Detailed Project Report on Cocoa Products [Cocoa Couverture (Liquor), Cocoa Butter, Cocoa Powder, Chocolate Spread, Chocolate Syrup]

COCOA PRODUCTS [COCOA COUVERTURE (LIQUOR), COCOA BUTTER, COCOA POWDER, CHOCOLATE SPREAD, CHOCOLATE SYRUP]

[EIRI/EDPR/4270] J.C. 2451XL

INTRODUCTION

Cocoa is the product of the fruit of the cocoa tree (lat. Theobroma cacao), which requires a hot, wet climate, a mean shade temperature of 27°C, and well-distributed rainfall. This is why it can only be grown in regions within 20º latitude of the Equator. 

Although the cocoa tree is indigenous to Latin America, Africa today accounts for 70% of the world’s cocoa bean production. Cocoa farming is mostly manual, requiring significant expertise and most cocoa in Africa is grown on small family farms of 2-5 hectares. Next to the Ivory Coast and Ghana, other major cocoa producing countries are Nigeria, Cameroon, Indonesia, Papua New Guinea, Malaysia, Ecuador, Brazil and Colombia.

The cocoa is a very unusual looking tree, with yellow, green and red coloured fleshy fruit pods, about 25 cm long, hanging directly from its trunk and branches. The cocoa beans are embedded within a sticky, white, sweet tasting pulp. At harvest, the cocoa bean has to have reached the proper level of ripeness as under-ripe or over-ripe pods will have a negative impact on the bean’s cocoa flavour.

Raw cocoa beans are bitter and quite inedible. Two processes are required to turn the raw bean into the raw material for chocolate: fermentation and drying. Once the beans have been removed from the pods they are stacked, covered and left to ferment for 3-9 days. The process generates high temperatures of about 50ºC activating enzymes in the beans to form compounds that produce the chocolate flavour when the beans are roasted. The fermentation process must have been concluded properly. Too little fermentation and the desired cocoa taste does not develop fully, too much fermentation and undesirable “off tastes” develop.

COST ESTIMATION

Plant Capacity            2525.84 Kg/Day

Land & Building (3300 sq.mt.)    Rs. 3.88 Cr

Plant & Machinery                    Rs. 7.38 Cr

Working Capital for 3 Months    Rs. 6.35 Cr

Total Capital Investment          Rs. 18.46 Cr

Rate of Return                          79%

Break Even Point                      29%

CONTENTS

INTRODUCTION

COCOA POWDER AND COCOA BUTTER

COMPLEX FACTOR

PROPERTIES/USES/APPLICATION  

MARKET OVERVIEW

GLOBAL COCOA PRODUCTS MARKET SCOPE AND MARKET SIZE

EXPORT

IMPORT

BIS SPECIFICATION

RAW MATERIAL 

PACKING AND MARKING

FORMULATION-COCOA PRODUCTS

THE RAW MATERIALS INPUTS FOR THE FOLLOWING PRODUCTS 

THE COMPOSITION OF VARIOUS PRODUCTS IS TABLED BELOW 

RAW MATERIAL DETAILS

RAW MATERIAL

MANUFACTURING PROCESS STEPS 

PROCESS FLOW DIAGRAM

CHOCOLATE SPREAD

CHOCOLATE SYRUP

PRODUCTION PROCESS OF COCOA 

PROCESSING DETAILS OF COCOA BUTTER AND COCOA POWDER

COCOA BEAN TO COCOA LIQUOR

BLENDING, MIXING, CLEANING

ROASTING

WINNOWING/SHELLING

NIB ROASTING

GRINDING

COCOA LIQUOR FLAVOUR IMPROVEMENT

COCOA LIQUOR REFINEMENT

COCOA LIQUOR TO COCOA BUTTER AND COCOA POWDER

PRESSING

CRUSHING, COOLING, GRINDING

PRINCIPLES OF PLANT LAYOUT

MAJOR PROVISIONS IN ROAD PLANNING FOR MULTIPURPOSE SERVICE ARE:

PLANT LOCATION FACTORS

PRIMARY FACTORS

RAW-MATERIAL SUPPLY:

MARKETS:

POWER AND FUEL SUPPLY:

WATER SUPPLY:

CLIMATE:

TRANSPORTATION:

WASTE DISPOSAL:

LABOR:

REGULATORY LAWS:

TAXES:

SITE CHARACTERISTICS:

COMMUNITY FACTORS:

FLOOD AND FIRE CONTROL:

PROJECT IMPLEMENTATION SCHEDULE 

PROJECT HANDLING

PROJECT SCHEDULING

PROJECT CONSTRUCTION SCHEDULE

TIME SCHEDULE

RAW MATERIALS SUPPLIER

PLANT & MACHINERY SUPPLIER 

BUCKET ELEVATOR

SILO

STEAM BOILERS

STORAGE TANKS

FILTER PRESS

LABORATORY EQUIPMENT AND LAB TESTING EQUIPMENT

BROAD PLANT MACHINERY/EQUIPMENT DETAILS 

WASTE MANAGEMENT 

GREEN BELT

WASTE WATER 

WASTE

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)