BISCUIT PRODUCTION UNIT (CAP: 35 TONS/DAY)
[EIRI/EDPR/4648]
Baking industry is the most stable sector in the food manufacturing industries. The principal basis for most products in this range is wheat flour. Addition of water and various other ingredients give us variety of products like cookies, crackers, cakes, pastries and biscuits. Biscuits are flat, crisp, baked good, whereas cookies are softer and thicker. Cracker means biscuits of a low sugar and fat content, frequently bland or savory.
Biscuit is a low moisture bakery product. Moisture content of biscuit is typically below 4% depending upon its weight, thickness and shape. Biscuit dough can be made from soft wheat flour with a high amount of sugar (25-55%) and shortening (20-60%). They are classified based on the way the dough is placed on the baking band e.g. rotary molded, wire-cut, cutting machine, etc.
The same Biscuit is made up from the word 'BIS' which means twice and 'Cut' means Balled suggesting that product should be twice balled. The Biscuit were originally developed to meet the requirement of longer life of the barley products and for this, purpose, the dough were made up and twice balled to make them moisture free to improve their keeping qualities. The Biscuit manufacturing was started a century ago mainly to meet the requirement of European Travellers. The industry was located near the sea port but today we have a large number of factories situated in various parts of the country. Producing best quality biscuits equivalent to international standards.
COST ESTIMATION
Plant Capacity 35 MT/Day
Land & Building (10,000 sq.mt.) Rs. 6.31 Cr
Plant & Machinery Rs. 7.00 Cr
Working Capital for 1 Month Rs. 6.07 Cr
Total Capital Investment Rs. 20.54 Cr
Rate of Return 35%
Break Even Point 53%
CONTENTS
INTRODUCTION
INDIA AT PRESENT PROCESSES MAINLY FOLLOWING VARIETIES OF BISCUITS:
INGREDIENTS
FLOUR
WATER
FAT
SUGAR
SALT
OTHER INGREDIENTS
TYPES OF BISCUIT
COMPOSITION OF BISCUITS
USES AND APPLICATION
B.I.S. SPECIFICATIONS
INGREDIENTS OF BISCUITS WITH THEIR B.I.S. SPECIFICATIONS
1. ESSENTIAL INGREDIENTS:-
2. OPTIONAL INGREDIENTS:-
PROPERTIES OF RAW MATERIALS
MARKET POSITION
BISCUIT CAN BE BROADLY CATEGORIZED INTO THE FOLLOWING SEGMENTS KEY TAKEAWAYS
BY TYPE - SEGMENT ANALYSIS
BY DISTRIBUTION CHANNEL - SEGMENT ANALYSIS
BY GEOGRAPHY - SEGMENT ANALYSIS
DRIVERS – BISCUITS MARKET
THE RISING DEMAND FOR HEALTHY COOKIE
REGIONAL INSIGHTS
HEALTHY BISCUITS MARKET SHARE INSIGHTS
INCREASING DEMAND FOR “READY TO GO” FOOD
THE HIGH COST OF RAW MATERIALS
BISCUITS INDUSTRY OUTLOOK:
ACQUISITIONS/PRODUCT LAUNCHES:
RISING DEMAND FOR HEALTHY COOKIES
NORTH AMERICA TO DRIVE THE MARKET
COMPETITIVE LANDSCAPE
MAJOR PLAYERS
EMBRACING INNOVATION TO OVERCOME CHALLENGES
BISCUITS-BAKERY SECTOR LOOKS LIKE A BATTLEFRONT
TRENDS
THE PREMIUM COOKIE MARKET
LOCATION AND REACH
QUALITY AND TASTE
RISING COSTS
PACKAGING
TECHNOLOGY, INFRASTRUCTURE
COMPETITION
MANPOWER
PRESENT MANUFACTURERS OF BISCUITS
RECIPE FOR VARIOUS TYPES OF BISCUITS
1. ARRAROOT BISCUIT:
2. DIGESTIVE BISCUITS:
3. HONEY COMB BISCUITS:
4. ALMOND FRUIT BISCUITS:
5. SODA BISCUIT:
6. COCONUT BISCUIT:
7. NICE BISCUIT
8. SALTISH BISCUIT:
9. MARIE BISCUIT:
10. MARIE BISCUIT:
11. SANDWICH TYPE BISCUITS:
12. CHEESE BISCUIT:
13. RICE BISCUITS:
14. CORN FLOUR BISCUITS:
15. COFFEE BISCUIT:
16. VICTORIA BISCUIT:
17. EDINBURG BISCUIT:
18. SNOW DROP BISCUIT:
19. LUNCHEON BISCUITS:
23. SOOJEE BISCUIT:
24. SPECIAL NUT BISCUITS:
25. SIMPLE ALL PURPOSE BISCUITS:
26. PEPPERMINT CREAM BISCUIT:
27. CORN FLOUR COCONUT BISCUIT:
28. CHOCOLATE VANILLA BISCUIT:
RECEIPE OF BATTER FOR WAFER SHEETS
SPECIAL VARIETY OF BISCUITS
MACAROON BISCUITS
EASTER BUNNY BISCUITS
BRANDY SNAPS
ACO BISCUIT
TYPICAL BISCUITS MIX
RECIPES FOR BISCUIT COATINGS
1. WHITE COATING:
2. DESK CHOCOLATE COATING:
3. LEMON COATING:
4. ORANGE COATING:
5. MALT MILK COATING:
GOOD QUALITY BISCUITS
SOME IMPORTANT REQUIREMENT FOR BISCUITS ARE AS FOLLOWS:
MANUFACTURING PROCESS
ACCORDING TO TEXTURE AND HARDNESS
ACCORDING TO THE RECIPE ENRICHMENTS WITH INGREDIENTS LIKE FAT AND SUGAR
PLANT & MACHINERY DESCRIPTION
THE UNIT WISE DESCRIPTION OF THE PLANT IS GIVEN BELOW:-
ELECTRIC OVEN
THE STANDARD CAPACITY OVENS, AVAILABLE INDIGENOUSLY ARE AS UNDER :-
OTHER UNITS OF A BISCUIT PLANT COMPRISE OF
THE STEPS INVOLVE IN THE PRODUCTION OF BISCUIT IS AS FOLLOWS:-
PRODUCTION PROCESS OF BISCUIT
THE STEPS INVOLVED ARE AS FOLLOWS:
PROCESS FLOW SHEET
STEPS IN INVOLVED IN BISCUIT MAKING
QUALITY CONTROL OF BISCUIT
TYPES OF BISCUITS
PREPARATION OF SAMPLE
PROCEDURE
APPARATUS
PROCEDURE
DETERMINATION OF ACIDITY OF EXTRACTED FAT
PROCEDURE
PRINCIPLES OF PLANT LAYOUT
MAJOR PROVISIONS IN ROAD PLANNING FOR MULTIPURPOSE SERVICE ARE:
PLANT LOCATION FACTORS
PRIMARY FACTORS
1. RAW-MATERIAL SUPPLY:
2. MARKETS:
3. POWER AND FUEL SUPPLY:
4. WATER SUPPLY:
5. CLIMATE:
6. TRANSPORTATION:
7. WASTE DISPOSAL:
8. LABOR:
9. REGULATORY LAWS:
10. TAXES:
11. SITE CHARACTERISTICS:
12. COMMUNITY FACTORS:
13. VULNERABILITY TO WARTIME ATTACK:
14. FLOOD AND FIRE CONTROL:
EXPLANATION OF TERMS USED IN THE PROJECT REPORT
1. DEPRECIATION:
2. FIXED ASSETS:
3. WORKING CAPITAL:
4. BREAK-EVEN POINT:
5. OTHER FIXED EXPENSES:
6. MARGIN MONEY:
7. TERM LOANS:
8. TOTAL LOAD:
9. LAND AREA/MAN POWER RATIO:
SUPPLIERS OF RAW MATERIALS
YEAST
SUPPLIERS OF CHEMICALS
BAKING POWDER
MILK POWDER
FOOD FLAVOURS/ESSENCES
WHEAT FLOUR
SUPPLIER OF SUGAR
VANASPATI GHEE
COMPLETE PLANT SUPPLIERS FOR BISCUIT MAKING
SUPPLIERS OF PLANT AND MACHINERY
BISCUIT/WAFER MAKING PLANT MACHINE
MACHINERY PHOTOGRAPHS
MIXING EQUIPMENT
HORIZONTAL MIXTURE
VERTICAL MIXTURE
CONTINUOUS MIXTURE
FORMING & MOULDING EQUIPMENT
SHEETING LINE
MOLDING
DOUGH FEEDING SYSTEM
BAKING & COOLING
BAKING OVEN
PRODUCTS PHOTOGRAPHS
RAW MATERIAL PHOTOGRAPH
APPENDIX – A:
01. PLANT ECONOMICS
02. LAND & BUILDING
03. PLANT AND MACHINERY
04. OTHER FIXED ASSESTS
05. FIXED CAPITAL
06. RAW MATERIAL
07. SALARY AND WAGES
08. UTILITIES AND OVERHEADS
09. TOTAL WORKING CAPITAL
10. TOTAL CAPITAL INVESTMENT
11. COST OF PRODUCTION
12. TURN OVER/ANNUM
13. BREAK EVEN POINT
14. RESOURCES FOR FINANCE
15. INSTALMENT PAYABLE IN 5 YEARS
16. DEPRECIATION CHART FOR 5 YEARS
17. PROFIT ANALYSIS FOR 5 YEARS
18. PROJECTED BALANCE SHEET FOR (5 YEARS)
