CEREAL MILLING
[EIRI/EDPR/1369] J.C. 140
INTRODUCTION
Cereal milling and secondary processing are major source of income and Cereal processing therefore offers very good opportunities for small scale enterprises. The technology is available and affordable; the demand for products is high.
The main types of Cereal milled product are Maize flour, Rice flour, Sorghum flour, Millet flour etc. After cereal has been ground to flour they can be processed in a variety of ways and combined with potentially hundreds of other ingredients to produce a vast range of processed cereal produced.
The high demand for cereal flour and bakery products especially in Urban area has led to strong competition as more and more people start to produce these products.
Cereal milled products find its uses in different food industries and for direct human consumption.
The main goal of a cereal mill is to reduce the size of whole grains in some way. This could mean turning the grains into a fine powder that can be used as flour for baking, or it could involve cracking or splitting the grains so they can be softened in water and eaten more easily. The simplest type of mill is known as a stone mill or roller and is made from one stationary wheel and one moving wheel. The wheels can be made from stone, such as granite, but more often are made from composite materials or metal. The grain is milled by being crushed between the stones, allowing the finest grind of any milling method, although it cannot be used with oily grains.
A more common type of cereal mill uses a burr grinder. This is a wheel that has been studded with small, sharp teeth that break apart the grains as the wheel is rotated. A burr grinder can handle hard grains, but often is not capable of creating flour that is as fine as that created by a stone mill.
An inexpensive option that can be used in very small units is known as an impact cereal mill. This consists of two plates that have concentric circles of teeth mounted perpendicular to the plane of the plate. The teeth are placed so that, when the plates are rotated, they weave together but do not touch. As grains are fed between the plates, the pressure of the teeth breaks apart the grains. An impact mill can be very effective, although not all models allow for the grind size to be adjusted, and the plates themselves are sometimes subject to damage from harder grains or impurities in the grains, such as stones.
There are some issues that can arise while using a cereal mill. One is the heat generated from quickly grinding the grains, which may shorten the lifespan of the flour by heating the oils or reduce the natural amount of nutrients in the grains. Another common issue is the noise generated by the mill, which can be extremely loud in some electric models.
The size of a cereal mill can vary greatly. For home use, the mills can range in size from very small and compact - about the size of a coffee grinder - to extremely large, sometimes taking up an entire tabletop. Commercial mills can be as large as an entire room and operate with gas-powered motors.
COST ESTIMATION
Plant Capacity 30 MT/Day
Land & Building (4000 sq.mt.) Rs. 2.80 Cr
Plant & Machinery Rs. 1.28 Cr
Working Capital for 3 Months Rs. 5.17 Cr
Total Capital Investment Rs. 9.47 Cr
Rate of Return 23%
Break Even Point 54%
CONTENTS
INTRODUCTION
USES AND APPLICATION
B.I.S. SPECIFICATION
MARKET SURVEY
PRODUCTION FACILITIES IN CEREAL MILLING
DETAILS OF CEREAL BY- PRODUCTS
MAINTENANCE OF EQUIPMENTS
QUALITY OF RAW MATERIALS AND MILLED CEREAL
MANUFACTURING PROCESS OF CEREAL MILLING
COMBINATION OF GRAIN
PROCESS FLOW DIAGRAM
DETAILS OF CEREAL MILLING EQUIPMENTS AND THEIR MAINTENANCE
PLANT LAYOUT
ADDRESSES OF RAW MATERIALS
SUPPLIERS OF PLANT & 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)