Detailed Project Report on liquor bottling plant (imfl bottling unit)

LIQUOR BOTTLING PLANT (IMFL BOTTLING UNIT) [3638]

An Alcoholic beverage is a drink containing ethyl alcohol of agricultural origin in any percentage, derived either through natural fermentation, or addition during process. Ethanol or ethyl alcohol is produced through a natural process when the yeast converts the sugar contained in fruit, cereals and sugarcanes, into alcohol. Pure alcohol is a colorless, pure liquid. The process used for its preparation is called fermentation. India is the third largest global spirits market by volume in the world, just behind China and Russia. It is also one of the fastest growing markets in the world. The domestic alcohol industry has recognized that the young people and women are the key target populations for them and they are assertively focusing on these vulnerable groups through their marketing campaigns. India is one of the world‘s most restrictive places for trade and doing business. In 2014, it is ranked 110 out of 152 countries, in terms of economic freedom, by the Economic Freedom of the World Report. Its Freedom to Trade Index was 6.2 (highest score 10.0), 124 Doing business in India remains difficult for both foreign and domestic companies. The country was ranked 133 out of 152 countries by the World Bank this year in its Doing Business Score. Many studies have indicated trade barriers continue to be a major hindrance to India‘s development and prosperity, making trade liberalization and further deregulation critical to its economy. The industry is consistently launching new products, such as flavoured alcoholic drinks, to attract the nondrinkers in this group.The availability of alcohol is increasing in India; there are more outlets in shopping malls and popular market places, which make it easily accessible. In some states, certain alcoholic beverages like wine and beer can be sold in supermarkets that further increase the availability. Increase in physical availability of alcohol leads to rise in alcohol consumption and alcohol related harm. Intensive engagement of the alcohol industry is observed in social initiatives and policy related activities under the broad framework of corporate social responsibility (CSR), which now-a-days are part of a more general strategy that is designed to further the industry’s political and economic interests. The Indian alcohol industry is a high-risk industry, on account of the high taxes and innumerable regulations governing it. The international liquor industry, the Indian one too has seen players with strong brands; diversified portfolios and large operations achieve market leadership positions. The Indian liquor industry comprises the IMFL, country liquor, foreign liquor bottled in origin (BIO), illicit alcohol, beer and wine segments. The maximum permissible limit for alcohol content in spirits is 42.8 per cent v/v (volume to volume). The overall IMFL market is increasing at the rate of 9 to 10 per cent annually. There is a tremendous growth in the vodka market. It is the fastest growing among all types of liquors. Vodka consumption has been growing at the rate of about 44 per cent over the past few years. The average alcohol content in country liquor is 33 per cent volume to volume. It is produced in local licensed distilleries and is made of cheap raw material, primarily rectified spirits of grains or molasses. In the southern states coconut and other palms are used as raw materials in the production of local liquor. It is called as arrack, desi sharaab, daru, tharra, toddy, fenny and tari. The production cost for country liquor is low; the excise duties are also lower than they are for other liquor. The idea behind country liquor was to provide cheap alcohol and thus check the illicit trade of alcohol. Beer has become a popular beverage in the country only over the last two decades. It’s growing at a rate of about 17 per cent per year. In India, beer is manufactured in licensed breweries and there are more than 60 beer brands available in the market. The growth in the beer market appears to be driven by young consumers and professionals who consider beer a trendy drink, as compared with traditional spirits. There is also a small demand for foreign beer in the up market urban areas. The highest levels of beer consumption in India are observed in the southern states. Imported liquor forms a very small part of alcohol consumption in India. It is usually consumed by the rich and upper middle class in metropolitan cities. It is also subjected to customs duty, making it much more expensive. The imported spirits market in India is growing at the rate of 25 per cent annually. Wine is an alcoholic beverage made from fermented fruit juice, usually that of grapes. Wines made from other fruits are usually named after the fruit from which they are produced (for example, apple wine or elderberry wine) and are generically called fruit wine. The term “wine” can also refer to the higher alcohol content of starch-fermented or fortified beverages such as barley wine, sake, and ginger wine. The alcohol industry is very important for the government. It generates an estimated Rs. 18,000 crore per annum in spite of the fact that the per capita consumption of liquor in India is the lowest in the world. The total liquor industry is worth Rs. 2,000 crore. IMFL accounts for only a third of the total liquor consumption in India. Most IMFLs are cheap and are priced below Rs. 300 per bottle. Alcohol sales proceeds account for 45% of the total revenue collection in the country. Whiskey accounts for 60% of the liquor sales while rum; brandy any vodka account for 17% 18% and 6% respectively. MNC’s share is only 10%and they have been successful only in the premium and super premium ranges. Post WTO the government may have opened India to foreign distilleries, but the duty has been increased from 222% to 464-706%.This is due to the fact that there is a 100% customs duty, 150%contravening duty, local taxes, distributor’s margin, retailer’s margin and publicity charges. The cost is finally borne by the consumer. Though the government claims that this is being done to protect the domestic liquor industry, the domestic industry accounts for 99% of the market share. This protectionist policy could prove to be counterproductive and lead to smuggling. As of now, only 45% of the sales are through legal channels and only 25% of this is duty paid for. Within India itself, the policy of alcohol retail differs form state to state. While some states like Maharashtra. Uttar Pradesh, and Tamil- Nadu have a liberal policy, come states like Haryana and Andhra

COST ESTIMATION

Plant Capacity                       2500 Cases/Day  
Land & Building (1.5 Acre)     Rs. 4.87 Cr
Plant & Machinery                    Rs. 3 Cr
Working Capital for 2 Months   Rs. 7.09 Cr
Total Capital Investment          Rs. 15.22 Cr
Rate of Return                         27%
Break Even Point                     22%


INTRODUCTION    
INDIAN MADE FOREIGN LIQUOR:    
COUNTRY LIQUOR:    
BEER:    
FOREIGN LIQUOR BOTTLED IN ORIGIN (BIO):    
WINE:    
INDIAN LIQUOR INDUSTRY IS DIVIDED INTO TWO BROAD CATEGORIES    
LEGAL ENVIRONMENT    
CUSTOM & DUTIES
SOCIAL ENVIRONMENT    
WESTERN CULTURE INFLUENCE    
PROHIBITION IN INDIA    
THREAT OF NEW ENTRANTS    
BARGAINING POWER OF CUSTOMERS    
BARGAINING POWER OF SUPPLIERS    
PREDICTIONS REGARDING RAW MATERIALS    
RIVALRY    
ETHYL AND METHYL ALCOHOLS    
ETYL ALCOHOL (ETHANOL)    
ALCOHOLIC BEVERAGE    
THERE ARE A LARGE VARIETY OF ALCOHOLIC BEVERAGES    
OTHER FORMS OF ALCOHOL    
DIFFERENT ALCOHOLIC DRINK    
WHISKY    
RUM    
3. BRANDY    
4. VODKA    
5. BEER    
6. GIN    
WHISKY    
TYPES OF WHISKY:    
USES AND APPLICATIONS    
CHARACTERISTICS OF THE INDIAN LIQUOR MARKET    
FACTORS INFLUENCING THE GROWTH OF ALCOHOL INDUSTRY IN INDIA    
URBANIZATION:    
FAVOURABLE DEMOGRAPHICS:    
CHANGING SOCIAL NORMS:    
INCREASED ALCOHOL ACCESSIBILITY AND AVAILABILITY:    
STRATEGIES FOR PROMOTION AND ADVERTISEMENT OF ALCOHOL PRODUCTS    
SURROGATE ADVERTISING OF ALCOHOL PRODUCTS:    
SPONSORSHIP OF EVENTS:    
PROMOTION AND THE ENTERTAINMENT INDUSTRY:    
ATTRACTIVE PACKAGING AND LABELING OF ALCOHOL PRODUCTS:    
NEWER PROMOTION CHANNELS:    
LIQUOR MARKET IN INDIA    
ALCOHOL COMPANIES AND THEIR MAJOR BRANDS IN INDIA    
MARKET OVERVIEW OF IMFL (INDIA MADE FOREIGN LIQUOR)    
1. AT AN INFLECTION POINT    
INITIATE BUY; 50% POTENTIAL UPSIDE FROM CMP    
2. INVESTMENT THESIS    
2.1 INVESTMENT POSITIVES–OPPORTUNITY TO RE-RATE    
RDCK’S CURRENT VALUATION DOES NOT TRULY REFLECT ITS PREMIUM POSITIONING    
PREMIUM PORTFOLIO EXPANDING    
PREMIUM VODKA AND BRANDY BRANDS ALREADY POSITIONED STRONGLY    
PREMIUM BRANDING AIMED AT OFFERING A WIDER PRODUCT PORTFOLIO AND WIDEN CUSTOMER BASE    
MARKET SHARE GAINS GOING FORWARD    
PREMIUM MARKET TO OUTPERFORM REGULAR MARKET GROWTH    
VERTICAL INTEGRATION TRANSFORMED THE COMPANY    
TRANSFORMATION INTO A PREMIUM LIQUOR COMPANY FROM A BULK PRODUCER    
SCOPE OF RE-RATING ON CONSISTENT MARKET SHARE GAINS IN PREMIUM SEGMENT    
25% EPS CAGR, IMPROVEMENT IN RETURN RATIOS    
2.2 INVESTMENT NEGATIVES    
STRINGENT LAWS MAKE LIFE TOUGH    
HIGHLY REGULATED INDUSTRY    
PROHIBITION HAS MADE A COMEBACK IN THE POLITICAL VOCABULARY
  – KERALA AND BIHAR HAVE ANNOUNCED PHASED PROHIBITION    
PROHIBITION RELATED UNCERTAINTIES    
VOLUMES TO BE IMPACTED IN SHORT TERM    
ALMOST NO PRICE HIKES HAVE COME THROUGH IN THE PAST 18-24 MONTHS
 FROM STATES WITH PRICE CONTROLS    
PRICE HIKE IN THE HANDS OF GOVERNMENT BODIES    
GST IMPACT COULD HAVE A NEGATIVE MARGIN IMPACT    
RISK FOR MARGINS POST GST    
HIGHER TAXES FOR LIQUOR COMPANIES    
3. RDCK’S PREMIUMISATION STRATEGY HAS BEEN SUCCESSFUL    
STRONG SUCCESS IN MAGIC MOMENTS, POSITIVE EARLY SIGNS
 ON MORPHEUS BRANDY    
PREMIUMISATION IS THE KEY CATALYST TO MARGIN IMPROVEMENT    
TRANSFORMING TO PREMIUM FROM BULK    
MAGIC MOMENTS GIVING COMPETITION A TOUGH TIME    
RDCK IS A LEADER IN THE DOMESTIC VODKA MARKET    
FOCUSING ON BRANDY SEGMENT TO AUGMENT MARKET SHARE    
TARGETING BRANDY MARKET AS WELL    
MORE BRAND LAUNCHES    
NINE BRAND LAUNCHES SINCE 2006    
4. PRICING OUTLOOK MORE POSITIVE    
GOVERNMENT CONTROLLED DISTRIBUTION    
SOME PRICE HIKES IN RECENT TIMES    
TREND OF LOWERING OF TAXES ON LIQUOR IN SOME STATES    
OVERALL POSITIVE OUTLOOK    
5. COMPETITIVE DYNAMICS    
FOURTH LARGEST PLAYER IN VOLUME TERMS    
RDCK’S VOLUMES STAND AT 18.2MCS, 6.4% MARKET SHARE    
6. WELL POSITIONED TO CAPITALIZE ON RISING PREMIUM IMFL CONSUMPTION    
INDIAN SPIRITS MARKET ON GROWTH TRAJECTORY    
6.1 INDIAN SPIRITS MARKET SIZE AND GROWTH OPPORTUNITY    
MARKET SALES VALUE GROWTH –6.3% CAGR FY16-20E    
KEY TRENDS:    
6.2 STRUCTURAL CHANGES IN THE INDUSTRY MAKES INDIAN SPIRITS
 MARKET MORE ATTRACTIVE    
ENTRY OF GLOBAL MAJORS    
SHIFT FROM VOLUME GROWTH TO VALUE GROWTH    
INCREASING PREMIUMISATION–IMPROVING PRODUCT-MIX    
6.3 VODKA TO OUTPERFORM OVERALL IMFL GROWTH IN THE COMING YEARS    
POTENTIAL MARKET GROWTH FOR WHITE SPIRITS (VODKA) AN OPPORTUNITY
 FOR RDCK    
WHITE SPIRITS IS JUST 3.5% OF ALCOHOL VOLUME IN INDIA (VS 47% GLOBALLY)    
6.4 KEY DRIVERS FOR GROWTH OF LIQUOR CONSUMPTION IN INDIA    
INCOME GROWTH    
ATTRACTIVE DEMOGRAPHICS    
UNDERPENETRATED MARKET    
6.5 RURAL CONSUMPTION TO GROW 3.8X AND TIER 2 & BELOW CITIES
  TO GROW 4.4X BY 2025    
7.0 FINANCIAL ANALYSIS    
7.1 REVENUE TO RISE 5% IN FY18, 6% IN FY19    
BRANDED IMFL 73% OF REVENUE; CONTRIBUTION OF COUNTRY LIQUOR,
  BULK SPIRITS ON THE DECLINE    
REVENUE CAGR OF 6% FY17-20E    
EXPECT SALES CAGR OF 6% OVER FY17-19E    
WE EXPECT RDCK'S SALES TO GROW AT A CAGR OF 6% OVER FY17-19E
 DRIVEN BY:    
MANUFACTURING PROCESS OF IMFL BOTTLING PLANT    
PROCESS FLOW DIAGRAM FOR IMFL BOTTLING PLANT    
PROCESS DESCRIPTION    
DETAILED PROCESS DESCRIPTION    
1. ALCOHOL MASS METERING SYSTEM (SPIRIT CONCENTRATION METER)    
2. RECEPTION SYSTEM FOR ALCOHOL/WATER MIXTURES    
3. BLENDING SYSTEM FOR ALCOHOL/WATER MIXTURES    
4. WATER DEAERATION SYSTEM    
5. FILTRATION SYSTEMS    
6. EQUIPMENT FOR STORAGE TANK FACILITIES    
7. BATCH MIXING SYSTEM    
8. CONTINUOUS IN-LINE BLENDING SYSTEM,    
9. COMBINED BLENDING SYSTEM    
10. CARBONATION AND BEVERAGE ANALYSIS    
11. MOBILE METERING UNITS    
12. PRODUCT TRACING FOR INTERNAL DOCUMENTATION BY MEANS OF    
13. CLEANING SYSTEM    
PACKAGING    
PACKING STANDARDS:    
GREEN COLOURED BEER BOTTLES    
CLEAR COLOURED BORDEUX BEER BOTTLES    
STANDARD CAPACITY OF LIQUOR BOTTLES    
PACKAGING REQUIREMENT:    
SWOT ANALYSIS OF ALCOHOL INDUSTRY    
STRENGTHS:    
WEAKNESSES:    
OPPORTUNITIES:    
THREATS:    
LIST OF MACHINERY AND EQUIPMENTS USED IN ALCOHALIC BEVERAGES PLANT    
MULTI-TUBE COAXIAL HEAT PASTEURIZER    
ACCESSORIES    
BALANCE TANK    
PASTEURIZER FEED PUMP    
HOT WATER PREPARATION SYSTEM    
MULTI COAXIAL HEAT EXCHANGER/ HOLDING TUBES    
HOT WATER RECIRCULATION PUMP    
CIP SYSTEM (FULLY AUTOMATIC)    
CIP SYSTEM CAN BE CONFIGURED WITH THE FOLLOWING OPTIONS
 TO SPECIFIC NEEDS    
ONLINE DUPLEX FILTER    
ROTARY BOTTLE RINSING MACHINE    
UNI BLOCK FILLING AND CAP SEALING MACHINE    
SLAT CHAIN CONVEYOR    
INSPECTION CONVEYOR    
ROTARY LABELING MACHINE    
CASE PACKER MACHINE    
AUTOMATIC CARTON SEALER MODEL    
PROCESS FLOW CHART OF ALCOHOLIC BEVERAGES PROCESSING PLANT    
SCHEMATIC FLOW DIAGRAM OF “ALCOHOLIC DRINK BOTTLING PLANT”    
B.I.S. SPECIFICATIONS    
RECTIFIED SPIRIT    
IS 324 - 1956    
346 - 1952    
IS - 321 - 1964    
IS - 6613 - 1972    
PRODUCTION OF BRANDY    
COMPONENTS OF BRANDY:-    
ETHYL ALCOHOL:-    
OTHER ALCOHOLS:    
METHYL ALCOHOL (WOOD ALCOHOL):-    
ALDEHYDES:-    
ESTERS:-    
COLUMN STILLS:-    
CONDENSERS:-    
PRODUCTION OF RUM    
TYPES OF RUM AND THE RAW MATERIALS:    
PRETREATMENT OF RAW MATERIAL:-    
FERMENTATION:-    
1. FERMENTATION TEMPERATURE:-    
(2) PH VALUE:-    
(3) FERMENTATION TIME :-    
(4) YEAST :-    
THE BEST YEAST ARE FROM MOLASSES.    
DISTILLATION:-    
CONTINUOUS DISTILLATION:-    
MATURING:    
PRODUCTION OF SPIRIT FOR GIN    
RAW MATERIAL:    
PRODUCTION FROM GRAIN:    
1 COOKING:-    
CONVERSION:    
FERMENTATION:-    
MANUFACTURING PROCESS OF WHISKY    
(B) ACIDIC FERMENTATION:    
3. BOTTLING:    
VODKA:    
TREATMENT METHODS    
MANUFACTURERS OF ALCOHOLIC BEVERAGES    
LIST OF IMFL/LIQUOR MANUFACTURER IN INDIA    
SUPPLIERS OF RAW MATERIALS    
ENA    
GLASS BOTTLES    
SUPPLIERS OF PLANT AND MACHINERY    
SUPPLIERS OF COMPLETE PLANT AND MACHINERY    
SUPPLIERS OF PLANT AND EQUIPMENTS    
COLUMN    
CONDENSER    
BOTTLE FILLING MACHINE    
BOTTLE SEALING MACHINE    
BOTTLE WASHING MACHINE    
LABELLING MACHINE    
CONVEYOR BELT    
STAINLESS STEEL TANKS    
PLANT LAYOUT     

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)