is now available to the Indian bakers. Many Indian firms now represent foreign manufacturers and help in proper selection, import, installation, training and service of bakery machines. A limited of amount technical know is also available from the manufacturers. A large variety of bakery additives, that will be useful for preparing world class bakery products, as found in western world, are now available for the Indian bakers. Along with the additives, again some amount of basic technical help is also available to use such sophisticated additives. Recently American Institute of Baking, USA, the world renowned bakery training organization has commenced correspondence courses and specialized training in India on bakery production, engineering, GMP and HACCP etc which can be taken advantage of by Indian bakers. Short and long term training in many other aspects including that of specialty products are also given by AIB at their facility at Kansas, USA. Similarly CFTRI and many other Indian institutions have courses tailored for the Indian needs. The stage is now set for bakers to vastly expand and improve their production, marketing, quality and variety of bakery product to the people of India. 42 latest Formulations, Books and Visit https://www.eiriindia.org for Bankable Project Reports

BREAD MANUFACTURERS/SUPPLIERS

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PROCESS OF MANUFACTURE WITH FORMULATION BREAD THEORY : Bread manufacturing is a process of mixing o bread ingredients and prepared a proper dough of the Ingredients, after complete making of doughing dough is divided, rounded, moulding and proofing, after proofing the products is further pass through the baking own to complete bake the product. The product i.e. bread is ready for cooling, slicing and packing for marketing. GENERAL RAW MATERIAL : 1. Wheat Flour, 2 . Yeast, 3. Sugar, 4. Salt, 5. Water, 6. Shortening agent (like vanaspati), 7. Milk or milk powder etc.

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There are different types of bread of whose formulas are given below:

WHITE BREAD (NORMAL)

INGRIDIENTS

PERCENTAGE ON WT. BASIS OF MAIDA

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BREAD MAKING PROCESS WITH FORMULATION Ingredients: Wheat flour, Sugar, Yeast (ADY), Calcium propionate. Acetic acid, Salt, Ice-crystal, Water Process:

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Mass Balance: Raw materials input: Yield: (220 Pkts X 400 Gms)

69.82 Kgs 82.5 Kgs

Role of chemicals: 1. Acetic acid: Prevents the formation of off smell in bread when storage time increases (2-3 days) 2. Calcium propionate: Acts as a preservative 3. Ice-crystal: It is only added in summer (in hot condition) to regulate the temperature during mixing and improves mixing process. Dissolve the yeast in partly water with the complete addition of sugar in it, stirred the ingredients until it will not formed a homogeneous solution. Temperature of the mixture will be 30oC - 35o. Now added salt in another pot containing residual water. Mix Diet throughly to make a homogeneous solution. Now yeast sugar solution and salt solution is ready. Took the proper amount of flour, first mixed with sugar yeast solution by mixing machine, after complete mixing added to it salt solution to form proper dough. After complete water, sugar and salt mixing, added the shortening in the dough mixer to make a smooth and soft dough. Keep the smooth dough for one hour for fermenting the dough. After one hour, the dough has gone to knock-back operation, after knock-baking of the dough is pass through the divider and rounder. From the rounder to it should go to moulder, in the moulder it is kept for final proofing. AFter final proofing in the mould It will take 40-70 mintues at temperature 40oC) it is pass through baking open where temperature control around 200oC - 300oC ad the baking time around 15-30 mintues. After complete baking of the dough, that is hot form of bread is allow to pass in cooling zone to cool the bread at 30oC, it will take time around 2-3 hour. 50 latest Formulations, Books and Visit https://www.eiriindia.org for Bankable Project Reports

After cooling the bread, now pass it through slicing machine and then wrapping the bread of wrapping machine and seal the bread. Now bread is ready for marketing.

PROCESS FLOW SHEET

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FLOW CHART BREAD MANUFACTURING PROCESS

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PROCESSING

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Moulding /or Cutter Unit These are equipment which cuts the dough sheet into desired shape and size. Plant out put are calculated as per the design of the moulder or cutter. These cutters or moulders have dies , cups or inserts which are fixed on the cavities or surface of the moulder or cutter. Moulder are used for short dough where as cutters are used for hard dough variety. Scrap return conveyor These conveyors returns the scrap dough back to mixers which are again used for production thus minimizing waste. Swivel Panner Swivel panner is installed at the feed end of oven where it centres the dough piece entrance on baking oven band it has swivel arrangement on which it balances the web or centres the web so that wet dough pieces enter s oven in straight line. Baking Oven Dough pieces then enters oven and travels on wire band for baking . Burners generates heat which is circulated through ducts or pipelines to bake wet dough pieces . length and width of oven are designed as per the capacity required. Oven speed is adjusted as per the standards baking time for particular variety Stripper Conveyor Stripper conveyors are provided at the delivery end of oven so that baked biscuit are cooled and doest not come into contact of any surface when hot . Stripper conveyors has wire mesh which carries these hot baked biscuit.

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Cooling Conveyor These conveyors are provided in biscuit production line to bring down temperature of hot biscuits which comes out from oven. normally they 1.5 -2 times of oven length. Magnetic Stacker Stacker are used to distributes and arrange biscuits in a line and are thus could be stacked easily for packing process. These biscuits are made to pass of plates which acts as guides which makes these biscuits to fall into space between the guides. Packing Table Biscuit s travels into guidelines on packing table where either they are fed into into packing machine automatically or are fed into feeding chutes manually by operators. Packing Machine Biscuits are fed into packing machine for packaging there are various types of biscuit packing such as pile type, on the edge and cream sandwich type. Horizontal flow wrap machines are mostly used to pack with flexible packaging. BREAD Bread, One of our biggest staples. How often we take this wonderful food for granted. In today's hectic world, most people get their bread from the grocery store or possibly a bakery. It isn't difficult to make your own bread at home, however. A little time and patience will do the trick, along with some good instructions, which we'll provide.

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No time or patience? You can still have wonderful home made bread, thanks to the incredible bread baking machines on the market. These machines are (pardon the pun) the greatest thing since sliced bread. You simply pour in a few ingredients, turn them on, and in a few hours your kitchen will be filled with the wonderful aroma of home baked bread. You can even set a timer to wake up in the morning to freshly baked bread. For the purposes of this article, however, we will assume you are not using a bread machine and are going to do the entire process by hand. Well, maybe not entirely by hand. A food processor or a heavy duty electric mixer with a dough hook will help tremendously. If you don't have either of these kitchen machines, you can make bread by hand, but be prepared for a good work-out. The dough will need a lot of kneading and mixing. Contrary to making cake or pie doughs, breads generally get better the more they are kneaded and handled. If you're mixing bread by hand, get a very heavy duty wooden spoon and use your muscles. Bread Ingredients

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Whether dried yeas is used or compressed, it is advisable to make a ferment as a first step in dough making. Take a small quantity (minimum six times of the weight of yeast) of water (from total doughing water), add little sugar, and mix. For dried yeast, it is advisable to use luke warm water. Add yeast. Compressed yeast should be broken and dried yeast should be sprinkled. Let it soak until all the yeast starts floating on top which should not take more than 5 to 7 minutes. Add enough flour to make a thick paste, whisk it slightly in order to incorporate some air and leave aside (preferably in a warm place) for 10 to 15 minutes to allow it to rise. This batter is known as flying ferment and serves the purpose of invigorating the yeast activity in a thinner medium which is congenial to yeast activity before it is added to stiffer medium ie. dough where it will be less active in the initial stage. The quality of yeast is also ensured by the speed with which a flying ferment rises. If there is not enough rise within 15 to 20 minutes, the yeast is unsuitable for use and should be discarded. Small quantity (0.1-0.2%) of ammonium chloride will help speed up fermentation process. Yeast activity is optimum at the temperatures between 78-80 deg. F(26-28 deg.C). Water is the only medium which can be heated or cooled in order to bring out the dough at desired temperature for proper fermentation. Water temperature above 120 deg.F is harmful to yeast while temperature below 78 deg.F will slow down yeast activity considerably. Method of calculating desired water temperature for dough making in order to have the dough at 78 deg.F is as follows. Desired water temperature= (Desired dough temperature x 3)(FT+RT+FF) FT denotes Flour Temperature RT denotes Room Temperature FF denotes Friction Factor

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For example: Desired dough temp. is 78 deg.F Let us assume that

FT is 86 deg.F RT is 84 deg.F FF is 12 deg.F

Now substituting figures in our formula we will get; (78 x3)-(86+84+12) = 52 deg.F will be the desired water temp. Friction Factor (FF) is to be calculated by actually running a trial dough where temp. of water used for dough making and the temp. of the finished dough is recorded. Thus we can use the same formula in the following form. Tap water temp. = (Actual dough temp. x 3)- (RT +RT+FF) or FF= (Actual dough temp. x 3)- (Ft +RT+WT.) For example let us assume that ; Tap water temp. (WT.)-84 deg.F Flour temp. (FT) - 82 deg.F Room temp. (FIT) - 80 deg.F Dough temp. (DT) - 94 deg.F By substituting these figures in the above formula we get; FF = (94x3)-82+80+84) = 282 - 246 = 36 deg.F In order to bring down the temperature of water, ice is used. Following is the formula for calculating the quantity of ice to be used in order to bring down the temperature of know quantity of water to desired level. 64 latest Formulations, Books and Visit https://www.eiriindia.org for Bankable Project Reports

Wt. of ice = Wt. of water (tap water temp. = calculated Water temp.) tap water temp. + 112 For example; Wt. of water - 60 kg. tap water temp. - 88 deg F Calculated water Temp.- 68 deg.F Then wt. of ice required to bring down the temp. of 60 kg. water to 65 deg.F will be calculated as follows: Wt. of ice

=

60 (88-68) 88 + 112

= 6 kg. In case of sponge and dough method of bread making, the formula for finding the desired water temp. is as follows: Desired water temp. = (4 x desired dough temp.)(ST. + FT + RT + FF) ST is sponge temperature For example; Desired dough temp. Sponge temp. (ST) Flour temp. (FT) Room temp.(RT) Friction Factor (FF)

78 deg.F 84 82 80 24

Then desired water temp. = (4x78)-(84+82+24) = 42 deg.F

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Having discussed the scientific for calculating the desired water temperature, it may be said for the benefit of retail bakers existing in remote areas where ice may not be available that as a general rule, during summers doughs should be made cool by the use of cold water and water should be sufficiently warmed during winters to allow for loss of temperature through atmosphere or cool equipments. A baker is well advised to make use of thermometer in order to get even results. Mixing While the flying ferment is under way, other ingredients are weighed and prepared. Flour is sifted, salt and sugar are dissolved in water and if any foreign matter is present should be strained through cloth; if the fat is granular, it should be melted without effecting any appreciable rise in temperature. The dough could be mixed by hand as well as machine. If machine is used, water with salt, sugar, bread improvers is added to the bowl first, then flour is added and mixed at low speed. Then ferment is added and dough is developed. Flour contains gluten in which join together and form gluten when water is added to flour and it is mixed. Initially this gluten does not have much elasticity and appears to be wet. As the mixing proceeds, elasticity and water absorptive capacity continue to improve until the dough reaches the final stage of development. As the texture of bread is very much dependent on proper development of gluten it is very necessary that the mixing operation is carried out properly in order to obtain optimum development of gluten. While commencing the mixing operation. It will be observed that the machine does not labour initially. This is known as "Pick up" stage when flour picks up water and all the ingredients are in the process of distributing themselves evenly throughout until the whole mass becomes homogeneous. During this stage the dough seems to be slack but as the mixing proceeds, the gluten takes up water and the dough seems to be drying up. This is termed as "drying up" stage. The dough is still sticky and adheres to the sides of the bowl as well as the mixing arm. As the mixing proceeds, the dough cleans the sides of the bowl and pulls away from the mixing arm. This is known as "Clean up" stage. Shortly afterwards comes the "Development stage" when the dough is considered to be properly mixed. In case of flour having very strong quality of gluten, dough may require longer mixing time to reach development stage. At this stage mixing operation should be stopped. 66 latest Formulations, Books and Visit https://www.eiriindia.org for Bankable Project Reports

Many bakeries follow delayed salt method of bread making, which involves two mixing operations. All the flour, yeast, water, yeast food is mixed sufficiently to make a homogeneous mass. At this stage, aim is not to develop gluten which is accomplished in the second operation. The dough is fermented for a short period. The remaining ingredients i.e. salt, sugar, fat is added during second mixing. Fat should be added at the last stage of mixing allowing just sufficient time for its even, thorough dispersal. If fat is added at the early stage, it will adversely affect the water absorption, and also the gluten development. Quantity and quality of gluten will decide the length of mixing time. Strong flours as a rule require more mixing time. In case of sponge, it is not necessary to mix to clean up stage. It should be mixed just enough to distribute the ingredients evenly throughout the mass. Although, dough making by hand is a laborious job, the operation should be carried out to the right stage without let up in order to ensure quality of product. When the dough is properly mixed, the surface of the dough becomes smooth (which had been rough at earlier stage of mixing), and surface may show some round, coin shaped gas bubbles trapped under very thin film of dough. A small piece of correctly mixed dough can be stretched between fingers into a (paper like) very thin, translucent film. Weak flours and freshly milled flours are mixed for shorter time, with such flours quantity of salt and yeast should be raised and fermentation time should be reduced. If the dough is over mixed, the gluten structure will break down and the rise during fermentation time will be very poor resulting in slow speed of fermentation. The dough will heat up, be sticky and will tend to flatten out during intermediate and final proofing. Bread produced from excessively mixed dough will have less volume, and dark, crumbly texture. Conversely, under mixing will not develop the gluten sufficiently and the dough will be less elastic. The resultant bread will have less volume and a rough break shred. There is possibility of collapse of bread during proofing or in the oven as the gluten will not have enough elasticity to extend with expanding gases. 67 latest Formulations, Books and Visit https://www.eiriindia.org for Bankable Project Reports

FERMENTATION After the dough is correctly mixed, it is fermented for a predetermined time. Although "Fermentation" has been discussed under the paragraph on "Yeast" it is worthwhile to repeat it again. Fermentation is a process whereby yeast organisms feed on sugar and produce CO2, gas and alcohol CO2 gas raises the dough fabric. Part of alcohol evaporates, part is converted into acetic acid and the remaining contributes to the characteristic flavour of bread. There are three sources of sugar in a fermenting dough: 1. Natural sugar present in the flour 2. Formula sugar added in the mix, and 3.

Sugar produced from the starch of flour through enzyme action.

Apart from gas and alcohol, some quantities of glycerin, lactic acid, acetic acid and succinic acid are also produced. These acids and protease enzyme together have a mellowing effect on the gluten there by imparting extensibility to it. The balance between elasticity and extensibility of gluten in a properly conditioned dough should be such that the gluten should remain strong enough (elastic nature) to hold the gases and still mellow enough (extensibility) to expand with the expanding gases. This condition in gluten is achieved by fermenting the dough in the right environment (temp. 78 to 80 deg.F, relative humidity 70 to 75%) for the right time which is decided according to the strength of flour and formulation of the product. An experienced baker can make out by the feel of dough when the right degree of fermentation is achieved. If the dough is allowed to over ferment, if becomes soft and sticky due to over action of protease enzyme and acids. The structure forming capacity of gluten will weaken and depending on the degree of over fermentation, the bread may have an excessive volume with very open texture, or it may collapse during proofing or baking. In any case, the water binding capacity of bread will be reduced resulting in crumbliness and quick staling of bread. Such bread will have a pale crust colour and dark or greyish crumb. The bread will have irregular appearance with rough top and /or caved in sides and bottom. The bread will have a sour taste and aroma. Over fermentation can take place due to a number of factors i.e. use of too much yeast for the method followed, prolonged fermentation time without due consideration to the strength of flour, very slack doughs, lack of salt, fermenting the dough in a warm place and so on. 68 latest Formulations, Books and Visit https://www.eiriindia.org for Bankable Project Reports

An under fermented dough will produce bread with less volume and a harsh redish brown crust colour. The texture will be close and compact. The bread will dry out soon and will have a tendency to be crumbly due to insufficient conditioning of gluten. Taste and aroma of bread will be flat. The dough will have a tendency to flatten out which could be observed during intermediate proofing and due to this fluidity of dough the bread will have sharp edges. Under fermentation may be caused due to a number of factors i.e. less fermentation time given according to the strength of flour, less yeast used for the method followed, too much salt, too tight a dough, dough chilled during fermentation and so on. Knock back After the (straight) dough is fermented for two third of its estimated fermentation time, it is knocked back. The process of knocking back should be carried out correctly by extending the sides of the dough and putting it in the center, so that the whole mass of the dough comes in contact with fresh air and the dough is virtually turned upside down. 1. When the dough is fermenting, the temperature of the upper surface is lower than the temperature of the bottom part of the dough. This variation in dough temperature causes variation in the speed of fermentation in different parts of the same dough. By knocking back correctly the temperature of the whole mass of dough is fairly equalised and fermentation speed becomes even. 2. After a dough has fermented for some time, the gluten is in a stretched condition and if it is allowed to remain so, it will collapse by itself. But this natural collapse will not put the dough in its original compact position and the mass of the dough will have an uneven distribution of gas pockets thereby affecting uneven fermentation after the collapse. By knocking back, the condition of dough becomes even and the fermentation speed remains even throughout the mass. 3. When the dough has fermented for some time, the yeast cell is surrounded by gas and other fermentation products which slow down its activity, as it is drawn away from its food by surrounding gas. By knocking back, the gas is expelled and yeast cell is again in position to carry out its function efficiently.

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The stretching action to which the gluten is subjected during knocking back operation has a beneficial effect on the finished product as this stretching action helps proper conditioning of gluten. After knock back, the dough is again fermented for the remaining one third period during which the dough is filled with gas and the gluten becomes pllable and in a fit condition for further processing. Dividing and rounding The dough is cut into pieces of desired weight according to the size of the mould. While dividing the dough by hand, it is desirable to cut the dough with a regular dough cutter. Pulling and breaking the dough should be avoided as it disturbs the trend of gluten strands thereby adversely affecting the final texture of the product. When dough is cut, the cut surface is exposed while the remaining surface has a stretched gluten film. It is obvious that some gas will escape from the cut surface (technically known as bleeding) and the condition of the dough piece will be uneven. If the piece is moulded in this state, the texture of bread will also be uneven. Therefore, the dough piece is rounded in order to make it uniform. The process is known as rounding or handing up. In large bread factories, dough is divided by Divider machine. Machine divides the dough by volume and not by weight. Therefore it is very necessary that dough is correctly fermented. Otherwise, in case of over fermented dough a particular volume of dough will weigh less due to excessive gas in it and the same volume of under fermented dough will weigh more due to lack of gas in it. Intermediate Proofing Whenever a fermented dough is handled, some of the gas escapes and gluten strands collapse, making the dough tight. If the dough piece is manipulated when it is in tight condition, it will tear off leaving a rough surface. The torn surface will allow escape of gas ehich will have adverse effect on the texture of bread. Therefore, before manipulating the dough further, it should be rested for 10 to 15 minutes. During this period, the piece is again filled with gas and gluten comes back to its pliable condition making further handling possible without tearing. This resting of the rounded dough piece is known as "Intermediate Proofing". 70 latest Formulations, Books and Visit https://www.eiriindia.org for Bankable Project Reports

Moulding and panning" The dough piece, soft and pliable after intermediate proof, is moulded according to the desired shape of the finished product. While moulding the dough piece, it should be remembered that the moulding pressure is even through out the dough piece. Uneven pressure will leave gas pockets of uneven size in the dogh piece which will eventually result in uneven texture. Secondly; the dough piece should not be moulded too tight or too loose. Too tight moulding may tear off the surface which should remain smooth and may also increase the proofing time. Too loose moulding will open up the texture to an undesirable extent. Moulded pieces are put into clean and well greased pans of appropriate size. Too little or too much dough according to the size of pan will spoil the texture. The ratio between the size of the mould and weight of the dough should be 35 cc per 10 g of dough (6 cu.in.per oz.of dough). Proffing After panning, the bread is proofed, under suitable conditions (temperature-95 to 98 deg.F, Relative humidity-80 to 83%) to allow it to rise again and acquire volume. The process is known as proofing. During fermentation time, the gluten should be so matured that it expands with the expanding gas and still retains sufficient strength to hold the gas. When gluten is in such perfect condition, and the temperature and humidity of proofing cabinet are ideal, the rise of bread is faster without taking unduly long time. If the dough is under fermented, the gluten will have less stretchability and more resistance, which may result in excessively long proofing time. If there is crust formation on bread due to lack of humidity, or if there is lack of temperature in proofing cabinet then also the rise will be very slow. Under all these circumstances, the texture of bread will suffer. On the other hand, if there had been excessive fermentation of dough, the bread may rise faster and then collapse. If there is excessive temperature, in the proofing cabinet, there may be partial coagulation of gluten which is immediately in contact with the walls of the bread-mould. That, alongwith faster rise of the rest of the bread, will adversely affect the texture. During proofing operation, the yeast should have sufficient food to affect a faster gas production. Therefore it is necessary that there is sufficient diastatic activity in the flour in order to produce fermentable sugars for yeast to carry out its function efficiently during the critical stage of proofing. If there is insufficient diastatic capacity in the flour, the proofing period is unduly prolonged affecting the texture adversely. Excessive diastatic action will also adversely affect the texture as there will be excessive gas production and gluten will also be excessively mellowed causing it to collapse. 71 latest Formulations, Books and Visit https://www.eiriindia.org for Bankable Project Reports

Baking After the bread has acquired full volume, it is baked. The temperature and humidity of the oven should be well maintained in order to get good results. The temperature of the oven is set according to the quantity of product to be baked, its size and its formulation. Normally, bread products are baked between 400480 deg.F Open top loaves are baked at lesser temperature than sandwich bread. Further, if a formulation contains more than 6% sugar or any amount of milk solids, the product should be baked at lesser temperature. Similarly, large size products are baked at higher temperature than small size products. When the bread is kept in the oven, it acquires heat gradually. Due to increase in temperature, the yeast starts functioning vigorously producing gas which raises the volume of the product. The difference in the size of a product from the time it was kept in the oven to the time it is properly baked is known as "oven-spring". During this period of baking, yeast should get appropriate quantity of food in order to produce gas. This, much needed food, is provided by the breakdown of starch into maltose sugar. As the temperature further rises the yeast cells start getting inactive and completely cease functioning at around 140 deg.F. The enzymes still remain active up to about 170 deg.F, producing sugar from starch. This activity is enhanced due to the fact that the starch is partially gelatinized making it more susceptible to enzymatic action. As the yeast, which had been consuming sugar, is already inactivated, this sugar remains in bread and performs its usual functions of retaining moisture in he product, imparting colour to the crust, improving flavour and taste. As baking proceeds further, the proteins are coagulated (at about 172 deg.F) setting the structure of the product, after which there is no further rise in the volume of bread. Once the structure of the product is set, it starts gaining temperature. Weight is lost due to the evaporation of moisture from the product and the crust starts acquiring golden brown colour.

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1. SELECTION OF RAW MATERIAL 2. WEIGHING OF RAW MATERIAL 3. PREPARATION OF RAW MATERIAL 4. MIXING 5. FERMENTATION 6. KNOCK BACK 7. FLOOR TIME 8. DIVIDING AND ROUNDING 9. INTERMEDIATE PROOFING 10. MOULDING AND PANNING 11. PROOFING 12. BAKING 13. COOLING 14. SLICING AND WRAPPING

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The temperature of the oven for baking bread is very important. If the oven is very hot, the coagulation of protein, (forming of crust) on the outer surface will take place very soon. This crust formation will block the easy transmission of heat inside the bread. As a result when gas expands in the inner portion and crust being nonstretchable, there will be an exaggerated break in the bread. The crust colour will be too dark and the bread may not be baked properly from inside. Since the early crust formation will check full rise of bread, the volume will remain small and due to uneven expansion, there will be poor shape. Conversely, if the oven is too cold, coagulation of protein will be delayed and yeast will remain active for longer period, which will result in excessive volume of bread. Due to lack of temperature, bread will be required to be baked for longer duration, resulting in evaporation of more than necessary amount of moisture. Resultant product will be crumbly and will state faster. When there is sufficient humidity in the oven, expansion of bread will be even, enabling the bread to acquire proper volume. Lack of humidity in oven will cause faster evaporation of moisture from external surface of bread. As a result, there will be faster formation of crust which will eventually result in small volumed loaf. There will be uneven expansion and poor shape. If bread is baked in excessive humidity, the crust will become tough and leathery and adequate amount of moisture may not bake off from bread, making the crumb over moist and vulnerable to mould infection. If the oven is over loaded (in relation to the temp. of oven, which may usually happen with fire wood oven) each bread will get leasser share of heat. As a result yeast activity will continue for longer time and coagulation of protein (i.e. setting of structure) will be delayed. In such condition, texture of bread will open up excessively, promoting crumbliness and early staling. Crust colour will also remain dull. In case of under loading, the effect will be same as in case of baking bread in too hot oven. If it becomes necessary to bake a small batch of bread in a large oven, humidity should be sufficiently increased and bread should be protected from fierce heat by covering it suitably (with baking trays etc.).

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Bread moulds should always be placed in oven at a distance of about half an inch from, and parallel to, each other which will ensure proper circulation of heat and evenly baked product. If moulds are loaded too close to each other, the sides of the bread which are in close contact, will be insufficiently baked, without proper curst colour. Whitish sides give a poor appearance and usually get infected by fungus very soon. However, present day practice of using set of three or four moulds strapped together at appropriate distance takes care of such problems. When an open top loaf (without putting the lid as in case of sandwich bread) is baked, it should get a break on the sides of the loaf and the characteristic of this break (shred) should be smooth. This break shred is a test of good bread and is the result of proper processing, mainly fermentation and baking conditions. Adequate fermentation creates such a balance between the gassing power of the dough and condition of gluten that the dough has capacity to expand with expanding gas and still has sufficient strength to retain it (and not give way to expanding gases). When this condition is achieved in the dough and bread is placed in the oven for baking, the crust formation takes place first on top and sides of the bread. The junction point of top crust and side remains the weakest part where from the gas escapes creating a smooth break. In hearth type products (French bread, Vienna bread etc. which are baked without any mould) this break could be predetermined by docking or scoring (cutting with a sharp blade) the product. If the dough is under matured, there will be less stretchability and more resistance in it. In such case, depending on the degree of under maturing there could be blind appearance (if too much under fermented) or a wild break or flying tops where the upper crust is separated from the crumb body of the bread like a lid with hinge. Over fermentation will mellow the gluten excessively which will have little resistance power. In this case bread will have blind appearance without any break. Bread will also have sunken appearance.

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COOLING Bread should be released from the mould immediately after baking,otherwise the moisture trapped between the break and surface of the mould will make the product soggy, technically known as "Sweating". When the bread is withdrawn from the oven after baking, the process of moisture evaporation continues as long as it is warm. If the bread is wrapped during this stage, the water vapours will be absorbed by the bread itself (specially crust) and will remain as free moisture. This free moisture will be conducive to fungus infection. Therefore, the bread should be packed only when it is thoroughly cooled (especially center of crumb) to room temperature. When the bread is hot, starch granules are in a swollen state and held unstably by gluten framework. If the bread is sliced in this state, the unstably positioned starch granules will lump up together giving a very poor appearance to slice. After the bread is brought down to room temperature, the starch granules will shrink and stabilise in gluten framework and then only bread could be sliced in neat slices. PACKING Bread is packed in order to preserve its freshness and to protect it from hazards of external contamination. Air tight wrapping is not advisable in tropical climate. The bread should be allowed to breathe but not unduly exposed. Wax paper or indented poly propylene material will serve the purpose satisfactorily.

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BREAD MAKING METHODS

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PRINCIPLES OF PLANT LAYOUT

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PLANT LOCATION FACTORS

Primary Factors 1.

Raw-material supply: a. Availability from existing or future suppliers b. Use of substitute materials c. Distance

2.

Markets: a. Demand versus distance b. Growth or decline c. Inventory storage requirements d. Competition - present and future. 89 latest Formulations, Books and Visit https://www.eiriindia.org for Bankable Project Reports

3.

Power and fuel supply: a. Availability of electricity and various type of fuel b. Future reserves c. Costs

4.

Water supply: a. Quality - temperature, mineral content, bacteriological content b. Quantity c. Dependability - may involve reservoir construction d. Costs

5.

Climate: a. Investment required for construction b. Humidity and temperature conditions c. Hurricane,a tornado, and earthquake history

Specific Factors 6.

Transportation: a.

Availability of various services and projected rates 1. Rail - dependable for light and heavy shipping over all distances 2. Highways - regularly used for short distance and generally small quantities

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3. Water - cheaper, but may be slow and irregular 4. Pipeline - for gases and liquids, particularly for petroleum products 5. Air - for business transportation of personnel

7.

Waste disposal: a. Regulations laws b. Stream carry-off possibilities c. Air-pollution possibilities

8.

Labor: 1. Availability of skills 2. Labor relations - history and stability in area 3. Stability of labor rates

9.

Regulatory laws: a. Building codes b. Zoning ordinances c. Highway restrictions d. Waste-disposal codes

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10. Taxes: a. State and local taxes 1. Income 2. Unemployment insurance 3. Franchise 4. Use 5. Property b. Low assessment or limited term exemptions to attract industry

11. Site characteristics: a. Contour of site b. Soil structure c. Access to rail, highway, and water d. Room for expansion e. Cost of site f. Site and facilities available for expansion on present company-owned property

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12. Community factors: a. Rural or Urban b. Housing costs C. Cultural aspects - churches, libraries, theatres d. School system e. Recreation facilities f. Medical facilities - hospitals, doctors

13. Vulnerability to wartime attack: a. Distance important facilities b. General industry concentration 14. Flood and fire control: a. Fire hazards in surrounding area b. Floor history and control

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EXPLANATION OF TERMS USED IN THE PROJECT REPORT

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PROJECT IMPLEMENTATION SCHEDULES

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PLANT LAYOUT OF BREAD MAKING PLANT

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COMPLETE PLANT AND MACHINERY SUPPLIERS FOR BREAD MAKING UNIT

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SUPPLIERS OF RAW MATERIALS

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PLANT AND MACHINERY S.No.

Description

Price

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TOTAL

------------------Rs.XX, XX, XX, XXX -------------------

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BREAD PLANT [EIRI/EDPR/1074] J.C.: 9718 J.C. 9718

Page A-

1

PLANT ECONOMICS

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BREAD PLANT [EIRI/EDPR/1074] J.C.: 9718 J.C. 9718

Page A-

2

LAND & BUILDING

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BREAD PLANT [EIRI/EDPR/1074] J.C.: 9718 J.C. 9718

Page A-

3

PLANT & MACHINERY

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BREAD PLANT [EIRI/EDPR/1074] J.C.: 9718 J.C. 9718

Page A-

4

OTHER FIXED ASSETS

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BREAD PLANT [EIRI/EDPR/1074] J.C.: 9718 J.C. 9718

Page A-

5

FIXED CAPITAL

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BREAD PLANT [EIRI/EDPR/1074] J.C.: 9718 J.C. 9718

Page A-

6

WORKING CAPITAL REQUIREMENT/MONTH RAW MATERIALS

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BREAD PLANT [EIRI/EDPR/1074] J.C.: 9718 J.C. 9718

Page A-

7

SALARY & WAGES / MONTH

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BREAD PLANT [EIRI/EDPR/1074] J.C.: 9718 J.C. 9718

Page A-

8

UTILITIES AND OVERHEADS

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BREAD PLANT [EIRI/EDPR/1074] J.C.: 9718 J.C. 9718

Page A-

9

TOTAL WORKING CAPITAL/MONTH

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COST OF PROJECT

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BREAD PLANT [EIRI/EDPR/1074] J.C.: 9718 J.C. 9718

Page A- 10

TOTAL CAPITAL INVESTMENT

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BREAD PLANT [EIRI/EDPR/1074] J.C.: 9718 J.C. 9718

Page A- 11

COST OF PRODUCTION/ANNUM

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BREAD PLANT [EIRI/EDPR/1074] J.C.: 9718 J.C. 9718

Page A- 12

TURN OVER/ANNUM

PROFIT

=

RECEIPTS - COST OF PRODUCTION

=

x,xx,xx,xx,xx,xxx

=

x,xx,xx,xx,xx,xxx

PROFIT SALES RATIO = =

=

Profit / Sales

-

x

x,xx,xx,xx,xx,xxx

100

x,xx,xx,xx,xx,xxx ------------------------------ X 100 x,xx,xx,xx,xx,xxx xx.xx %

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RATE OF RETURN =

Operating profit / T.C.I =

=

x

100

x,xx,xx,xx,xx,xxx ------------------------------ X 100 x,xx,xx,xx,xx,xxx xx.xx %

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BREAD PLANT [EIRI/EDPR/1074] J.C.: 9718 J.C. 9718

Page A- 13

BREAK EVEN POINT (B.E.P) Fixed Costs of the plant are as under -

B.E.P.

=

FIXED COSTS ------------------------------ X 100 FIXED COSTS + PROFIT

=

x,xx,xx,xx,xx,xxx ------------------------------ X 100 x,xx,xx,xx,xx,xxx + x,xx,xx,xx,xx,xxx

=

xx.xx %

LAND MAN RATIO = Total land / Manpower 4000 : 40

::

100 :

1

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BREAD PLANT [EIRI/EDPR/1074] J.C.: 9718 J.C. 9718

Page A- 14

RESOURCES FOR FINANCE

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BREAD PLANT [EIRI/EDPR/1074] J.C.: 9718 J.C. 9718

INSTALMENT PAYABLE IN

Page A- 15

5 YEARS

================================================================================ Year To Financial To Commercial To others Total institutions banks (Rs. 38161500) (Rs. 5193159) (Rs. 23344817) ================================================================================

=== =============================================================================

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INTEREST PAYABLE IN

5 YEARS

================================================================================ Year On term loans On bank loans On self loans Total (Rs. 38161500) (Rs. 5193159) (Rs. 23344817) @ 13.50 % P.A. @ 13.50 % P.A. @ 13.50 % P.A. ================================================================================

=== =============================================================================

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TOTAL REPAYMENT SCHEDULE FOR 5 YEARS ================================================================================ Year Interest Instalments Total ================================================================================

================================================================================

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BREAD PLANT [EIRI/EDPR/1074] J.C.: 9718 J.C. 9718

DEPRECIATION CHART FOR

Page A- 16

5 YEARS

================================================================================ Year Building costs Plant & Machinery fur. & office equip. Total ( Rs. 23100000.00 ) ( Rs. 8360000.00 ) ( Rs. 600000.00 ) @ 10.00 % P.A. @ 20.00 % P.A. @ 20.00 % P.A. ================================================================================

=== =============================================================================

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BREAD PLANT [EIRI/EDPR/1074] J.C.: 9718 J.C. 9718

PROFIT ANALYSIS FOR

Page A- 17

5 YEARS

================================================================================================ YR CAP. Sales Mfg. Gross DepreInterest Net profit Net profit UTIL Expenses Profit ciation before tax after tax @ 35.00% ================================================================================================

==== ============================================================================================

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CASH FLOW STATEMENT FOR

5 YEARS

================================================================================ YR CAP. Net profit DepreCash Repayment of Net surplus UTIL (after tax) ciation in hand Instalment ================================================================================

=== =============================================================================

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BREAD PLANT [EIRI/EDPR/1074] J.C.: 9718 PROJECTED BALANCE SHEET FOR ( 5 YEARS)

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We hope MARKET SURVEY CUM DETAILED TECHNO ECONOMIC FEASIBILITY REPORT in your possession at the time, must have conveyed you the elementary idea on process data, market and economics. We feel you must have now taken a decision to finalize your project plan for ultimate implementation in a successful manner. Before you go ahead, we suggest you to take our PRACTICAL PROJECT EXECUTION KNOW HOW REPORT. "EIRI" offer you PRACTICAL PROJECT EXECUTION KNOW HOW REPORT on this project. Brief contents of PRACTICAL PROJECT EXECUTION KNOW HOW REPORT are as under : THIS REPORT SHALL BE FULLY BASE DON CLIENT’S REQUIREMENTS WITH THEIR PROJECT COST, CAPACITY, PROJECT LOCATION WITH DETAILED MARKET SURVEY, DELIVERY SHALL BE MADE WITHIN 20 DAYS ON RECEIPT OF 60% AS ADVANCE- EIRI • • • • • • • • • • • • • • • • • • • • • • •

Introduction Properties BIS (Bureau of Indian Standard) Specifications & Requirements Uses & Applications Present Indian Market Position Expected Future Demand Export & Import Statistics Data Names and Addresses of Existing Units (Present Manufactures) List of Plant & Machineries Miscellaneous Items and Accessories Instruments, Laboratory Equipments and Accessories Electrification, Electric Load and Water Maintenance, Suppliers/Manufacturers of Plant and Machineries Process of Manufacture with formulae if applicable Flow Sheet Diagram List of Raw Materials Availability of Raw Materials Requirement of Staff & Labour Personnel Management Skilled & Unskilled Labour Requirement of Land Area Built up Area Plant Layout.

along with financial details as under: Summary of Capital Cost of Project Land & Side Development Exp. Buildings Plant & Machineries Misc. Fixed Assets Technical Know how Fees & Exp. Preliminary Expenses Pre-operative Expenses Provision for Contingencies below mentioned financial statements (Annexure) will be for 5 to 10 Years

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Annexure Annexure Annexure Annexure Annexure Annexure Annexure Annexure Annexure Annexure Annexure Annexure Annexure Annexure Annexure Annexure Annexure Annexure Annexure Annexure Annexure Annexure Annexure Annexure Annexure

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Cost of Project and Means of Finance Output, Profitability and Cash Flow Chart Assessment of Working Capital requirements Sources of Finance Balance Sheets Break-Even Analysis and profitability analysis. Quantitative Details-Output/Sales/Stocks Sales Realisation Raw Material Cost Other Raw Material Cost Packing Material Cost Consumables, Store etc., Employees Expenses Fuel Expenses Power/Electricity Expenses Repairs & Maintenance Exp. Other Mfg. Expenses Administration Expenses Selling Expenses Depreciation Charges - Profitability Depreciation Charges Interest and Repayment - Term Loans Tax on Profit Assumptions for Profitability workings Assessment of Working Capital

Engineers India Research Institute (EIRI) is a renowned name in the industrial world for offering technical and financial consultancy services. EIRI services are: Detailed Feasibility Reports New Project Identification Project Feasibility and Market Study Identification of Lucrative Industrial Project Opportunities Preparation of Project Profiles / Pre-Investment and Detailed Feasibility Studies, Market Surveys / Studies, Market Survey Cum Detailed Techno-Economic Feasibility Reports Project Reports in CD Roms Identification of Plant /Process/Machinery and Equipment, Industrial General Guidance for setting up new industrial projects. PLEASE SEND YOUR CONFIRMED ORDER WITH REMITTANCE AT: ENGINEERS INDIA RESEARCH INSTITUTE 4449, Nai Sarak, Main Road, Delhi-110 006 (India) Ph: 91-11-23916431, 23918117, 45120361, 64727385, 23947058 E-Mail: [email protected] Website:www.eiriindia.org, www.eiribooksandprojectreports.com Mob: 9811437895, 9811151047

139 latest Formulations, Books and Visit https://www.eiriindia.org for Bankable Project Reports

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Handbook of alcoholic beverages, distilled spirits, beer, rum, whisky, fruit spirits,.. Handbook of animal farming, agro cultivation, plantation, floriculture and tree farmi.. Handbook of ayurvedic and herbal medicines manufacturing unit.. Handbook of bakery and confectionery products manufacturing unit.. Handbook of biofuels production and processing technology.. Handbook of biotechnology techniques - environmental biotechnology - animal biotechno.. Handbook of building materials - chemicals and technology.. Handbook of ceramics, glass, asbestos, bricks, construction material manufacturing un.. Handbook of chemicals, dyes, petrochemicals, lubricating oils, electroplating product.. Handbook of cold storage unit - frozen food processing and technology.. Handbook of dairy farming, milk processing and products with ice cream technology.. Handbook of drugs and pharmaceuticals technology - formulations, process and science.. Handbook of essential oils, flavors and aromatic plants production units - process - .. Handbook of export oriented units (100% eou/eou) .. Handbook of ferrous and non-ferrous metals production - steel, stainless steel, rolli.. Handbook of fish farming - fisheries and aquaculture, fish and marine products, proce.. Handbook of food coloring technology - food colours, flavours, flavors, gums, stabili.. Handbook of food processing and dairy milk processing industry - formulations, proces.. Handbook of fruits and vegetable processing technology.. Handbook of gum, sealants and adhesive manufacturing process - formulations.. Handbook of herbal cosmetics and synthetic cosmetics - ingredients and formulations.. Handbook of herbs, medicinal and aromatic plants - cultivation, process and technolog.. Handbook of honey processing and beekeeping technology - commercial production and mo.. Handbook of mining, minerals and mineral based industry.. Handbook of most profitable small scale industries, home based businesses, export ori.. Handbook of mushroom cultivation and processing technology.. Handbook of offset printing and screen printing process - modern printing technology .. Handbook of oils, fats and derivatives - methods, formulations, process and technolog.. Handbook of packaged drinking water and water based industries.. Handbook of paint manufacturing process, chemical formula - varnish, solvent, thinner.. Handbook of perfumes, flavours and fragrance manufacturing unit - incense sticks, aga.. Handbook of pesticide manufacturing plant and agro chemicals - insecticides, weedicid.. Handbook of plastic and polymer processing - modern plastics and applied plastics eng.. Handbook of pulp and paper technology, manufacturing process - handbook of pulping an.. 140 latest Formulations, Books and Visit https://www.eiriindia.org for Bankable Project Reports

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Handbook of rosin processing, rosin derivatives, oleoresin and pine chemicals, terpen.. Handbook of rubber chemicals, compound and rubber goods industries (with technology a.. Handbook of soap and detergent manufacturing process, technology and formulations.. Handbook of spice and masala manufacturing process - technology, seasoning and formul.. Handbook of starch, maize, corn and allied products technology, process and formulati.. Handbook of synthetic resins, emulsifiers, polymers, coating and allied technology - .. Handbook of tea processing technology - cultivation, composition and manufacturing pr.. Handbook of textile auxiliaries, chemicals, dyes and dye intermediates formulations a.. Handbook of textiles, cloths and garments industry - chemicals, dyeing, bleaching and.. Handbook of tree farming - profitable and fast growing trees technology.. Handbook of vermiculture technology and biotechnology - process and formulations.. Handbook of waste based industry - products from industrial waste, agriculture waste,.. Handbook of wood based industries - veneer, plywood, particle board, fibreboard, bamb..

Bankable Project Reports 

100% profitable export oriented units projects..  Abrasive, asbestoes, cement refractories, tiles, bricks etc..  Activated carbon viz activated carbon from rice husk, straw, cashewnut shell,coir pit..  Agro based industries..  Alcohol, beer industry, wine, imfl, country liquor, wine, spirit from sugarcane molas..  Allied and chemical industries..  Aluminium and aluminium based projects (extrusion, utensil, rolling mill etc.)..  Aluminium industry and aluminium extrusion, wire drawing, aluminum ingot, aluminum pr..  Automobiles, mechanical and mechanical projects..  Ayurvedic/herbal pharmacy & cosmetic products..  Bakery and baking products, biscuits, cakes, pies, pastries, cookies, breads, baking ..  Bakery and confectionery products..  Banana based industries and banana processing..  Beer and wine industry..  Best agricultural research projects including poultry farming, organic farming, cow f..  Beverages, non carbonated drinks, tea, coffee, non alcoholic, cold drink, soft drinks..  Biochemicals and biotechnology..  Biodegradable products, tableware, recyclable, disposable, eco-friendly plastics, car..  Breakfast foods such as grains or cereals, fruit, vegetables, protein foods viz eggs,..  Cables viz cable industry, cable manufacturing, aluminium cable, copper cable, pvc ca..  Cereal processing projects.. 141 latest Formulations, Books and Visit https://www.eiriindia.org for

Bankable Project Reports

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Chemicals (organic/inorganic) and allied industries.. Chillies viz. red chilli powder, modern chily powder, chilly oil, chilli sauce, tomat.. Coal and coal bye products, smokeless coal, coal tar, crude coal creosote oil, coal t.. Coconut & coconut products, coconut shell products, coconut plantation, coconut w.. Coffee industry viz coffee plantation, instant coffee, green coffee beans, coffee pow.. Cold storage, cold supply chain, cold storage by controlled atmosphere, cold storage .. Computer products.. Confectionery, sweets, lollipops, candy bars, chocolates, caramels, ice cream, toffee.. Copper and copper products like copper enamelling, copper flats & tubes, copper w.. Dairy farming, milk processing and dairy products.. Detergent like washing powder, synthetic detergent powder, detergent cake, detergent .. Disposable and surgical products.. Dyes, pigment dye & intermediates, acid dyes, azo dyes, sulfur black dye, dye lev.. Edible oils, essential oils and lubricating oils industry.. Education based projects (school/ college).. Electrical, electronic, computer and software with infotech projects.. Electroplating, anodising and metal treatments etc... Entertainment, media and leisure based projects.. Fast moving consumer goods (fmcg) .. Fasteners, wire nails, high tensile fasteners, nuts, bolts, washers, rivets, clips, h.. Fertilizers feasibility, inorganic fertilizers (mineral fertilizer), diammonium phosp.. Fisheries and aquaculture, fish processing, fish and marine products, fish farming, a.. Food packaging industries, namkeen packaging, milk packaging, honey packaging, spices.. Food processing industries, food technology, food science & technology, food indu.. Food processing, agro food, agro plantation, cultivation & farming.. Food technology, foods, food processing projects.. Formaldehyde, urea formaldehyde, melamine formaldehyde powder, phenol formaldehyde re.. Ginger cultivation, ginger processing, ginger oil, ginger paste, ginger powder, ginge.. Glass sheet, flat glass, multiaxial glass fabric, art glass, hollow glass, fibre glas.. Glass, ceramics and refractories.. Gums, adhesives and sealants.. Herbs, ayurvedic and herbal, herbal cosmetics projects.. Hospital specialized (super speciality) hospitals, healthcare, nursing home, diagnost.. Ice cream and ice cream by products (frozen, dairy, food, ice candy, butter, softy, v.. Industrial & textured paints, epoxy paints, primer, pigments, enamels, paint addi.. Industrial adhesives, sealants, glues, gums, wood adhesives, rubber adhesive, synthet.. Industrial gases projects - oxygen & nitrogen gas, acetylene, natural, ammonia ga.. 142 latest Formulations, Books and Visit https://www.eiriindia.org for Bankable Project Reports

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Infotech/it, hotel, hospital, school, college, medical college, entertainment club, w.. Inks, printing inks, flexographic inks, offset inks, digital ink, gravure inks, inkje.. Insecticides, disinfectants, pesticides, mosquito repellents, phenyl, fertilizer, fun.. Jute and jute based projects, jute batching oil, jute products, coir, shopping bags, .. Lacquer industry, nitrocellulose (nc) lacquer, water based lacquer, polyurethane (pu).. Leather and leather products, leather tanning, leather accessories, finished leather .. Lithium ion battery manufacturing (lib manufacturing), electric vehicles and brushles.. Maize, corn, starch, glucose and its products processing projects.. Mango like mango powder, mango juice, mango pickles, mango pappad, mango processing a.. Mining, granite, gypsum, mica, marble and minerals based projects.. Miscellaneous products.. Mosquito preventive projects viz mosquito coil, mosquito repellent, mosquito liquid v.. Non ferrous metals- rolling, aluminium, copper, nickel, brass, tin, zirconium, cadmiu.. Onion and onion products viz onion dehydration, onion and garlic powder, onion flakes.. Packaging industry, bottling, labels, beverage can, bottles, foils, blister, carton, .. Paint, pigments, enamel, inks, solvents, thinners and varnish.. Paper industry, kraft paper, disposable paper products, waste paper recycling, pulp, .. Perfumes, flavours and essential oils.. Petrochemicals, polypropylene, propylene, ethylene, benzene, toluene, xylene, ethane,.. Petroleum and petroleum products, automotive & industrial lubricants, refining, l.. Petroleum oils, chemicals, lubricating oils, greases, brake oil etc... Pharmaceutical, drugs, ayurvedic medicines.. Pipe fitting research report - plastic, b.o.p.p., acrylic, pet, pvc, hdpe/pp, ldpe, r.. Polishes viz liquid floor polish, wax floor polish, buffing & polish compound, li.. Potato and potato based products.. Poultry and poultry farming, chicken, hatchery, meat, cattle, pork, eggs, fish, broil.. Power plant (hydro, hydel, lignite, bio gas, gas based, coal, solar, wind energy) .. Printing & packaging.. Printing - flexography, offset printing, laser printing, rotary printing, screen prin.. Products from wastes (agro based and industrial waste).. Profitable multi crores industries/units.. Pulp, paper, straw/grey board, stationery and paper based projects.. Ready to eat project report - agriculture and food processing, agro processing techno.. Readymade garments, textile & textile auxiliaries, leather garments, jute garment.. Resins, emulsion polymers, synthetic resins, emulsion polmers and coating projects.. Rice husk, rice hull, paddy, bagasse, rice husk ash (agricultural waste) like furfura.. Rolling and re-rolling, steel re rolling, rolling mill, aluminium rolling, sheet roll.. 143 latest Formulations, Books and Visit https://www.eiriindia.org for Bankable Project Reports

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Rubber & plastic industries, reclamation, frp products, polymers, pet, pvc, ldpe,.. Rubber and rubber products, rubber chemicals, goods, latex, compounds and industries,.. Rubber chemicals, goods, latex, compounds and industries.. Soap industries like bar soap, herbal soap, bath soap, toilet soap, industrial soap, .. Soap, detergent, cosmetics, perfumes and allied projects.. Solar & solar photovoltaic panel (pv panels), solar electrical panel, solar water.. Solar and solar based projects (power plant, geyser, cell, modular etc.).. Soya and soya products, soyabean oil, soya paneer, soyabean processing solvent extrac.. Stationery viz stationery products, pens, pencils, computer stationery, ball pen and .. Steel and steel products, steel wire, rolling mill, foundry, mild steels, iron & .. Steel, metals, rolling mills and automobiles.. Surgical & disposable medical projects (syringes, gloves, needles, cotton and ban.. Tamarind based products (tamarind juice concentrate, tamarind kernel powder, gum from.. Tea industry viz tea processing, caffeine from tea waste, tea plantation, black tea, .. Textile, woollen, cotton, bleaching, dyeing, hosiery, yarn, readymade garments etc... Tobacco, pan masala, khaini, gutkha, supari, toxin free pan masala, tobacco-less gutk.. Tomato products: tomato juice, tomato ketchup, tomato chutney, tomato sauces, tomato .. Township, cinema hall, multiplex, villa, holiday resort, residential complex, shoppin.. Water industry, bottled drinking water, vitamin water, mineral water, water treatment.. Wax viz sugarcane wax, natural sugar wax, dental wax, candle making, micro crystallin.. Wheat like bakery unit, automatic biscuit making plant, automatic bread making plant,.. Wire and wire products viz aluminium wire drawing, copper wire drawing, galvanised ir.. Wooden products, furniture, bamboo, timber, board, plywood, door, window, mdf board, ..

144 latest Formulations, Books and Visit https://www.eiriindia.org for Bankable Project Reports