DALL MILL (PULSE MILL) (CAP: 30 TPD)
[EIRI/EDPR/1853] J.C. 720
INTRODUCTION
Dal milling industry is one of the major agro processing industries in India. Out of the total production of 13.19 million tones of pulse in the country, 75% is processed by these dal mills. There were about 2000 dal mills in the country in 1972. The numbers grew steadily to 6000 units in 1982, 12000 units in 1995 and 14000 units during the year 1999-2000.
Most of the dal mills in the country are concentrated in selected pockets of the country i.e. pulses producing areas such as Indore (MP), Jalgaon, Akola and Nagpur (Maharashtra) and in or near major consumption centres such as Kolkata, Mumbai, Chennai, Hyderabad and Delhi. The units are mostly traditional ones. They are capital intensive and energy sapping in nature. The dehusking efficiency in traditional mills is quite low. Moreover, the yield of dehusked and splitted pulses in traditional mills is about 65-70 % in comparison to 88-89% maximum potential recovery of splits.
Thus, there is excessive loss of pulse cotyleadons and embroyos in the form of brokens and powdered grains (5- 15%). The industry is also besieged with other problems such as low domestic availability of pulses, high block capital and working capital requirement and presence of large number of intermediaries in pulses procurement and marketing of finished products.
Need for improved Dal Mills:
The present losses being encountered by the milling industry can be minimized to a great extent by the use of improved dal mills. These dal mills are highly versatile and energy efficient. Many agricultural universities , ICAR institutions in the country have developed modern improved dal mills . Some of these institutes are PKV Akola, CFTRI- Mysore, GBPUAT- Pantnagar, CIAE- Bhopal, IIPR-Kanpur, TNAU- Coimbatore and IARI- New Delhi. The improved dal mills have dehusking efficiency of about 95% and the yield of split pulses is about 80-85% depending on the variety of pulse and conditioning of the pulse grain.
COST ESTIMATION
Plant Capacity 30 MT/Day
Land & Building (1800 sq.mt.) Rs. 2.70 Cr
Plant & Machinery Rs. 1.50 Cr
Working Capital for 1 Month Rs. 5.76 Cr
Total Capital Investment Rs. 10.13 Cr
Rate of Return 39%
Break Even Point 37%
CONTENTS
INTRODUCTION
USES AND APPLICATIONS
PROPERTIES
B.I.S. SPECIFICATION
MARKET SURVEY
PROCESSING DETAILS OF DAL MILL
PRODUCTION PROCESS IN PULSE MAKING MILLS
PROCESS FLOW DIAGRAM OF A TYPICAL PULSE MILL
CONVENTIONAL PULSE MILLING METHODS
FLOW DIAGRAM OF WET MILLING OF PULSES
FLOW DIAGRAM FOR DRY MILLING OF PULSES
UNIT OPERATION IN DAL MILLING
ENVIRONMENTAL POLLUTION IN PULSE MILL (DAL MILL)
PFD OF A TYPICAL PULSE MILL SHOWING POLLUTION SOURCES & CONTROL SYSTEMS
PROCESS FLOW DIAGRAM
PRINCIPLES OF PLANT LAYOUT
PLANT LOCATION FACTORS
EXPLANATION OF TERMS USED IN THE PROJECT REPORT
SUPPLIERS OF RAW MATERIALS
SUPPLIERS OF PLANT AND 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)