AUTOMATIC BAKERY BUSINESS TO PRODUCE PUFFS, CROISSANT ETC. [3547]
Puff pastry is the main example of a laminated paste and there are related products such as Danish pastry, croissant, and crackers which are yeast raised. Puff pastry is lighter, flakier, and more delicate than standard short crust or flan pastry. It contains a higher fat level and has a unique preparation method that is critical for preparation of a successful product. This pastry can be used for a wide variety of products, including turnovers, shells filled with whipped cream, custards or fruit, vol au vents, and sausage rolls, and is considered a staple in commercial bakeries. The pastry is prepared with high protein flour (bread), water, salt and shortening. A firm, plastic shortening, equal to 50% of the dough weight and containing some moisture, is optimum. Other ingredients, such as eggs and acids (cream of tartar, vinegar, or lemon juice) can be used. There are three commonly used methods for mixing and handling the puff pastry dough the French (roll-in). English (roll-in), and the Scottish (all in) method. The French method involves rubbing a portion of pastry fat into the flour to lubricate the gluten. A portion of the water, acid, and eggs is placed into the center of a ring made from the mixed flour and shortening. The dough is mixed well, and the procedure is repeated until all the ingredients, with the exception of the remaining fat, have been added. The dough is rolled into a rectangle, 1.25 cm thick with a thinner outside border, and the fat is rolled to the size of the thicker dough. After the fat is placed on the thicker dough, the thinner dough is folded over on the thicker dough and the thinner dough is folded over, making a type of pocket. The fat and dough is then rolled into a rectangle. One half turn of the dough is formed by folding one end of the dough two thirds of the way down the rectangle and folding the opposite end to cove the first fold. The English method is the most popular in the USA. The dough is sheeted into a rectangular shape, and the roll in fat is spread uniformly over two thirds of the area. Three fold pastry preparation is used to form three dough layers separated by two layers of fat. The Scottish method is similar to pie-crust preparation, simple, and widely used commercially. All the pastry fat is broken into lumps (5 cm) and mixed loosely in the flour. The remaining ingredients are then added to form a lumpy dough. The rolling procedure is the same as the French method with the addition of one extra half turn. After the final rolling, the dough is shaped and relaxed before baking. For maximum volume, puffed pastries should be baked at high temperatures (204-212oC) The Blitz method is a modification of the Scottish method that partially develops the gluten prior to adding the firm shortening. To mechanical mixers are commonly used in batch commercial pastry production. The low speed, double arm mixing machine with a large dough bowl and slow mixing produces a good quality commercial puffed pastry. The Scotch pastry method must be followed when the high speed mixer is used in large scale, high product capacity operations, Careful timing is critical with these mixers to prevent over mixing that results in an intimate mixing of fat with the dough and formation of a short rather than a puffed pastry. After mixing the dough any of the methods described in the commercial pastry preparation section can be applied. Continuous puff pastry dough production equipment extrudes the dough and shortening into a double layer continuous tube with the shortening in the center layer. This is flattened and reduced by a dough stretcher. The sheet is folded, stretched, and thinned. Pieces are cut into their final shape for pastry shells, cheese or savory sticks, napoleons(mile feuilles), turnovers, sugar crisps, etc. Products prepared with this continuous process are usually intended for wholesale distribution. Thus, their size and flakiness are limited to prevent breakage during shipping. Crescent-shaped roll made from yeasted dough layered to make fl aky puff pastry. May be fl avoured with almond paste, chocolate or cheese. Should be light and fl aky in texture and melt in the mouth. Croissants are thought to have originated in Austria. In 1683 when the Turks were secretly digging tunnels under Vienna to make a surprise attack on the city they were heard by bakers working early in the morning. The bakers who raised the alarm and saved Vienna from being defeated by the Turks then baked a special commemorative roll in the shape of the crescent, as seen on the Turkish fl ag. Marie Antoinette introduced the roll to France where it became known as the croissant, the French word for crescent. The bread industry in India, valued at INR 33bn (~USD 0.53 bn) in FY 2015(E), grew at a CAGR of ~9% over the last three years. Value Notes estimates that the industry will be worth approximately INR 53bn (~USD 0.86bn) by FY 2020, growing at a CAGR of ~10%. ? Demand for brown and fruit breads is estimated to increase further due to an increasing urban consumer base and a rise in health awareness about nutritional food. ? Growing disposable incomes, changing lifestyles and preferences of consumers supported by an increase in the youth population, female work participation as well as a widening scope of the Indian retail market will drive the industry growth. ? Latest trends witnessed in the industry reveal that companies manufacturing bread products are likely to increase their manufacturing capacities to expand their foothold in different regions. With a change in eating habits and preferences of consumers, the bread industry is coming up with innovative products and flavors, and a variety of breads. Chocolate confectionery value sales are expected to see a constant value CAGR of 8% over 2016-2021, to reach INR162 billion. Increasing availability in rural India and an expanded offer will contribute to chocolate confectionery growth during the forecast period. Pastries, Rusks, Bread, Cakes, and Toffees etc. come under the bakery product. Now the advancement of age food habits of the ready-made food. Most of all the bakery items are under the category of ready-made food. Now school going children are like to have the items like parties cakes, breads etc. for their tiffin use office going peoples like to take breads and parties products, in our daily break fast table also take. The share of bakery products even daily wages laborers also habituated to spend their lunch by taking bread or like that baking product. By the large utilities of baking products in our life takes part the programme of progress of bakery unit itself. Small scale production of baking item can be achieved by cary professional ways of life.
COST ESTIMATION
Plant Capacity 500 Kgs/Day
Land & Building (20000 sq.ft) Rs. 1.12 Cr
Plant & Machinery Rs. 1 Cr
Working Capital for 2 Months Rs. 38 Lacs
Total Capital Investment Rs. 2.69 Cr
Rate of Return 23%
Break Even Point 67%
INTRODUCTION
PROPERTIES
BAKERY PRODUCTS
A. BREAD
B. BISCUITS
B.I.S. SPECIFICATION
FOR WHITE BREADS
INGREDIENTS OF BISCUITS WITH THEIR B.I.S. SPECIFICATIONS
1. ESSENTIAL INGREDIENTS
2. OPTIONAL INGREDIENTS
PROPERTIES OF RAW MATERIALS
FLOUR
YEAST
YEAST FOOD
SUGAR
SHORTENING
EMULSIFIERS
MILK AND MILK SUBSTITUTE
SALT
ENZYMES
MARKET OVERVIEW OF BAKERY INDUSTRY
BAKERY MARKET IN INDIA COMPARISON WITH GLOBAL MARKETS
BAKERY MARKET IN INDIA
BAKERY - KEY PLAYERS IN INDIA
INDIAN MARKET HAS HUGE POTENTIAL FOR BAKERY PRODUCTS
POTENTIAL FOR BAKERY PRODUCTS
FACTORS INFLUENCING GROWTH
LARGE CUSTOMER BASE
FACTORS DRIVING GROWTH
SPENDING, CONSUMING CLASS
BAKERY- SUB-SECTOR OF FOOD PROCESSING
BREAD
BISCUITS
CAKE AND OTHER BAKERY PRODUCTS
TRENDS
INNOVATION
INGREDIENTS FOR CROISSANT
TYPES OF PUFF PASTRY
STRUCTURE AND INGREDIENTS OF PUFF PASTRY
TABLE SHOWS THE INGREDIENTS USED IN PUFF PASTRY.
RECIPES OF PASTRIES
DANISH PASTRY
PUFF PASTRIES
METHODS OF MAKING PUFF PASTRY
THESE METHODS ARE AS FOLLOWS
THREE FOLD OR SINGLE TURN
BOOK FOLD OR DOUBLE TURN
COMBINATION METHOD
FRENCH METHOD
ENGLISH METHOD
MAKING OF PUFF PASTRY BY ENGLISH METHOD FROM THE
FOLLOWING STEPS
SCOTCH METHOD
INVERTED PUFF PASTRY
SOME OF THE POINTS THAT NEED TO BE KEPT IN MIND ARE AS FOLLOWS
PROCESSING DETAILS OF PUFF PASTRIES
THE PROCESSING STEPS ARE AS FOLLOWS.
DOUGH MIXING
LAMINATION
FOLDS AND FAT LAYER IN LAMINATED DOUGH
MAKE UP
FILLING
PROOFING
BAKING
PROCESSING DETAILS AND TROUBLE SHOOTING IN CROISSANTS
MANUFACTURE
TROUBLE SHOOTING
FILLING FOR DANISH PASTRIES
BURGER MASTER PASTE.
REMONCE.
BAGECREME.
MACHINE-MADE SHORT PASTE SUGAR IN PASTE
SUGAR IN PASTE
RUBBED-IN-METHOD
CREAMED BATTER METHOD
RUSK
MANUFACTURE
RUSK MANUFACTURING PROCESS -STAGES
RUSK MANUFACTURING PROCESS FLOW CHART
FORMULATION OF BREAD RUSK
PROCESS MANUFACTURING OF BREAD
GENERAL RAW MATERIAL
NORMAL BREAD
MILK BREAD
SOME APPROVED RECIPE OF THE MAJOR MANUFACTURING PLAYER IN INDIA
PROCESS 84
FLOW CHART FOR BREAD MANUFACTURING PROCESS
PROCESS MANUFACTURING OF BUNS
SWEET BUNS
BATH BUNS
SAFFRON BUNS
HAMBURGER BUNS
GENERAL PROCESS
BUN MANUFACTURING PROCESS STAGES
MANUFACTURING PROCESS OF CAKES
NAME OF THE INGREDIENTS
MANUFACTURING PROCESS
CAKE PRODUCTION LINE
DIFFERENT FORMULATIONS OF CAKES
ORIDINARY YELLOW CAKE
HIGH RATIO YELLOW LOAVES
HIGH RATIO YELLOW LAYERS
POUND CAKE
ORDINARY WHITE CAKE
HIGH RATIO WHITE LAYERS
LIST OF MAJOR MACHINERY USED DURING MANUFACTURING
OF BISCUIT & ALLIED PRODUCTS
BUCKET ELEVATORS
AUTO LOADING CONVEYOR
INSPECTION/GRADING CONVEYOR
TRAY DRYER
CABINET
AIR CIRCULATION
HEATERS
COOLING TUNNEL
WEIGHMETRIC FILLER MACHINE
BAND SEALER FOR STANDY POUCH
PROCESS FLOW BLOCK DIAGRAM FOR PRODUCTION OF BISCUIT
(MOULDING VARIETY)
IMPLEMENTATION SCHEDULE
WORKSHOP EQUIPMENT
LABORATORY EQUIPMENT
FIRE FIGHTING EQUIPMENT
OFFICE EQUIPMENT
SWOT ANALYSIS OF FOOD PROCESSING INDUSTRIES IN INDIA
STRENGTHS
WEAKNESS
OPPORTUNITIES
THREATS
PLANT LAYOUT
BAKERY & ALLIED PRODUCT CONSULTANT IN INDIA
SUPPLIERS OF RAW MATERIALS
BAKING POWDER
BAKING ENZYMES
CRATES, BUCKETS, DRUMS, ETC.
CAKE GEL
EGG POWDER
BAKERY CHEMICALS
SUPPLIERS OF PLANT AND MACHINERY
PACKAGING MACHINERY
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)
