MARKET SURVEY CUM DETAILED TECHNO ECONOMIC FEASIBILITY REPORT (PROJECT FEASIBILITY REPORT) ON
BOTTLING PLANT (WHISKY, BRANDY, RUM, VODKA, GIN) FROM RECTIFIED SPIRIT/ENA Published Date: 23 March 2014 For Latest Report – Visit www.eiriindia.org
INDENTIFICATION & EVALUATION DIVISION FOR HI-TECH PROJECTS
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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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BOTTLING PLANT (WHISKY, BRANDY, RUM, VODKA, GIN) FROM RECTIFIED SPIRIT/ENA [EIRI/EDPR/1467] J.C. 248
CONTENTS
PROJECT AT A GLANCE
INTRODUCTION
USES AND APPLICATIONS
PROCESS DESCRIPTION
LIST OF MACHINERY AND EQUIPMENTS USED IN ALCOHALIC BEVERAGES PLANT
EFFLUENT TREATMENT AND DISPOSAL
EQUIPMENT REQUIREMENT
MANPOWER
PLANT LAYOUT OF LIQUOR BOTTLING PLANT
PROJECT IMPLEMENTATION SCHEDULE
B.I.S. SPECIFICATIONS
VARIOUS TYPES OF INDUSTRIAL ALCOHOL
PRODUCTION OF BRANDY
PRODUCTION OF SPIRIT FOR GIN
MANUFACTURING PROCESS OF WHISKY
MANUFACTURERS OF ALCOHOLIC BEVERAGES
SUPPLIERS OF RAW MATERIALS
SUPPLIERS OF COMPLETE PLANT AND MACHINERY 3
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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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PROJECT AT A GLANCE i. Capacity of the plant Capacity of the plant Shift per day No. of working days
= = =
xxx Box /Day xxx xxx Days
= =
xxx KW xx KL/day
=
xx Nos.
ii. Utilities Power load Water
iii. Manpower requirement Total
iv. Project Schedule The project can be implemented in a period of xx months from zero date.
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BOTTLING PLANT (WHISKY, BRANDY, RUM, VODKA, GIN) FROM RECTIFIED SPIRIT/ENA [EIRI/EDPR/1467] J.C. 248 INTRODUCTION An Overview of the Indian Liquor Industry The alcohol industry is very important for the government. It generates an estimated Rs. 18,000 crore per annum in spite of the fact that the per capita consumption of liquor in India is the lowest in the world. The total liquor industry is worth Rs. 2,000 crore. IMFL accounts for only a third of the total liquor consumption in India. Most IMFLs are cheap and are priced below Rs. 300 per bottle. Alcohol sales proceeds account for 45% of the total revenue collection in the country. Whiskey accounts for 60% of the liquor sales while rum; brandy any vodka account for 17% 18% and 6% respectively. MNC’s share is only 10%and they have been successful only in the premium and super premium ranges. Post WTO the government may have opened India to foreign distilleries, but the duty has been increased from 222% to 464-706%.This is due to the fact that there is a 100% customs duty, 150%contravening duty, local taxes, distributor’s margin, retailer’s margin and publicity charges. The cost is finally borne by the consumer. Though the government claims that this is being done to protect the domestic liquor industry, the domestic industry accounts for 99% of the market share.
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This protectionist policy could prove to be counterproductive and lead to smuggling. As of now, only 45% of the sales are through legal channels and only 25% of this is duty paid for. Within India itself, the policy of alcohol retail differs form state to state. While some states like Maharashtra. Uttar Pradesh, and Tamil- Nadu have a liberal policy, come states like Haryana and Andhra Indian Liquor Industry is divided into two broad categories
Indian Made Foreign Liquor (IMFL) Country Made Liquor
Indian Liquor Industry is growing at 12-15% P.A over last 2 yrs. • Shift from country liquor to IMFL because of rising per capita. http://www.livemint.com/articles/2011/11/23210054/B oom-time-for-country-liquor.html
Industry Structure Alcoholic beverages (8500 Crore) IMFL Country Liquor Rs 6150 Crore Rs 2350 CroreBrown Spirits White Spirits Licensed Illicit Whisky Vodka Brandy Gin Rum http://www.livemint.com/articles/2011/11/23210054/ Boomtime-for-country-liquor.html
Major Competitors Manufacturer Brands United Breweries (UB) Group( Bangalore) King Fisher, Kalyani Black Label, Signature, Blue Riband Shaw Wallace (Calcutta) Haywards Jagajit Industries (Kapurthala, Punjab) Aristocrat Mohan Meakins (Solan, Himachal Pradesh) Golden Eagle Associated Breweries & Distilleries (Mumbai) London Pilsner, Smirnoff, Gilbeys Green Label, Malibu, Archers Peach Schnapps Legal Environment • Ban on direct advertising Excise regulations and Licenses • „Regulated‟ industry - movement, prices of intermediate goods (molasses, ethanol) tightly controlled - state governments exert considerable influence. • Subject to licensing under Industrial (Development and Regulation) Act, 1956 • Cap on licensed capacity; special license for expansion • Plethora of duties and taxes from bottling to sales stage; varying from state to state. 7
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Custom & Duties • Sales tax, Bottling Fee, Litre Fee, Vend Fee, Privilege Fee, Import/ export Pass duty • Other taxes levied are: Excise Duty : Liquor from spirits - Rs. 45/- bulk litre; Premium Malt Whisky - Rs. 60/- bulk/ litre; Litre Fee - Rs. 20/- bulk litre; Sales tax : 60%; cess 5% • Import duty on whisky, rum, gin & vodka, liqueur - 230 % www.crisil.com Social Environment • Increase in disposable income • Changing lifestyles of middle class Western culture influence • Changing Trends – Youngsters, Parties and Celebrations Hard liquor - from 21 to 25 • In India 40-50 % of all males and 1% of all females Beer - from 18 to 21 Minimum age consumed alcohol last yr. • 62% drinkers classified as light,29% as moderate drinkers and 9% as hard drinker. http://www.livemint.com/articles Prohibition in India Soon after independence, prohibition was imposed in the erstwhile state of Bombay. • The first large-scale movement against alcohol began in the 1970s, when rural women in various parts of the country protested against the sale of liquor in their villages. • Information and Broadcasting ministry of India banned the ads. • Even after the ban, liquor companies continued to advertise their drinks in the form of surrogate advertisements.
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Legitimate business & their surrogate advertisements Brands Surrogate advertisements McDowell’s malt whisky McDowell’s Soda/water Radico Khaitan’s 8 pm whisky Radico Khaitan’s water Hayward’s 5000 Beer Hayward’s water/soda Derby Special Derby special soda Bacardi Liquor Bacardi Blast CDs & Cassettes Bagpiper liquor Bagpipers soda and cassettes Kingfisher Beer Kingfisher bottled drinking water Royal Challenger whisky Royal Challenger golf accessories & mineral water & cricket team White Mischief Liquor White Mischief holidays Smirnoff Vodka Smirnoff cassettes & CDs Economic Environment It is a well developed - Rs 8,200- 8500 Crores industry in India Past growth 12 % CAGR per annum • Brown spirits - particularly whisky, rum & brandy account for over 75 % of this market • South and North share 60% of market •Market size – 20 million cases in 1999 to 84 million cases in 2011 http://articles.economictimes.indiatimes.com/2010- 09Threat of New Entrants • There are huge complexities and high regulations to get entry in this industry. The new players need to satisfy the licensing and need to get approvals by the states and central government. • For international players, the key is find the right partners and links who understand the Indian market and legislations. With liquor makers, both local and foreign, becoming active, competition is intense. • UB-Carlsberg, South African Breweries and some others are awaiting clearance following government stalemate on account of the Supreme Court judgment, the judgment has created a confusion whether the proposals related to FDIs and the issuing of licenses for the liquor industry will be addressed by the Central or the State governments.
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A lot of mergers and acquisitions in the international arena have begun to impact the joint ventures. http://articles.economictimes.indiatimes.com/2010-09-
Bargaining Power of Customers • The Liquor industry has witnessed the consumers always at a weaker end. • There is not much bargaining power in the hands of the consumers in Indian liquor industry as the prices are set by the forces of demand & supply and the demand for liquor here is high as compared to the supply. • Hence, the producers are at a beneficiary end and charge higher prices. • In India, a liquor brand is identified and is appreciated only on the basis of it’s higher price. • It is an interesting fact that Companies use “High Price” as one of it’s promotional strategy to attract the consumers. http://articles.economictimes.indiatimes.com/2010-09Bargaining Power of suppliers •The key raw material for IMFL players is Molasses which is a by product of sugar. Molasses is distilled & processed to form rectified spirit called Ethanol. •The players which have primary distillation facilities in their Plants directly consume molasses, rest all have to purchase Ethanol. •As molasses demand arises only from ethanol demand, the demand supply scenario for ethanol determines the raw material prices for the IMFL Players.( www.crisil.com) Ethanol demand is expected to rise in future, when the commercial blending of ethanol with petrol (for producing Gasohol) will take off. • In Long term -Molasses supply is going to increase as more sugar manufacturers are expected to set up primary distilling facilities and as new sugar factories are expected to come up in the form of integrated plants with cogeneration & distilling facilities • The suppliers are able to play easily with the prices of these raw materials hence charging higher prices from the Liquor producers. www.crisil.com 10
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Predictions regarding Raw Materials • It is predicted by the analysts that after the commercial production of “Gasohol” the prices of Molasses is likely to increase. www.crisil.com Rivalry within the industry & their Market Share The top five competitors in Liquor industry are: United Breweries (UB) Group( Bangalore) 48% Shaw Wallace (Calcutta) 36% Jagjit Industries (Kapurthala, Punjab) 6 % Mohan Meakins (Solan, Himachal Pradesh) 5.5% Associated Breweries & Distilleries (Mumbai) 4.5% www.oppapers.com Rivalry • Major players create competition on the basis of: – Looks of the liquor bottle – Pricing the product much higher – Innovative promotional campaign • Beer sales in India are forecasted to grow at CAGR of 17.2 % by 2012 • Future plans for the industry depicts strong growth for the Indian beer market as the major players like kingfisher have been quoted saying that they have significant expansion plans for the next few years..
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ETHYL AND METHYL ALCOHOLS
ETYL ALCOHOL (Ethanol) Alcohols are hydroxy derivatives of aliphatic hydrocarbons. When unqualified, ‘alcohol’ refers to ethyl alcohol or ethanol. Pharmacology of alcohol is important for its presence in beverages (which have been used since recorded history) and for alcohol intoxication, rather than as a drugs. Alcohol is manufactured by fermentation of sugars: Fermentation proceeds till alcohol content reaches – 15 %. Then the reaction is inhibited by alcohol itself. Starchy cereals, e.g. barley, when soaked produce malt: ALCOHOLIC BEVERAGE There are a large variety of alcoholic beverages
Malted liquors : Obtained by fermentation of germinating ereals; are undistilled-alcohol content is low (3-6 %) e.g. Beers, Stout. Now strong beers (upto 10 %) are also available. Wines : Produced by fermentation of natural sugars as present in grapes and other fruits. These are also undistilled.
Light wines Claret, Cider; alcohol content 9-12 % cannot exceed 15 %.
Fortified wines Port, sherry (alcohol 16-22 %): distilled beverages are added from outside.
Effervescent wines Champagne (12-16 % alcohol): bottled before fermentation is complete.
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Wines are called ‘dry’ when all sugar present has been fermented and ‘sweet’ when some is left.
Spirits : There are distilled after fermentation; e.g. Rum, Gin, Whiskey, Brandy, Vodka etc. Though the alcohol content of these can very from 40-55 %, in India (and almost internationally) for all licensed brands it is standardized to 42.8 % v/v or 37 % w/w.
The taste, flavour and value of alcoholic beverages depends not only on alcohol content but on the presence of higher ethers, higher alcohols, aldehydes, esters, polymers, and volatile oils; many of these are formed during ‘maturation’ of the beverage. Other forms of alcohol
Absolute alcohol : 99 % w/w ethanol (dehydrated alcohol.) Rectified spirit : 90 % w/w ethyl alcohol-from mollases, by distillation. Proof spirit : It is an old term. If whisky is poured on gun powder and ignited and it explodes, then it was labeled to be of ‘proof strength’. If water is mixed to it, gun powder will not ignite. 100 % proof spirit is 49.29 % w/w or 57.1 % v/v alcohol.
Alcohol is an astringent-precipitates surface proteins and hardens skin. By precipitating bacterial proteins it acts as an antiseptic. The antiseptic action increases with concentration from 20 to 70 %, remains constant from 70 to 90 % and decreases above that. That 100 % ethanol is more dehydrating but poorer antiseptic than 90 % ethanol, shows that antibacterial action is not due to dehydration of bacterial protoplasm. Alcohol does not kill bacterial spores.
CNS : Alcohol is a neuronal depressant. Since the highest areas are most easily deranged and these are primarily inhibitory-apparent excitation and euphoria are experienced at lower plasma concentrations (30-100 mg/dl). Hesitation, caution, self-critcism and restraint are lost first. Mood and feelings are altered; anxiety may by allayed. With increasing concentration (100-150 mg/dl) mental clouding, disorganization of thought, impairment of memory and other faculties, alteration of perception and drowsiness supervene. At 150-200 mg/dl the person is sloppy, ataxic and drunk; 200300 mg/dl result in stupor and above this unconsciousness prevails, medullar centers are paralyzed and death may occur. Though, alcohol can produce anesthesia, margin of safety is narrow. 13
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DIFFERENT ALCOHOLIC DRINK 1. WHISKY Whisky is amongst the most popular distilled liquor known all over the world. It is made of malt and molasses spirit, which is obtained by distillation of mash or cereal grains like maize, rice barley malt. Better the malt better the whisky. Large quantities of IMFL are manufactured in India and is the maximum sold alcohol. The content is whisky is 42.8%. 2. RUM Rum is a distillate from the fermented juice of sugarcane of molasses. RUM is characterized with its taste and aroma. Best rums are known to come from Jamaica, West Indies etc. The alcohol content of Rum is 42.8%. 3. BRANDY Brandy is generally obtained from fruits, thought the most commonly used fruit is grapes. The best quality of brandy is cognac, which is made in France. 4. VODKA Vodka is a sprit resulting out of distillation at very high proof. This results in virtual NPN existence of flavour in the resulting sprit,.Which is neutral , even after dilution required for palpability. The traditional source of making vodka has been potatoes. 5. BEER Beer is not a distillate like the drinks mentioned above but it is a beverage made by fermentation of malt obtained form carbohydrate rich material barley. Hops are used to add taste while yeast is used to ferment the beer. Beer is to two types :1.Pilsener or Lager 2.DraughtLager Beer is the most common bottled Beer found in almost all the retail shops in the country. This Beer is served chilled and is of two ypes.Mild Beer alcohol content of 6.75%.Strong Beer alcohol content of 8.75%.Draught Beer is served chilled in mugs and is generally available in Pubs only. It can be stored for 72 hours only and does not have any brand name. Mohan Meakins supports Draught Beer. 14
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6. GIN It is sweetened or un sweetened grain spirit flavoured with essential oil juniper berries and some other product including anglica roots, orange peel, cardamom, bitter almonds give it a kick and taste Whisky:Gin, vodka, and related spirits like aquarit are distinguishable from whisky, rum and brandy which themselves have a number of common characteristics. The most evident difference is in colour, with gin an vodka normally being colourless white whisky, rum and brandy vary in shade from straw-coloured to the deepest brown. This immediate difference is linked with distinguishing features of composition and flavour which are reflected in the methods of production of the two troup of sprits. The aurd whisky comes from the Gaelic word wisge-beatha, as the Irish called it, incoming the water of life. The colour in whisky, rum and brandy oves it origin to the practice of ageing or maturing these spirits in wooden casks, which as containers have previously used for transporting some compatible liquid such as slerry, wine or molasses. Residues of previous contents, together with substance extracted from the wood itself, serve to give the maturing spirit a brown colour which in interest of standardization, is supplemented by the addition of caramel. The requirement for maturation in wood is now codified in lay standing whisky is the potable spirit obtained by distillation of an aqueous extract of an infusion of matted barley and after cereals that has been fermented with strains of sacctromyus ceramisial. Various types of whisky are produced in a number of different countries in the world. They differ principally in the nature and proportion of the cerels used as a raw materials along with matted barley and also in the type of still used for distillation. The principal types of whisky are also characterized of particular geographical regions of the world. In Scotland, the characteristics product is manufactured using only matted barley as the raw material and the fermented matt wort is distilled in batches in relatively small pot stills. The product, known as scotch melt whisky, is manufactured in relatively small distillations of which there are over hundred in Scotland. Scotch melt whisky is marketed both as a straight malt 15
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whisky. Rum, the alcoholic beverage made from sugar cane has been known for centuries.
The origin of the name "rum" is obscure. It may have been derived from the latin for sugar, saocharum. Another, and according to some sources more prpbable, origin of the word rum is the Devonshire diaret word run (=run), which British colonists took with them to the west Indies. Equally prpbables is a derivation from the spanish 'ran' (=run), for the spaniards may will have had distilleries in the west before the arrival of the British. Rum production is centured on the west Indies. The best known distilleries are situated in Jameica, Martinigue, Puerto Rico and Cuba, but Barbados, Trinidad, Haiti, Guadetoupe, the hirgin islands, the Dominican Republic and Guyana (known as Domeraca in the rum trade). All have told traditions of making rum. Rum is also produced in the U.S.A.; Brazil Peru, Mexico and parts of Asia and Africa. In general, rum is produced wherever the climate is suitable for the cultivation of sugarcane. man brands of which have recently become extremely popular throughout the world, and also as a blend with another type of whisky produced in Scotland, namely scotch grain whisky, or because it is distilled continuously in Coffey type patent stills, as patent-still whisky. Most scotch whiskies available on the international market consist of blends with 30 - 40% malt whisky. Within the blend, there may be as many as 20 - 30 individual malt whiskies and grain whiskies. These blends are, by law, matured for atleast three years and, in practice, this period is normally much layer. Unblended scotch malt whisky are usually matured for a minimum of 8 years. Throughout the world since at least the middle ages wine has been distilled to concentrate the alcohol to a higher percentage than occured in the original wine. These wines distillates have ben called aquavini, eaux-vie, weinbrand, cognac, branntwein, aguardienrite, aquarit and in Englishspeaking countries. Brandy is produced from wine in many parts of the world mainly in France. Some of it is for industrial use. A small amount is used for fortifying dessert wines. That produced for beverage purposes may be divided into the following classes - cognac, Armagnac, eaw-de-via and eaux-de-vie demarc. Brandy is also produced in most of the wine producing countries.
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The term whisky without further qualification is universally understood to mean the product of alcoholic fermentation of the juice of the grape and other fruits. This not only excludes the fermented product of other fruit juices but when the definition is made more ridid, as in a legal standard it is usually specified that the whisky shall be made by the usual cellar treatment. The purpose of this is not only to restrict the original crude material to the grape juice also to limit all additions to those substances that occure naturally in sound grapes or which experience has shown to be of distinct benefit to the flavour or keeping qualities of the whisky. Although brandy, rum, & gin are substantially items in world markets, whiskies are by far the leading distilled alcoholic beverages; with those from Canada, Scotland & the U.S. accounting for most of the sales. There are 3 types of whisky manufactured from ripe grapes and to the fruits i.e. dry wine, Sweet wine and sparkling wine. A dry wine is one in which practically all the sugar certainly all that can be perceived by the taste has been by fermentation. Dry wine is wine in which the fermentation of the sugars is practically complete. A term 'proof' will always come in this report with which we must be familiar:Proof: This term is connected with alcoholic liquor, which contains one-half its volume of alcohol of a Sp.gravity of 0.7939 at 15.6oC. i.e. the figure for proof is always twice the alcoholic content by volume. For ex: 100o proof means 50% alcohol by volume.
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Whisky Types of whisky: Whisky is an alcoholic distillate from a fermented mash of grain distilled at less than 190o proof (95%) in such a manner that the distillate possesses the taste, aroma, and characteristics generally attributed to whisky. 1. Light Whisky: It has been distilled from at more than 160o (80%) & less than 190o (95%) proof and is stored in used or uncharred new oak containers. If light whisky is mixed with less than 20% by volume of 100o proof (50%) Straight whisky the mixture shall be disignated Blanded Light whisky 2. Rye, Bourbob whisky ; Bourbon whisky, rye whisky, wheat whisky, matt whisky is whisky which has been distilled at not exceeding 160o proof (80%) from a fermented mash of not less than 51% rye, corn, wheat, matted barlay, respectively, and stored at not more than 125o proof (62.5%) in charred new oak containers. 3. Straight Whisky ; Any of the whisky types mentioned quality as straight whisky by complying with the following:
above further
(i) withdrawn from the distillery at not more than 125o (62.5%) + not less than 80o (40%) proof & (ii) aged for not less than 24 months.
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USES AND APPLICATIONS Whisky is a kind of wine generally used by human beings. It is very useful for children if given a little doze say about one tea spoon in milk or water every day. It kills to cold and cough and the effect larger quantity will work as wine.
Apart from the above it is also used for the extraction of several drugs and for manufacture of several medicinal preparations. Whisky also kinds used in preparation of assences and flavours. It is used as a process material in the preparation of numerous organic compounds including synthetic drugs and dyestuffs especially for crystallization and purification. There are two types of whisky, one is white and the other id brown. The white brandy is made from the juice of fruit and the brown from the pulp. White brandy is used for the use by human beings and the brown for other purposes. Whisky is also used a preservative for anatomical specimens and as a dehydrating agent in microscopic technique.
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MARKET SURVEY
OVERVIEW
* Indian Made Foreign Liquor (IMFL)
Negative perceptions about alcoholic beverages widely prevalent This is a ‘regulated’ industry - movement, prices of intermediate goods (molasses, alcohol) tightly controlled - state governments exert considerable influence this is a well developed - Rs 8,200 crores (US $ 1907 million) industry in India Major players in the alcoholic beverages market - United Breweries (UB) Group( Bangalore), Shaw Wallace (Calcutta), Jagajit Industries (Kapurthala, Punjab), Mohan Meakins(Solan, Himachal Pradesh), Associated Breweries & Distilleries (Mumbai) Per capita beer consumption in India - 0.5 litres; as against 20 litres in China, 100 litres each in USA & Germany , annually
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LIQUOR : MARKET Market Size o o o o
Market : 58 million cases Past growth 15 % CAGR per annum Brown spirits - particularly whisky, rum & brandy account for over 75 % of this market South and North share 60% of market
Industry Structure o
Industry in the organised sector - an industrial license is required to start manufacture o Major brands (manufacturers) : Signature, Blue Riband (UB Group), Aristocrat (Jagajit Industries), Smirnoff, Gilbeys Green Label, Malibu, Archer’s Peach Schnapps(International Distilleries India), Passport (Seagrams), VAT 69, Black & White, Black Dog (United Distillers India)
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LIQUOR MARKET: FEATURES
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FUTURE
Business Concerns
Key Success Factors
Demand Drivers
Blend, body, firmness, heritage brand image and distribution - key factors International image - not successful in India; success rate < 10% Local strategy - a must; in fact, due to high (sales) tax rate differential, marketers of alcoholic beverages have state-wise marketing strategy.
Deregulation of this industry; at the state level Increase in disposable income Changing lifestyles of middle class
Industry expected to grow by 12% per annum Beer likely to grow to 7.6 million by the year 2003 - 04 Liquor industry to grow to 0.92 million by the year 2003 - 04 New capacities Beer : One (100,000 HLPA) Liquor One (500 KLPA) Expansions Beer: Two (765,000 HLPA) Liquor One (5,000 KLPA)
Future
Prohibition policies of states - vary from time to time Tax differentials curbs free movement of these beverages across states To avoid multiple taxes, manufacturers set up bottling plants in each state Curbs on advertisement of alcoholic beverages Finance constraints - banks reluctant to lend Constraints on availability of key raw material molasses Bootlegging - a major concern
According to a survey conducted by a UK-based trade magazine on liquor, three Indian brands figured in the "TOP 25 Fastest Growing Brands 24
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in the world in 1994". While the survey is for both local as well as foreign sales, it takes into account only those brands which "export or produce more than 10 percent of their sales volumes overseas"- in other words, Indianmade Foreign liquor (IMFL) could actually be well on its way to becoming a preferred foreign liquor. SALES GROWTH OF MAJOR INTERNATIONAL BRANDS OF FOREIGN LIQUOR BRAND NAME
(% of Growth in Sales)
Source: The Drinks International Bulletin, U.K.
The above data that it will bring some cheer to Indian IMFL manufacturers, as they are depressed owing to the entry of well-known International brands like Johnnie Walker, J & B, Something special, 100 Pipers and Teachers into the country.
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The marketing strategy being played by one of the large group "International Distillers & Vintners (IDV), the UK liquor major which has tied up with polychem Industries to launch and market foreign liquor brands like Teacher's whisky, smirnoff Vodka and Kelly's Cream liqueur, has a welldefined strategy for its Indian operations. IDV has adopted three ways of entering the Indian Market. First, where it will launch brands like teacher's by importing the liquor and bottling it locally. Second, where, like smirnoff Vodka and kelly's, it will manufacture the locally; Third, where it will launch admixture, blending imported liquors with India Produce. While IDV is yet to launch an admixture blended brand in India, sources say.
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SELECTED COMPANY WITH THEIR BRAND NAME
BRAND NAME
COMPANY NAME
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Indian Consumption of whisky has grown at an average 14% annually for the past eight years, climbing to 30 million cases (of 12 bottles of 750 ml each) per annum. That makes India the hottest whisky market in the world.
Alcoholic Drink Exports From India During 2011-2012 2012-13 Sr No.
Country
1 2 3 4 5
U Arab Emts Angola Ghana Singapore Nepal
6 7 8
Netherland Oman Tanzania Rep
Quantity in MT
Value in Lacs
19,774.00 19,818.00 16,163.00 10,018.00 6,404.00
18,592.00 17,113.00 5,704.00 4,236.00 2,861.00
2,000.00 1,263.00 4,059.00
2,662.00 1,507.00 1,434.00
9
Sri Lanka Dsr 4,207.00 1,414.00 Vietnam Soc 10 Rep 916 1,402.00 Page Total 84,622.00 56,925.00 Major Importing Countries of Alcoholic Beverages from India during 2013 2013 Sr No. Country Quantity in MT Value in US$ Millions 1 USA 59,11,655.00 14,549.00 United 2 Kingdom 25,97,591.00 6,458.00 3 Germany 35,88,932.00 5,776.00 4 Canada 10,57,682.00 3,335.00 5 France 15,70,586.00 2,698.00 6 Japan 9,08,776.00 2,370.00 7 Netherlands 12,04,592.00 2,352.00 Russian 8 Federation 13,25,671.00 2,101.00 9 Spain 7,75,680.00 1,915.00 10 Belgium 6,84,638.00 1,841.00 Total 1,96,25,803.00 43,395.00 28
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PROCESS DESCRIPTION 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12.
Alcohol mass measuring system (spirit concentration meter) Reception system for alcohol/water mixtures Blending system for alcohol/water mixtures Water deaeration systems type Filtration systems Equipment for storage tank facilities Batch mixing system type Continuous in-line blending system Combi blending system Carbonation and beverage analysis type Mobile metering systems Product tracing for internal documentation by means of determination of volume in the filler line 13. Cleaning system 14. Automation and after-sales service
Detailed Process description 1. Alcohol mass metering system (spirit concentration meter) • To determine the amount of excise duty due • Complete unit installed on a base frame • Possible for all ranges of flow rate 2. Reception system for alcohol/water mixtures • Reception from tankers 29
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• • • • •
Determination of excise duty due Determination of the mass of alcohol/water Determination of the proportion of pure alcohol Flow rate of up to 60,000 l/h possible Use as a counterchecking device for verification purposes
3. Blending system for alcohol/water mixtures • Reception of alcohol/water mixture • Automatic concentration measurement (Better than 0.1% vol.) • Preselection of final concentration • Data capture and data transfer possible 4. Water Deaeration system • Preparation of high-quality beverage water • Minimisation of oxidation in the beverage • Reduction of residual oxygen to under 0.05 ppm possible • Minimisation of foaming during filling 5. Filtration systems • Continuous filtration • Batch filtration • Particle filtration • Sterile filtration 6. Equipment for storage tank facilities • Storage tank for product • Sterile tank for liquid sugar • CIP tank • concentrate starter tank with catwalks and working platforms • Automatic valve manifolds 7. Batch mixing system • batch mixing 30
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• • • •
Flow rate up to 10,000 l/h One measuring device for all components 12 components in the standard version High mixing precision • Recipe memory and automatic running of program sequence
8. Continuous in-line blending system, • In-line blending process • No mixing tanks required • Flow rate up to 30,000 l/h; other ranges possible on application • compact arrangement, requires little space • Automatic control with recipe memory 9. Combined blending system • Syrup made available quickly • Uninterrupted production • starting quantities directed towards a predetermined production volume • Small tank volumes • Quick and easy to clean (cleaning possible between batches) • Extremely low syrup losses • High flow rate, thanks to the combination of batch and in-line processes 10. Carbonation and beverage analysis • CO2 dosing, measurement and correction in the finished beverage • Beverage analysis before the start of production • CO2 content automatically determined through recipe memory
11. Mobile metering units Particularly suitable for small or medium-sized pro- duction facilities. Depending on the version, diffe- rent metering tasks can be carried out: • flow metering 31
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• Volume dosing with preselection of quantities • batch mixing using several component valves • filling control
12. Product tracing for internal documentation by means of • Determination of volume in the filler line • Determination of consumption of individual basic ingredients, concentrates, syrup, beverage water and alcohol/water mixture • Documentation and storage of analysis values • Determination of storage capacities by measurement of tank contents • Storage of available basic ingredients and concentrates 13. Cleaning system • available with one or more circuits, depending on requirements • flexible program control allows precise adaptation of the cleaning procedures to the task in hand • cleaning media are largely recuperated, for greater economy
PACKAGING To keep the contents clean, fresh, and safe is the primary function of packages which adds to the convenience in distribution, handling, display, sale, opening, re-closing, use and reuse.
32
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Liquor may be filled in glass bottles conforming to IS 1662:1974 any other suitable neutral or non-reactive containers. The bottles or containers shall be properly sealed. Used bottles shall be permitted if sanitized and cleaned in a hygienic way by the manufacturer as per the clause 5.6.1.1 of IS 14348:1996. However, the State Excise Department may permit if the bottles are thoroughly cleaned and sanitized in a hygienic manner by the producer. Containers, both before and after filling, shall pass for inspection before a brightly illuminated background and be viewed, if necessary, under magnification. Automatic inspection by specially designed units may also be employed. Defective containers or products shall be rejected.
Packing Standards:
Clear Coloured Bordeux Beer Bottles
Green Coloured Beer Bottles
Standard Capacity of Liquor Bottles BOTTLE SIZES
750 milliliters
EQUIVALENT BOTTLES LITERS FLUID (ML) PER PER CASE CASE
721
12
9
Bottling of Liquor will be done in 750 ml clear glass bottles.
33
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Packaging Requirement: Packaging requirement includes 750 ml capacity bottles, corks, Aluminum foil, labels, and cases. The annual and per day requirement has been mentioned in The foil is in some ways a tamper proof seal, but it is also a barrier to moisture or any changes in temperature. Exposing the cork to high humidity can cause the cork to support some mold growth and low humidity will cause the cork to dry out and crack. This could cause the cork to disintegrate when you try to open it. The gestation period for humidity to effect the cork is significantly long, even without the use of foil as covering. The mold issue should be of especially little concern considering the mold would have to travel all the way down to the cork and then be able to survive in a highly acidic, low oxygen environment. This is practically impossible, however foiling also adds to the appearance of the Beer bottle. Requirement of foil per bottle is 3” X 3” or 0.0058 sq. m.
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LIST OF MACHINERY AND EQUIPMENTS USED IN ALCOHALIC BEVERAGES PLANT MULTI-TUBE COAXIAL HEAT PASTEURIZER
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CIP SYSTEM (FULLY AUTOMATIC)
CIP System can be configured with the following options to specific needs 1. 2. 3. 4. 5. 6. 7.
CIP tanks CIP return pump with low point Drain valve Chemical addition system(s) Steam control valve with condensate drip leg CIP return flow switch Heat exchanger
ONLINE DUPLEX FILTER
Suitable to filter impurities and particles from sugar syrup, liquid, beverages. Consist of 2 sets of filtration connected in parallel Capacity 1000 LPH Can be attached online in the interconnecting pipeline Complete with 3 way valve to enable user to switch for either of the two filtration media
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Rotary Bottle Rinsing Machine
Uni block filling and cap sealing machine
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Slat Chain Conveyor
Inspection Conveyor
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Rotery labelling machine
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Case Packer Machine
Automatic carton sealer model
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PROCESS FLOW CHART OF ALCOHOLIC BEVERAGES PROCESSING PLANT
Schematic flow diagram of “Alcoholic Drink Bottling Plant”
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GENERAL PLANT LAYOUT GMP/GHP CRITERIA FOR PLANT
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Internal Structures & Fittings a) Flooring shall be smooth, impervious, with no crevices or damaged. Floors shall be constructed to allow adequate drainage. The junctions with walls shall be such that they are cleanable eg coved (shall not be with sharp angles). b) Roof shall be constructed so as to be gap free, water resistant, and finished so as to minimize build up of dirt and shedding of particles. Overhead fixtures, if any, shall be constructed and finished to minimise the build up of dirt and condensation and the shedding of particles. c) Walls and partitions shall have a smooth surface. Wall paint shall not be flaking off. There shall be no crevices to harbor pests. If applicable and as appropriate to the operations, the walls up to a desired height shall be impervious and easy to clean. d) Windows and Ventilators shall be easy to clean, and where necessary fitted with cleanable insect‐proof screens/ louvers. Window glasses shall be shatter‐proof. Mesh on windows (ventilator) shall not be cut/ damaged to avoid pest entry. e) Doors shall have smooth non absorbent surfaces and be easy to clean and disinfect as appropriate. Strip PVC/air curtains/ wire mesh doors with self closing devices shall be fitted at entry/exit points. f) Working surfaces that come into direct contact with food shall be in sound condition (free from cracks, crevices, open seams, etc), durable and easy to clean, maintain and disinfect. They shall be made of smooth (such as free from sharp internal angles or corners; protruding rivets, nuts and bolts, etc), non‐absorbent materials and inert to food, detergents and disinfectants under normal operating conditions. 2.3 Equipment a) Equipment shall be located so that it permits adequate maintenance and cleaning; functions in accordance with its intended use; facilitates good hygienic practices, including monitoring, if required. b) Equipment and re‐usable containers coming into contact with food shall be durable, designed and constructed to ensure that they can be adequately cleaned, disinfected where necessary, and
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maintained to avoid the contamination of food. Where necessary, equipment shall be movable or capable of being disassembled to allow for maintenance, cleaning, disinfection, monitoring, etc.
c) These shall be made of materials with no toxic effect in intended use and should not pass on colours, odours or taste to food. d)
Non food contact surfaces of equipment should be free from unnecessary projections and crevices; and designed and constructed to allow easy cleaning and maintenance.
e) Equipment used to cook, heat treat, cool, store or freeze food shall be designed to achieve the required food temperatures (and other parameters as relevant) as rapidly as necessary for food safety and suitability and to be effectively maintained and allow parameters to be monitored and controlled. These shall be periodically calibrated & records maintained. The frequency of calibration shall be based on the type of equipment, criticality of the measurement, location & extent of usage. f) Maintenance programmes shall be in place which shall cover maintenance schedule, responsibilities, methods, tools and gadgets, etc for effective functioning of the equipment . 2.4 Containers for waste and inedible substances a)
Containers for waste, by‐products and inedible or dangerous substances shall be identifiable, suitably constructed and where appropriate made of impervious material. Those used to hold dangerous substances shall also be lockable.
2.5 Facilities
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Drainage and waste disposal
a) Drainage systems as relevant to the operations shall be appropriately designed and constructed. The sewage discharge shall comply with the requirements of environmental pollution Board (including ETP, rendering plant, etc as applicable). No manhole shall be situated inside any food processing area. Rainwater pipes, if inside, shall be constructed of impervious rust‐proofing materials. These shall not open in the food processing area. b) Drains, if any, in the processing area shall be made of impervious rust proofing material and shall be covered. These shall have adequate trapping devices to avoid entry of pests. Drains shall allow for effective cleaning as relevant (such as fat trap, pressure cleaning, etc). Cleaning a) Adequate facilities, suitable designated, where necessary, should be provided for cleaning raw materials and ingredients, food, utensils and equipment, etc. These facilities shall have an adequate supply of hot and cold potable water where appropriate. Personnel hygiene facilities and toilets a) Adequate means of hygienically washing and drying hands (as
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relevant), including wash basins and supply of adequate water of potable quality shall be provided. Taps shall be non‐hand operated. b) Hand wash basins/ sanitizers should be situated to enable hand washing prior to start of operations. c) Toilets/ lavatories of appropriate hygienic design at suitable location with adequate natural or mechanical ventilation and natural or artificial lighting shall be provided. d) Adequate changing facilities for personnel should be provided, as appropriate to the operations Temperature control a)
If operations require heating, cooling, cooking, refrigerating and freezing food, storing refrigerated or frozen foods, monitoring food temperatures, adequate facilities shall be available for the same.
b) Where necessary, ambient temperatures shall be controlled to ensure the safety and suitability of food.
Air quality and ventilation a) Adequate ventilation as appropriate to the food and the operations shall be provided for minimizing air borne contamination, controlling ambient temperatures and humidity where necessary which might affect the safety and suitability of food. These shall be achieved through either natural or mechanical ventilation. b) Food processing areas where operations result in release of fumes, smoke, steam or any vapour shall be equipped with an exhaust system or ventilation that can efficiently and effectively remove these. c) Ventilation systems shall ensure that air does not flow from unclean to clean areas and, where necessary, they can be adequately maintained and cleaned. Lighting a)
Natural and / or artificial lighting shall be provided in food premises for various operations and other activities within the facility (eg sanitary conveniences). The intensity of lighting shall be adequate on the nature of operations (eg sorting, cleaning, grading, inspection and testing require greater intensity of light). Where necessary, lighting should be such that the resulting colour is not misleading.
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b) Lighting fixtures shall especially where food or food contact surface is exposed to open), be shatter proof or protected with shatter‐proof covers to ensure that food is not contaminated by breakages. The fixtures shall be designed to avoid accumulation of dirt and be easy to clean. a) Suitable power back up facilities e.g generators, invertors etc shall be provided to ensure uninterrupted supply as necessary for production of safe food. a) Adequate facilities for storage of food, ingredients, packaging material and non food chemicals shall be provided. These shall be suitably designed and constructed as appropriate to operations (Further details at Cl 3.12). 3.
Control of operation
3.1 Time and temperature control a) Where time and temperature is critical to the safety of a food, define temperature and time controls for heating, cooling, processing and storage taking into account the nature of food, its shelf life, the processing method, its packaging, intended use of the product. These controls shall reduce any food borne pathogen that may be present in the food to an acceptable level. 3.2 Control of other Specific process steps a)
Define controls over other process steps which contribute to food hygiene which may include cleaning, sorting, chilling, thermal processing, irradiation, drying, chemical preservation, vacuum or modified atmospheric packaging, etc.
3.3 Specifications a) Define specifications for products at various stages of operations as relevant for ensuring food safety and compliance to regulatory and statutory requirements. These specifications shall be based on sound scientific principles. Document monitoring procedures, action limits and analytical methods. Maintain records. 3.4 Microbiological cross contamination a) When processing food, adequate steps shall be taken to prevent the same from microbiological cross contamination. b)
Raw, unprocessed food should be effectively separated either
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physically or by time from ready‐to‐eat foods, with effective cleaning and where appropriate disinfection. Similarly this should also be implemented for vegetarian and non vegetarian products. c) Access to processing areas should be restricted or controlled. Personnel should put on clean protective clothing including footwear and wash their hands before entering. In case of high risk products, access to processing areas should be only via a changing facility. d)
All surfaces, utensils, equipment, fixtures and fittings should be thoroughly cleaned and where necessary, disinfected after raw food, particularly meat, poultry, fish, etc, has been handled or processed to prevent contamination.
3.5 Physical and chemical contamination a) Foods shall not be contaminated by foreign bodies such as glass, metal particles from machinery, dust, harmful fumes and hazardous chemicals. b)
In manufacturing and processing suitable and effective detection or screening devices (such as filters, sieves, magnets, metal detectors) should be used where necessary.
c) If needed, a glass/ foreign body control policy may be defined and adopted to assist in achieving safe food.
3.6 Incoming materials requirements a) Only sound, suitable raw materials or ingredients shall be used. b) Where appropriate, specifications for raw materials shall be defined including Regulatory requirements. c) This may be achieved though supplier control, certificates of conformity, incoming inspection and testing etc. d) Where necessary, laboratory tests (in house or externally conducted) shall be carried out, at appropriate frequencies, to establish conformity. e) No raw material (including packing material) or ingredient shall be accepted by an establishment if it is known to contain parasites, undesirable micro organisms, pesticides, veterinary drugs, heavy metals or toxic, decomposed or extraneous substances which would not be reduced to an acceptable level by normal sorting and/or processing.
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f)
Imported Foods/ raw materials, if used, shall be as per the applicable regulations g) Records shall be maintained.
3.7 Packaging a) Packaging design and materials shall provide adequate protection for products to minimize contamination, prevent damage and accommodate proper labeling. The materials should be appropriate for the food to be packed and sufficiently durable to withstand the conditions of processing, handling, storage and transportation. Use of staple pins, strings, rubber bands, should be avoided. Glue if used should not come in contact with the food product. b)
Packaging materials and gases shall be non‐toxic and not pose a threat to the safety of food. Certificates of conformity or other evidence may be used for verification.
c) Packaging materials shall be stored and handled under hygienic conditions away from raw materials and finished products. d) Re‐usable packaging, if used, shall be suitably durable, easy to clean and where necessary, disinfect. It shall not have been used for packaging non food products.
3.8 Water Water, Ice and steam in contact with food a) Where used either as an ingredient, for making ice, for washing food, food contact surfaces or hands only potable water shall be used. b) Water, Ice and steam shall be produced, handled and stored to protect them from contamination. c) Steam used in direct contact with food and or food contact surfaces shall not contain any agent which is hazardous for food safety. d) Water that is re‐circulated shall be treated and maintained so that it is safe for use, and the treatment process shall be effectively monitored. Re‐circulated water which has received no further treatment and water recovered from processing of food by evaporation
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or drying may be used, provided its use does not constitute a risk to the safety and suitability of food. Water, Ice and steam not in contact with food a)
For steam production, fire control and other similar purposes not connected with food may not require the use of potable water. In certain processes (e.g. chilling) and in food handling areas where water does not constitute a hazard to the safety of food (e.g. use of clean sea‐water) the use of potable water may not be required. Water pipes & Storage tanks
a)
Water pipes, either hot or cold, should be maintained in good condition and order at all times to prevent leakage or defects that would result in contamination of food. Water storage tanks for potable water should be regularly cleaned and disinfected to prevent contamination.
3.9 Management and supervision a)
All operations shall be monitored and supervised appropriately. The type of control and extent of supervision needed will depend on the size of the business, the nature of its activities and the types of food involved.
3.10 Documentation and records a)
Appropriate records of processing, production and distribution shall be kept and retained for a period that exceeds the shelf life of the product.
b)
At a minimum records for the following processes shall be maintained ; • • • • • • • • •
Incoming material checks Inspection & test Temperature & time Product recall & traceability Storage Cleaning and sanitation, as appropriate Pest control Medical & health Training
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•
Calibration
3.11 Product Recall & Traceability a) Effective procedures shall be in place to enable a complete and rapid recall of any implicated lot/ batch of finished food. Where a product has been withdrawn, other products which are produced under similar conditions, shall be evaluated for safety and may need to be withdrawn. b)
Recalled products shall be held under supervision until they are destroyed, used for purposes other than human consumption, determined to be safe for human consumption or reprocessed in a manner to ensure their safety.
c) Food establishments should, as far as possible and appropriate, maintain an effective mechanism for identification and traceability of the incoming materials to the supplier and delivery of finished food product to the customer (not the ultimate consumer). This would help in implementation of an effective recall. d)
Records of recalled products shall be maintained.
3.12
Storage
a) Food storage facilities shall be designed and constructed to enable maintenance of cleanliness, ventilation, avoid pest access and harborage; prevent contamination and where necessary, provide suitable conditions of temperature and humidity for minimizing deterioration of food. b) Adequate facilities for storage of food, ingredients, packaging material and non food chemicals (eg cleaning materials, lubricants, fuels) shall be provided, and segregated appropriately. c) Food products shall be stored under conditions that prevent spoilage, protect against contamination and minimize damage. Food shall be stored away from the wall not directly on the floor. It should be stored preferably either on pallets / racks or any other manner to facilitate cleanliness, avoid ingress of moisture, etc. Food should be stored in clean areas and stacked in a manner that facilitates ease of movement. Food that requires specific storage conditions eg Temperature and humidity, air circulation etc shall be maintained. d) All products in storage should be clearly identified. e) Stocks of raw materials (including packing material) and
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ingredients shall be subject to effective stock rotation. f) Cleaning materials and hazardous chemical substances should have restricted access to authorized personnel. 4
Maintenance and sanitation
4.1Cleaning and sanitation programmes shall be in place which shall cover cleaning schedule, responsibilities, methods of cleaning, equipment and cleaning aids, etc to effectively control contamination of food These shall be continuously monitored for their effectiveness. It shall be ensured that cleaning chemicals do not contaminate food. 4.2 Pest Control a) Suitable pest control programme shall be in place and effective to ensure there are no signs of pest infestation including flies, cockroaches, lizards, rats, etc. The pest control programme shall identify the pests to be controlled, the area / locations where control is to be applied, the method of control eg physical, chemical etc., the dosage in case of usage of chemical, schedule, responsibilities, etc. These shall include use of insectocutors, traps & baits as appropriate; maintaining cleanliness, covering exposed foods and wastes, blocking drain pipes etc. b) The pest control activities shall be performed by trained personnel. These shall be continuously monitored for their effectiveness. It shall be ensured that pest control chemicals do not contaminate food. c)
The measures shall be documented and records maintained. .
4.3 Waste management a) Suitable waste management and waste disposal system shall be in place. Waste shall not accumulate in food processing, storage areas. Waste bins and areas must be covered and kept appropriately clean
5 a)
Personal hygiene Personnel working in processing area shall be checked for communicable, infectious and loathsome diseases at least once/year.
b) Personnel working in processing area shall not have any open cuts or wound/injury, contagious disease, or sickness such as Jaundice, Diarrhea, fever, etc. The open cuts or wounds shall not come in direct contact with food or food contact surface. c) Personnel while working in a food processing area shall maintain a
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high degree of personal cleanliness and shall wear clean uniform, head gear/cap, no loose or hanging jewellery/ glass bangles. Nails shall be trimmed, kept clean ad without nail polish. Street shoes shall not be permitted. Appropriate measure such as passing through a foot bath, using shoe covers, changing to separate foot wear for internal use etc shall be used. d)
Persons shall always wash hands with soap/ disinfectant at the start of activities, after use of toilets and after touching any contaminated material (including raw material, money, files etc) or unclean product / food contact surface / body parts.
e) No spitting, smoking, eating food and pan chewing shall be permitted in the processing areas. f) Visitors shall follow the same norms for protective clothing and personal hygiene as those working in the unit. g)
6.
Personnel Hygiene practices in simple local language / language understood by the personnel/pictorial shall be suitably displayed at appropriate places. Quality Control
a) The quality control programme shall include inspection and testing of incoming, inprocess and finished product. (for Specifications see Cl 3.3 a). b) Infrastructure shall be available for carrying out testing. In case the same is not available, a proper system for testing in external laboratories shall be in place.
7.
Transportation
a) Food shall be adequately protected during transport to assure food safety. b) The transportation or transport containers should be designed and constructed so that they do not contaminate food (Including ingredients) or packaging material. These should be kept clean and
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disinfected. Food and non‐food should be suitably segregated during transportation. Where the same conveyance or container is used for transporting different foods or non‐foods, effective cleaning and where necessary, disinfection shall take place between loads. c) The temperature, humidity, atmosphere and other necessary conditions, as appropriate to the product shall be maintained. 8. a)
9
Product information and consumer awareness All incoming, inprocess and finished products shall be suitably identified for product identification, stage of processing, inspection & test status, etc. so as to avoid inadvertent use. All legal/ statutory requirements shall be clearly given on the label of the final product as per W&M, PFA, etc. All finished products shall be given a unique Batch number. Any special requirements of handling, storage, processing, by customer etc shall be clearly indicated on labels. Competence & Training
a) Managers and supervisors shall have appropriate knowledge of food hygiene principles and practices. Suitable training shall be given to all persons to enable them to have the required knowledge & skills in GHP and GMP for the tasks to be performed by them effectively to enable a safe food. Trainings shall be held at required frequencies but atleast once in 6 months and records of the same maintained. Trainings can be provided on the job and or through class room sessions. 10. Temporary / mobile premises; vending machines a)All requirements of design, operations and hygiene as applicable shall apply to Temporary / mobile premises , vending machines (booths) with a view to ensuring safety and suitability of use.
EFFLUENT TREATMENT AND DISPOSAL
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STANDARDS Strict standards have been laid out by the regulatory agencies for the discharge of industrial wastes. The Government of India realized its importance and issued "The Water (Prevention and Control of Pollution) Act, 1974" and "The Air (Prevention and Control of Pollution) Act, 1981". These laws have been amended to "The Environment (Protection) Act, 1986", wherein the provision for heavier punishment (fine of Rs.1 lakh and for punishment for up to 5 to 7 years) has been made. B.O.D. and C.O.D. are abbreviations for Biological Oxygen Demand and Chemical Oxygen Demand, which are significant indexes to the quantity of organic material in waste water. B.O.D. may be defined as the quantity of oxygen (in parts per million) required by aerobic micro-organisms to stabilize decomposable organic matter in five days at 20ºC. C.O.D. is determined by the oxidation of decomposable organic matter with a strong oxidizing agent (such as potassium permanganate) which oxidizes all unstable organic material that is present. Toxicity, pH and presence of certain chemicals are also factors which determine the pollutants in the effluent and wastes. According to the standards, the industrial waste water should not have B.O.D. (mg/l) more than 30-100 for sewage water and land application. The other limits are pH, TDS (Total Dissolved Solids), TSS (Total Suspended Solids), sulphates and chlorides are given in Table 10-1. Therefore, it has become mandatory for the food processing industries not to discharge waste water having excess of pollutants than the prescribed limits and to adopt suitable control measures to meet the requirements of these agencies. Though there is a provision that the prescribed limits can be lowered or raised by the local or state authority. The discharge can be made into public sewers, natural water streams or for irrigation, as long as the effluent confirms to the standards laid down by the concerned agencies.
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Tolerance Limits for Industrial Effluent Discharge
IS PH Total Dissolve
Inland Surface Water 24 90 5.5 – 8.5
Public Sewer
21 00
2100
210 0
1 0 0
600
-
3 0 1 0 1
100
5
10 0 3 0 -
0 . 2 . 0
2.0
-
-
-
1 . 0-
-
-
2.0 600
-
1000
2. 0 60 0 100 0
3306 5.5 – 8.5
Land for Irrigation 330 7 6.0 – 8.5
Solids (Inorganic) Total susp. solids (850 I.S. sieves) BOD 5 days 20 C Oil & Grease Phenolic comp. on C 6H5OH(CN) Cyanide Sulphide (S)
Total Boron Residual Chloride chlorine Sulphates (SO4)
100
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Percent solid
-
60
60
e material Emitter C/ml
107
-
-
- do -
11
106
-
Radioactiv
(All results in Mg/l) (Source: Environment Protection Rules, 1986)
WASTE TREATMENT Primary Treatment In the screening treatment the suspended solids are not removed but only coarse solids are removed by commonly using screen sizes of 20-40 mesh. Normally 3 types of screens namely vibrating, static and rotating are typically used. To prevent pH shocks it may also be necessary to neutralize the discharge to a pH range of 5.0-9.0. Oil and grease removal with a grease trap may also become necessary. The success of primary treatments in removing pollutants depends largely on the type of the raw material processed and also the equipment and the design of the system. The suspended solids are removed either by gravity clarification, floatation clarifier or inclined plate separator as a settling device and further concentration by centrifugal concentrator or vacuum filter. Anaerobic Treatment Anaerobic Treatment has the advantages of (i)
Less use of electrical energy
(ii) (iii)
Lower nutrient requirements Production of usable by-product methane
(iv)
Production of less biological sludge for disposal.
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Methane fermentation is favored by a warm climate. However, its main disadvantages are: (1)
Anaerobic bacteria are more sensitive to toxic compounds
(2)
They grow slowly and require greater time for waste digestion
(3) Sensitive to pH changes, temperature variation and presence of oxygen. Anaerobic ponds, anaerobic filters and anaerobic contact processes are some of the commonly preferred methods of treatment. Secondary Treatment For reduction of B.O.D. to the limits prescribed for discharge, aerobic systems are most commonly used. In this system, dissolved nutrients like starch, sugar and other carbohydrates are utilized by micro-organisms as food. Since, micro-organisms require oxygen for the utilization of these nutrients conversions, it has to be supplied through the aerated lagoons, trickling filters, activated sludges, bio-filter sludge and rotating biological contractors. The criteria normally considered for the section of particular design are waste treatability, oxygen requirement, sludge production rate, solids settlability, nutrient, sludge dewaterability and ability to achieve desired effluent quality.
Tertiary Treatment To organic solids, inorganic pollutants and nitrogen or other nutrients which remain after secondary treatment are removed by the tertiary or the advance waste water treatment. Tertiary processes include nitrification, sedimentation by chemical precipitation and filtration to remove solids. The other tertiary processes are also there to produce an effluent of near drinking water quality.
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Solids Concentration
The solids from screening, primary, secondary and tertiary treatment processes needs to be concentrated and disposed of in a safe and effective manner before disposal. The purpose is to reduce the amount of organic matter and the number of disease-causing microorganisms present in the solids. The most common treatment options include anaerobic digestion, aerobic digestion, and composting. The characteristics and the approximate quantities of the waste solids generated in the treatment of a typical food processing industry waste . The solids are concentrated by conditioning and dewatering. Chemical conditioners, such as Alum ferric chloride, Lime or other chemicals may not be suitable for food processing wastes as it can also be used as an animal feed or for the preparation of other by-products like alcohol, pectin or human food. Other processes such as digestion, heat treatment, thickening etc. need to be considered for solids concentration. Choice of a wastewater solid treatment method depends on the amount of solids generated and other site-specific conditions. However, in general, composting is most often applied to smaller-scale applications followed by aerobic digestion and then lastly anaerobic digestion for the larger-scale municipal applications.
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Typical Waste Solids Characteristics Type Screenings
Character 20/50% solids screenings are usually dry and are handled as a solid rather than as a liquid
Silt
sludge. 20-40% solids slit at the lower solids concentration is a thick mud, difficult to handle. At higher solids concentrations, slit
Primary solids
has properties of a solid and handling is easier. Solids usually range from 1 to 5%. The presence of silt or chemicals can raise the
Secondary solids
percentage to 10-30%. Claimed solids concentrations range from 0.5 to 2% for clarifier underflow. Concentrations less than 1% are more typical with food
Tertiary solids
processing wastes, especially if the treatment plant is heavily loaded or nutrient deficient. For clarifier underflow proceeded by lime precipitation, 7% solids may be possible. For solids settled from sand filter backwash, settled from sand filter backwash, settled solids are likely to be less than 1%.
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EQUIPMENT REQUIREMENT It is expected that the B.O.D. of effluent leaving the proposed processing plant will have BOD varying from 500–700 or more, which will be treated to permissible limits before discharge. The solid waste could be disposed off separately. This includes the wastage from preparatory, as well as solids collected from the centrifuge and screening of drainage water passing out of the plant. The liquid waste could be disposed off into the drainage or for irrigation. The liquid sludge and solid waste could also be tried for landfill. The effluent to be generated from the instant mix plant will be in a very capacity and not hazardous.
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Equipment Requirements
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MANPOWER GENERAL The proposed factory plant involves a considerable number of operations, which require the services of skilled and un-skilled personnel. The total manpower required for the project is broadly classified into the following groups: a.
Production, Laboratory and
Maintenance b.
General Administration & Security etc.
c.
Finance, Purchase & Marketing.
d.
Casual Labour for production.
BASIS OF ESTIMATION The proposed estimation of manpower required for the smooth and efficient operation of the plant keeps in view of the following considerations. a. b. c.
Distinct division of the zones of supervision and minimizing the levels of
operations;
Classified activities;
fields
of
managerial
and
executive
Providing adequate working conditions with reference to Indian environment; and
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d.
Providing for proper quality control activities at appropriate points.
PLANT LAYOUT OF LIQUOR BOTTLING PLANT
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PROJECT IMPLEMENTATION SCHEDULE
Project implementation will take a period of 12 months. Months
Sr. No.
Particulars
1
1
Basic Engineering
*
2
Detailed Engineering
3
Placement of Orders
4
Receipt of Equipment
5
Shipping
6
Construction/ Erection Civil /Structural Equipment Electric / Instrumentation
7
Testing & Commissioning
4
6
8
10
12
* * *
* * * *
* *
* *
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ORGANIZATION STAFF
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B.I.S. SPECIFICATIONS
Following B.I.S. Specification can be sen as a reference for the manufacturers of Alcohol.
Rectified Spirit IS: - 323 - 1959: (revised with amendment No. 1 & 2 (Reaffirmed 1978) This standard specified the requirements and method of sampling and test for two grades. Grades suitable for use as a reagent for pharmaceuticals and medicinal purpose and for the production of alcoholic beverages and grade 2 for industrial purposes. Material of grade 1 required for acetone manufacture has also seen covered by prescribing additional requirements. IS 324 - 1956 ORDINRY Denatured spirit (revised) (reaffirmed 1978) prescribes requirements and method of sampling and test for the material produced from ethyl alcohol by denaturing with mineral pyridine bases and light caoutchoucme.
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Quality requirements for these two denaturant content in the denatured spirit have also been stipulated. Relation between S.G., percentage of alcohol by weight and volume and proof strength has also been covered. Ordinary denatured spirit is used as a solvent and vehicle in the paint industry as a fuel and for various other industrial purposes.
346 - 1952 Varnish, sprit clear, hard with amendments No. 1 & 2 (Reaffirmed and test, composition and requirements for solubility, drying time, `finish' colour, flexibility I adhesion, freedom from rosin and keeping properties. The material is used for painting of non ferrous metl surfaces, especially of instruments. IS - 321 - 1964 Absolute Alcohol (revised ) with amendment No.1) Reaffirmed 1979 prescribes requirements and methods of samlong and test, covers three grades namely, special, Grade 1 for pharmaceutical and medicinal purposes. The material is intended for use as raw material, reagent and solvent in the chemical and pharmaceutical industries and for the production of power alcohol by partial or complete denaturation. 5287 - 1978 : Country spirit (distilled) (first revision). This standard prescribes requirements and methods of sampling and test for plain country spirit (distilled ) it excludes spiced country spirit. IS - 6613 - 1972 Neutral spirit for alcoholic sampling and test.
drinks prescribes requirements and methods of
IS - 5287-(1978) Country Spirit (distilled). IS : 5287 - (1978) Country spirit (distilled) IS - 4117 - 1973 Alcohol denaturants (first) revision) (reaffermed 1978).
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Prescribes essential requirements of various alcohol denaturants (both for completely and specially denatured alcohol) and their limit test in the denatured alcohol. Ethyl alcohol is generally used as an industrial solvent and also as a raw material for chemical industry. Large quantities of specially denatured alcohol considered suitable for specific industries as covered by formulae evolved by the standing working committee of ministry of industry have also been included. These special denaturants do not make the alcohol monportable, but enable the consumer to carry to his manufacturing process. This specification is expected to introduce uniformity is the enforcement of various regulation under Excuse Acts of different states in regard to procurement and usuage of ethyl alcohol in industry. IS -322 - 1952 :- Power alcohol (with amendment No.1) Befaffermed 1975) This standard prescribes requirements and method of sampling and test for power alcohol which consists wholly of ethyl alcohol and added denaturant. It does not cover blends that may be produced from this denatured alcohol by mixing with other motor fuels such as petrol and intended for the distribution of power alcohol. The material is usually used in admixture with petrol as a fuel for automobile engines.
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VARIOUS TYPES OF INDUSTRIAL ALCOHOL
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PRODUCTION OF BRANDY BRANDY : Brandy is a distillate or a mixture of distillates obtained solely from the fermented juice, mash, or wine of fruit, or from the residue there of, distilled at less than 190o proof (95%) in such a manner as to produce the taste, aroma, & characteristics generally attributed to it. The most imported category of brandy is fruit brandy, distilled solely from the juice or mash of whole, sound, ripe fruit or from standard grape, intrus, or other fruit wine. Brandy derived exclusively from one variety of fruit is so designated. However, a fruit brandy derived exclusively from grapes may be designated as brandy without further qualification, and unless the product is specially identified, the term brandy always means grape brandy. Brandy is subject to a distillation limitation of 170o proof (85%) If distilled over 170o proof (85%) it must be further identified as neutral brandy. Although the age is not indicated on the label, brandies are normally aged from three to eight years. Brandies are produced in batch or continuous distillation systems. Perhaps the most popular brandy comes from the 'cognac' region of France. Thus, it is called 'coagnac'; 'Cognac' is produced in the traditional pot stills by Small farmers and sold to the bottles who age the brandies in limousin oak casks. When the brandy reach maturity, they are skill fully blended for marketing under their own brand name. Another well known brandy of France is Armagnac, produced in Southern France. Armagnac is distilled from wines in a continuous system using two pot stills in series. Armagnac is considered to be mnore heavy bodies and drier than cognac. In the U.S., California produces almost all of the grape brandy. Usually a continuous multicolumn distillation system is employed. Another class of beverage spirits, 'Flavoured Brandy', is a brandy to which natural flavoring materials have been added with or without the addition of sugar; it is bottled at no less than 70o proof (35%). The name of the predominant flavour appears as part of the designation, i.e. 'Blackberry Flavoured Brandy' ; 'Cherry Flavoured Brandy' etc. Such a flavoured brandy may contain up to 12 1/2 % of wine derived from the particular fruit corresponding to the labeled flavour.
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Components of Brandy:The chief constituents of brandy is, of course, ethyl alcohol, But many other volatile compounds are present in grapes or are formed during alcoholic fermentation of grape must. Since these are not completely separated from the alcohol during distillation they appear in larger or smaller amounts on the distillate. Other components are formed during aging or are extracted from the wood. Finally, same are added to beverage brandy during processing. Ethyl Alcohol :Ethanol C2 H5 OH is completely miscible with water and forms a constant boiling point mixture with it at 96% alcohol by weight. It is clear, colorless, inflammable liquid with a density of 0.7939 at 100 percent alcohol or at 200o proof. It is a good solvent for essential oils, esters, tannins, various organic acids and certain other organic compounds. It is, therefore, a very important industrial solvent. Other Alcohols: Methyl alcohol (wood alcohol):A small amount may be present in the brandy, as methyl alcohol and has physical properties similar to those of ethyl alcohol. It is apt to be higher in the brandy of the Pomace is present during distillation. Aldehydes:Aldehydes, chiefly acetaldehyde, are present in small amounts in brandy. During distillation and aging some acetaldehyde is produced by the oxidation of ethyl alcohol. C2 H5 OH + 1/2O2 ------- CH3 CHO + H2O This reaction is hastened by charcoal or aeration. Alcohol and acetaldehyde react slowly to form acetyl, a compound of rather pronounced odor. Furfural is mainly formed during distillation. The free aldehyde content of French cognac, is reported to be 38 to 112 mg/liter. The range of Italian brandies 30 to 116. The acetyl in French cognacs varied from 26.5 to 77.5 mg/liter. and in young Italian brandies, from 27 to 165, in old 18 to 112. The percent of total that is combined varies generally from 17 - 28 percent.
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Esters :During distillation and aging alcohols reacts with acids amounts of esters such as ethyl acetate.
to form small
C2H5OH + CH3CO OH --------> CH3 COOC2H5 + H2O. Many other esters are also formed during fermentation, distillation, and aging. They may be responsible for some of the flavour of the brandy. Among the esters of brandy, ethyl acetate is the most common. Esters of Propyl and butyl alcohols have also been reported and in small concentrations are not disagreeable. COLUMN STILLS :A continuous still is a sort of series of inter-connected pol stills. Their continuous operation is mere efficient than that of pot stills. The modern column still is a cylindrical shell divided into sections by a series of plates. The plates are perforated or have openings covered by bubble caps (about 10 percent of their area is open) to allow passage of vapour. Nowadays, perforated or sieve plates are used in the lower stripping section of the column since they permit using distilling material with a higher percentage of suspended solids. Bubble cap plates with a down pipes are used in the upper (rectifying) section of the column. The plates in the column are spaced 18 to 30 m. apart. If the plates are close together the vapour velocity is too great, mechanical carry-over of liquid will occur in the column. So the plates must be spaced a distance apart. inches equal to ten times the vapour velocity in feet per second. Thus, for a vapour velocity of 2.4 feet per second the plates should be 24 in. apart. In practice volumes are operated at velocities 25 to 50 greater than this:
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Heat is supplied by a steam sparger at the bottom of the column. Down pipes between plates provide for return of liquid from one plate to another. The down pipes are located on opposite sides of the still for alternate plates so that the liquid passes across the plate before entering the next down pipe. The upper part of the down pipe extends above the plate so as to allow a liquid layer of 1 to 2 in. on the plate. The lower end of the down pipe is inserted in a cup on the lower plate to form a liquid seal. Wine is introduced at some intermediate plate in column. The ascending steam vapour prevents the liquid from falling through the perforation on the plate. There is a layer of liquid on each plate. The overflow passing to the next lower plate through the down pipe. The vapour laving the boiling layer of liquid on the plate passes through perforation of the plate. Some of the liquid is evaporated by the heat released by the condensation of the incoming vapoures and passes on to the next higher plate. Alcohol has a higher vapour pressure than water and thus evaporates from each plate more easily than water. The alcohol concentration thus increases from plate to plate. The alcohol concentration on each plate of stripping sections remains essentially the same (once the still is in balance) since it continuously receives a fresh fed supply from the plate above. To conserve heat the hot dealcoholized liquid which accumulates at the base f the still is discharged through a heat exchanger which warms the incoming wine. Some columns, particularly the fractionating section, are insulated (lagged) to avoid heat loss. Insulation is also useful with small columns to secure better control.
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CONDENSERS :Whatever system of distillation is employed, the alcohol-containing vapour must be condensed back to a liquid. Condenses serve to functions: conversion of vapour to liquid and cooling the resultant liquid to room temperatures. The second step removes only a small amount of the total heat but requires greater condenser area since there is a slower heat transfer through cooling surfaces with liquids on both sides. The transfer of heat between liquid & vapour is by the film of state man liquid on the water side and the film of stationary vapour on the vapour side. Vapour films are thinner, hence, heat transfer is more rapid for an apparatus condensing a vapour than the same apparatus cooling a liquid. The heat transfer coefficient may be increased by increasing the velocity of the cooling water through the tubes or by using condensers of special design. The vapour from the top of the column still passes through a dephlegritor and condenser. A portion of the vapour condenses in the first and is returned to the column as the reflux. The condenser may also return a reflux to the column and the remainder be taken off as heads, the actual product in this care is removed as a side stream from the upper plates in the column. It has shown that a side stream take off results in less esters and aldehydes in the product. This was true either for production of fortifying brandy at 186o to 189o proof or of beverage at 164o to 167o proof.
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PRODUCTION OF RUM Types of Rum and the Raw Materials: Rum is produced from cane-sugar or sugar by products, the most common raw material being cane juice, syrup or molasses. The raw material used largely determines the type of rum produced. Cane juice is best suited for the production of rum with a light aroma. Finely ground sugar-cane is pressed in to a dry mass. Finely ground sugar-cane is pressed in to a dry mass, and the cane juice so obtained is used as such or after concentration. Syrup, a thick, viscous liquid, is obtained by evaporating water from cane-juice by vacuum distillation. Most rum is produced from molasses, which is especially is a by-product in the production of sugar. It remains as the mother liquor when sugar is separated from can juice by repeated crystallization. Depending on the sugar-cane variety, production methods and other factors such as climate, it contains some 50 - 60% sugar. The use of molasses in the production of rum does, however, other some advantages over other possible raw materials. Being a natural by-product of the sugar industry it is cheaper, for example, can juice. It keeps better than can juice, so that its storage causes no problems. Rum is an alcoholic distillate from the fermented juice of sugar cane, its syrup, molasses, or other by products, distilled at less than 190o proof (95%) in such a manner that the distillate possesses the taste, aroma, and characteristics generally attributed to rum, and bottled at not less than 80o proof (40%) & also includes mixtures solely of such distillates. Blackstrap molasses is the most common raw material for the manufacture of rum. The type of yeast, fermentation environment, distillation techniques & systems, the maturation conditions, & not least the blending skill all contribute to the final character & quality of rum. A typical composition of Pueoto Rican blackstrap molasses is as follows:
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pH
4.3
Density (% solids)
89o Brix
apparent purity
28.7%
True sucrose 'clerget'
33.8%
Reducing sugars
26.9%
Total sugars
60.7%
Pretreatment of Raw Material:Depending on the quality, cane juice is fermented as it is or after heating and clarifying. Pretreatment of molasses can be divided into several different storages. It must first be clarified to rename colloidal matter, especially calcium sulphate, which could otherwise block the column during distillation. Chemical classification can be carried out by precipitation with alumine and calcium phosphate or by adding H2SO4. This, however, can lowr the sugar content. Most of the remaining insoluble impurities can be removed by centrifugation, either cold or at higher temperatures. Micro-organisms, which could cause difficulties during the fermentation, are destroyed by pasteurization. The final stage in the pretreatment of molasses is dilution with water, which lowers the viscosity and brings the total sugar content to 10-12g/100ml wash, which is a suitable concentration for fermentation. At the same time, it is usual to adjust the pH value of the solution to about 5.5 and to add ammonium sulphate or urea as yeast nutrients. FERMENTATION:The course of fermentation depends mainly on the fermentation temperature and time, the pH value of the solution and the kind of yeast present.
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1. Fermentation Temperature:Various fermentation temp. and times are used. According to 18 anson, the temperature is head between 31oC and 32oC and the fermentation allowed to run for 36-48 hours. Puerto hico rum distilleries use a temperature between 28oC and 33oC and a fermentation time of some 28-36 hours. Temperatures as high 35-37oC have been reported. A temperature between 30oC and 33oC is usual but, when bacteria are used for fermentation, the temperature of the solution must not be allowed to exceed 30oC after addition of the bacteria. (2) PH Value:The pH value of the wash radically affects course of fermentation and the metabolic products formed. Relatively high contents of alcohol can be obtained at lower pH value, but the optimum pH value for production of good aroma is probably in the region 5.5 - 5.8. Because bacteria lose their activity even at pH-4, the pH value must not be allowed to fall much below 5 when a contamination of yeast and bacteria is used for fermentation. (3) Fermentation Time :The fermentation time depends on the amount and kind of yeast, the fermentation temperature, sugar concentration and quantity of yeast nutrients. A time of 30-48 hours are normally employed, but a period as long as 72 hours has been reported. (4) Yeast :Fission-type top yeasts, such as schizosaccharomyus strains, are best suited for the production of rums with a heavy aroma wheras, for the ligher rums, the quick-fermenting budding-type saccharahus yeast are better.
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The best yeast are from molasses. Distillation:Before being distilled, the fermented mixture is usually allowed to stand for some hours so that the yeast cells can settle out. The remaining insoluble material is finally separated by centrifugation. Both pot still and continuous distillation units are in general use. The pot still method is used mainly in the English and French-speaking areas of the West is that is requires a relatively small capital outlay. The method is also quite flexible and yields a high quality product. Continuous distillation is used to produce the lighter rums, for example Puerto Rican and cuban rums. Continuous Distillation:Continuous Distillation units consists of at least three columns, A diagram of a three-column unit is shown. The first column, known as the beer, or exclusive column, is used to remove all of the alcohol from the fermented wash. The vapour at the heed of this column containing volatile impurities and with an alcohol content of 40-65 (v/v) is condensed, part returning as reflux and the remainder being lead to the feed tanks for the purifying column., the raw distillate is suitably diluted with water, usually to 20-80 (v/v). Low-boiling impurities are taken away at the had of the purifying column, while the partially purified alcohol water mixture is taken off at the bottom and lead to the rectifying-column feed tanks. The rectifying column is used to concentrate the alcohol to the desired strength and to remove the remaining impurities. Alcohol or beverage products are taken off from the upper trays of the column, while oils acemulate in the intermediate plates and are removed as a side stream. Heats are removed from the top of the column. A modification of this distillation procedure in which the purifying column was made to act as an extractive column by feeding in water at the lead. The use of extractive distillation can lead to the removal of almost all impurities.
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The effect that the distillation process can have on the arome composition of rum can be clearly seen by comparing the two gas-liquid chromatogrems presented. These are two west Indian rums, which contain substantially the same components but differ greatly in quantitative composition the aroma fraction of light rum being only same 10% of that of the rum with the heavy aroma. Maturing: Freshly distilled rum often has a raw aroma which can be improved by storing the liquor in oak casks. It is generally kept for two to ten years, although some heavy rums are matured for 10-12, or even 15 years. There is an English law, which was applicable in the former British colonies that Whisky rum and brandy can not be sold as such until they are three years old. The recent increase in the popularity and production of the lighter flavoured rums, which don't improve greatly with maturing, led to this being disregarded. The ratio of surface area of a cark to the volume of beverage it contains has an important effect on the course of the maturing. A capacity of about 150 litres are the most suitable. The interior sufaus of the casks ae usually chamed to promote the maturing process, and the casks are kept upright during the maturing period. The process occurring during maturing are not known in detenol. The oak walls of the cask are more or less permeable to easily volatile compounds depending on the temperature and relative humidity of the store. Another process occurring during maturing is extraction of wood components into the rum and their graudal decomposition. Additionally, it has been shown, that esters are formed and that certain compounds are oxidised. The changes occuring on quantity of aroma compounds in whisky and its colour during twelve years maturing more than half of the final level of acids and aldehydes were reacted during the first four years, whereas the amount of esters continued to increase steadily throughout the whole period, maturing had no noticeable effect on the concentration of higher alcohols.
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PRODUCTION OF SPIRIT FOR GIN Raw Material: The production of alcohol is not an antrinsic part of the process of manufacture of gin where a suitable high-quality spirit is selected and redistilled with flavouring materials or produced in some other way. The manufacturer of gin, therefore, may select a spirit to suit him purpose from a range of distilled neutral spirits. He may be activated in his selection by a number of factors, among them the influence of nay particular spirit flavour quality on the ultimate quality of his product, or a marketing requirement to claim that is product is made from spirit from a particular origin, grain, In general, however, it can be claimed that any fermentation based spirit, correctly made & distilled in modern multicolumn stills, is likely to serve as a suitable bale for the manufacture of the London dry style of gin. Any material containing carbohydrate which can easily and economically be made available for fermentation can be considered as a suitable source material for spirit production. Such materials are generally rich in starch, which required to be converted into a readily fermentable form, for examplegrain & potatoes, or in directly fermentable sugars, such as molasses. Production from Grain: The system of spirit production in a grain distillery encompasses a number of discrete stages, namely - grain storage and lending cooking and corrosion, fermentation and, finally, distillation and by product recovery. The efficiency of each stage in the system is important in contributing to the optimal performance of the distillery.
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1 Cooking:Maize is delivered to the distillery in bulk and drawn out of the transportation containers by suction or mechanical screw conveyor. It is sifted to remove fines and large particulates material and conveyed to silos for storage, provided the moisture content of the maize is below 14% it can be safely stored in silo. When required for mashing, the grain is drawn mechanically from the base of the silo in weighed quantities. In order to transform the starch granules of maize into a medium capable of being fermented by yeast, they required to be first disintegrated and then subjected to corrosion into sugars, normally by enzymes. Several procedure exist to achieve these ends, among them being some important new development in distillery technology. The first stage is effected by cooking the grain under condition of temperature and pressure intended to bring about gelatinization of the starch granules. There are four distinct methods of cooking in operation in grain distilleries namely --(1) boiling atmospheric pressure (ii) infusion at low temperature (iii) High pressure batch cooking (iv) continuous cooking. Boiling at atmospheric pressure, a simple but absolute method of operation suffers the disadvantage of incomplete gelatinization of the starch granules, with consequent lower yields of spirits. Infusion method of grain softening and conversion are appropriate only where spirit is made from small grains such as barley, rye and wheat. For example in scotch malt whisky or German kornbrarithein. For a specific type of distillery operation, infusion mashing give excellent spirit yields although the temperatures used are not sufficiently high to sterilize the mash. The other two methods of cooking under high pressure are economically important, Until recently, all large maize spirit distillers operated a batch pressure cooking process using cylindrical pressure vessels equipped with agiattors and capable of withstanding about 7 * 105 rascals (100 psi) but in many distilleries this system has now been superseded by continuous cooking maximum pressure & temperatures vary with practice in industrial distilleries, have been reported to lie in the range 150oC to 135oC and 4 * 105 Pascal’s (4-2.5 atm). Typical condition in continuous cooking process are temperature 1500C, 4.5 * 105 Pascal’s pressure (65 psi) and a total holding time of 10 minutes. At the exist of the cooking tube, the cooked mash is brought down to a suitable conversion temperature by continuous vacuum cooling.
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Conversion: At the termination of cooking, the gelatinized starch in suitable condition for conversion into fermentable sugars are cooled to a temperature favoring anyhydtic enzyme activity and mixed with the enzyme medium in a suitable conversion vessel. The agent of starch conversion in the potable-spirit distillery has until recently been the enzymes of molted grain, usually barley, although from moved source have historical interest in the amyh-process, and current importance in the manufacture of sake. A residence time of a few minutes are sufficient to achieve an anylolysis approaching equilibrium, the converted mash after passage through another tabular color is discharged direct into the fermenter. Fermentation:Saccharomyous cerevinisial on a rate of between 0.1 and 0.15 kg yeast dry weight per 1,000 litres of mash. Distillers growing up a yeast from culture medium pass it through a minimum of three inoculation stages. The medium used for plant inoculation is an enriched vension of the fermentation wort, adjusted to a pH value below 4.0 Each. state is allowed to ferment for 12-18 hours, and in transferred to the next when the degree Brix reading drops by 50% the final sage may be used to pitch two fermenters and to allow some flexibility an inoculum can be stored for a short period by holding the temperature at 16 - 18.5oC provided the degree Brix reading is not lowered by more than 40%. The finalinoculum represents about 2% of the fermentation mash and is discharged into the fermenter when it is about a tenth full. In the absence of supplementary temperature control, the selling temperature of the fermenter is capable of critical variation. Temperature within the region 15 - 25oC and an lye on the weather forecast to prevent a nise in temperature during fermentation. To improve the buffering the power of the wort in the range 4.4 to 4.1. Now we distill the fermented mesh sane as in the cale of rum. After that these product is bottled in desired amount and desired shape of bottles.
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MANUFACTURING PROCESS OF WHISKY
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LIST OF IMFL/LIQUOR MANUFACTURER IN INDIA Sri S.K. Kishorepuria, Managing Director, M/s. S.C.I. India Limited, 113, Park Street (6th Floor) “Poddar Point” KOLKATA-700016 Sri P.N. Poddar, Divisional Vice President(Mfg.) M/s. United Spirits Limited, “Le Parc Richmonde, 51, Richmond Road, BANGALORE-560025 (Karnataka) Sri Ajay K. Modi, Managing Director, M/s. Ashoka Distillers& Chemicals Pvt. Ltd., 501, Chiranjeev Tower, 43, Nehru Place, NEW DELHI-110019. Sri Lalit Dewan, Asstt. Vice President, M/s. Devans Modern Breweries Ltd., BHHRI, Talab Tillo, JAMMU-180002 (J & K ) Sri Amit Modi, M/s. Chadigarh Distillers & Bottlers Limited, SCO No. 140-141, City Sub Centre, Sector 34-A, CHANDIGARH-160022
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Sri Arun Dhandhania, Managing Director, M/s. Ratnesh Enterprises P. Ltd., 17/1, Civil Lines, Rampura, Suraj Nagar (East) JAIPUR-302006 (Rajasthan) Sri Vijay Kapoor, Managing Director, M/s. Jagatjit Industries Limited, JAGATJITNAGAR-144802 Dist. Kapurthala ( Punjab) Sri M.K.Pradhan, Managing Director, M/s. Sikkim Distilleries Limited, Sai Baba Nagar, RANGPO- 737132 ( Sikkim) Sri Ashok Agarwal, Sr. General Manager, M/s. Kesar Enterptires Ltd., (Distillery) BAHERI-243201 Distt. Bareilly Sri Tilak Dhar, Managing Director, M/s. D.C.M. Shriram Sugar Division, Kanchenjunga Building, 10th Floor, 18, Barakhamba Road, New delhi-110001.
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Sri Gurmit Singh Mann, M/s. Simbhaoli Sugars Limited, (Distillery Division) SIMBHAOLI-245207 Distt. Ghaziabad (U.P.) Sri Vivek Viswanathan, M/s. Sir Shadi Lal Enterprises Limited, SHAMLI-247776 Distt. Muzaffarnagar (U.P.) Sri Atul Kumar Singh, M/s. Lords Distillery Limited, 18, Community Centre, New Friends Colony, NEW DELHI-110065. Sri K.P. Singh, M/s. Rampur Distillery Unit of Radico Khaitan Ltd.,) Bareilly Road, RAMPUR-244901 (U.P.) Sri Tilak Raj Sharma, M/s. Unnao Distilleries & Breweries Limited, Shekhpur,UNNAO-209801 (U.P.) Dr. A.V. Singh, Head Distillery Business, Bajaj Hindusthan Limited, B-10, Jamna Lal Bajaj Marg, Sector-3,NOIDA -201301 (U.P.)
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Sri Anil Gujral (CEO), DCM Shriram Industries Ltd., Daurala Sugar Works., 10th Floor, Kanchenjunga Building 18, Barakhamba Road, NEW DELHI-110001 Sri Ajay K. Swarup, Managing Director, M/s. Associated Distilleries Limited, C- 631, New Friends Colony, NEW DELHI-110065. Sri S.P. Seth, Chairman & Managing Director, M/s. National Industrial Corporation Limited, 801-803, Ashok Bhavan, 93, Nehru Place, NEW DELHI-110019 Sri Rajesh Dhingra, Business Head, M/s. Mawana Sugars Limited, Plot No. 15 Institutional Area, Sector-32 GURGAON-122001 (Haryana). Major S.K. Bakshi, M/s. Mohan Meakin Limiteed, MOHANNAGAR-201007 Distt. Ghaziabad (U.P.)
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Sri Rameshwar Havelia, Managing Partner, M/s. Doon Valley Distillers, (Alcohol Division) Kuanwala, PO HARRAWALA DEHRADUN (Uttaranchal) Dr. J.A. Gore, President- Distillery, M/s. IFB Agro Industries Limited, Plot No. IND-5- Sector-I, KOLKATA-700078 Sri J.C. patel, M/s. Shree Chalthan Vibhag Khand Udyog Sahakari Mandli Limited, CHALTHAN-394305 Distt. Surat (Gujarat) Sri O.P. Patodia, Whole Time Director M/s. Kanoria Chemicals & Ind. Ltd., 3407, GIDC Ind. Estate, ANKLESHWAR-393002 (Gujarat) Sri Aspi D. Bapuna, M/s. Gwalior Distilleries Limitd, Byramji Town, Gondwana Square, Banaz Building (Near Kodvi Chowk Fly Over) NAGPUR-440013 (Maharashtra)
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SUPPLIERS OF RAW MATERIALS
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BOTTLING PLANT FROM RECTIFIED SPIRIT [EIRI/EDPR/1467] J.C.248 J.C. 248
Page A-
1
PLANT ECONOMICS
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BOTTLING PLANT FROM RECTIFIED SPIRIT [EIRI/EDPR/1467] J.C.248 J.C. 248
Page A-
2
LAND & BUILDING
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-----------------------TOTAL Rs. x,xx,xx,xxx.xx ------------------------
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BOTTLING PLANT FROM RECTIFIED SPIRIT [EIRI/EDPR/1467] J.C.248 J.C. 248
Page A-
4
PLANT & MACHINERY
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BOTTLING PLANT FROM RECTIFIED SPIRIT [EIRI/EDPR/1467] J.C.248 J.C. 248
Page A-
5
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BOTTLING PLANT FROM RECTIFIED SPIRIT [EIRI/EDPR/1467] J.C.248 J.C. 248
Page A-
6
B. LIST AND COST OF LAB. EQUIPMENTS
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BOTTLING PLANT FROM RECTIFIED SPIRIT [EIRI/EDPR/1467] J.C.248 J.C. 248
Page A-
7
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BOTTLING PLANT FROM RECTIFIED SPIRIT [EIRI/EDPR/1467] J.C.248 J.C. 248
Page A-
8
OTHER FIXED ASSETS
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BOTTLING PLANT FROM RECTIFIED SPIRIT [EIRI/EDPR/1467] J.C.248 J.C. 248
Page A-
9
FIXED CAPITAL
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BOTTLING PLANT FROM RECTIFIED SPIRIT [EIRI/EDPR/1467] J.C.248 J.C. 248
Page A- 10
WORKING CAPITAL REQUIREMENT/MONTH RAW MATERIALS
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BOTTLING PLANT FROM RECTIFIED SPIRIT [EIRI/EDPR/1467] J.C.248 J.C. 248
Page A- 11
SALARY & WAGES / MONTH
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BOTTLING PLANT FROM RECTIFIED SPIRIT [EIRI/EDPR/1467] J.C.248 J.C. 248
Page A- 12
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UTILITIES AND OVERHEADS
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BOTTLING PLANT FROM RECTIFIED SPIRIT [EIRI/EDPR/1467] J.C.248 J.C. 248
Page A- 13
TOTAL WORKING CAPITAL/MONTH
COST OF PROJECT TOTAL FIXED CAPITAL
Rs.
X,xx,xx,xx,xxx.00
MARGIN MONEY Rs. TOTAL
X,xx,xx,xx,xxx.00
-----------------------Rs. X,xx,xx,xx,xxx.00 ------------------------
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BOTTLING PLANT FROM RECTIFIED SPIRIT [EIRI/EDPR/1467] J.C.248 J.C. 248
Page A- 14
TOTAL CAPITAL INVESTMENT
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BOTTLING PLANT FROM RECTIFIED SPIRIT [EIRI/EDPR/1467] J.C.248 J.C. 248
Page A- 15
COST OF PRODUCTION/ANNUM
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BOTTLING PLANT FROM RECTIFIED SPIRIT [EIRI/EDPR/1467] J.C.248 J.C. 248
Page A- 16
TURN OVER/ANNUM
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PROFIT
=
RECEIPTS - COST OF PRODUCTION
PROFIT SALES RATIO =
Profit / Sales
x
100
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RATE OF RETURN =
Operating profit / T.C.I
x
100
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BOTTLING PLANT FROM RECTIFIED SPIRIT [EIRI/EDPR/1467] J.C.248 J.C. 248
Page A- 17
BREAK EVEN POINT (B.E.P) Fixed Costs of the plant are as under -
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B.E.P.
=
FIXED COSTS ------------------------------ X 100 FIXED COSTS + PROFIT
LAND MAN RATIO = Total land / Manpower
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BOTTLING PLANT FROM RECTIFIED SPIRIT [EIRI/EDPR/1467] J.C.248 J.C. 248
Page A- 18
RESOURCES FOR FINANCE
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BOTTLING PLANT FROM RECTIFIED SPIRIT [EIRI/EDPR/1467] J.C.248 J.C. 248
INSTALMENT PAYABLE IN
Page A- 19
5 YEARS
================================================================================ Year To Financial To Commercial To others Total institutions banks (Rs. 51653555) (Rs. 25340198) (Rs. 41458175) ================================================================================
================================================================================
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INTEREST PAYABLE IN
5 YEARS
================================================================================ Year On term loans On bank loans On self loans Total (Rs. 51653555) (Rs. 25340198) (Rs. 41458175) @ 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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BOTTLING PLANT FROM RECTIFIED SPIRIT [EIRI/EDPR/1467] J.C.248 J.C. 248
DEPRECIATION CHART FOR
Page A- 20
5 YEARS
================================================================================ Year Building costs Plant & Machinery fur. & office equip. Total ( Rs. 28980000.00 ) ( Rs. 32312008.00 ) ( Rs. 800000.00 ) @ 10.00 % P.A. @ 20.00 % P.A. @ 20.00 % P.A. ================================================================================
================================================================================
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BOTTLING PLANT FROM RECTIFIED SPIRIT [EIRI/EDPR/1467] J.C.248 J.C. 248
PROFIT ANALYSIS FOR
Page A- 21
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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BOTTLING PLANT FROM RECTIFIED SPIRIT [EIRI/EDPR/1467] J.C.248 PROJECTED BALANCE SHEET FOR ( 5 YEARS) LIABILITIES
ASSETS
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BOTTLING PLANT FROM RECTIFIED SPIRIT [EIRI/EDPR/1467] J.C.248
4
Year
90
% Capacity
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5
Year
100
% Capacity
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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
:: :: :: :: :: :: :: :: :: :: :: :: :: :: :: :: :: :: :: :: :: :: :: :: ::
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
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Technology Books & Formulations
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Handbook of pulp and paper technology, manufacturing process - handbook of pulping an.. 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
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Cereal processing projects.. 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..
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Rolling and re-rolling, steel re rolling, rolling mill, aluminium rolling, sheet roll.. 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, ..
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