Industry Overview
The baking industry is one of the stable sectors within food manufacturing, with wheat flour serving as the principal base for a wide range of products, including biscuits, cookies, crackers, cakes, and pastries. Biscuits are low-moisture baked products, typically containing less than 4% moisture, and are manufactured using formulations based mainly on flour, fat, sugar, water, salt, and selected flavouring, colouring, and aerating agents.
Biscuits may be classified as soft biscuits, hard biscuits, and crackers, with further classifications based on dough formulation and forming methods such as rotary moulding, wire-cutting, and cutting machines. In India, commonly processed varieties include plain, slightly sweet, sweet, short, and fermented biscuits. Their convenience and long shelf life make biscuits popular as breakfast foods and snacks throughout the day.
The manufacturing process involves preparing dough from suitable soft wheat flour and other ingredients, forming the dough into the required shape, and baking it in travelling ovens until the desired moisture level is achieved. Ingredient selection is important for product quality: flour provides the structural base, water supports hydration and processing, fat contributes tenderness and shortness, sugar affects sweetness, texture, colour, and shelf life, while salt enhances flavour. Aerating agents such as ammonium bicarbonate and sodium bicarbonate may also be used according to product requirements.
Cost Estimation
| Particulars | Value |
|---|---|
| Plant Capacity | 7.2 Ton/Day |
| Land & Building (3000 sq.mt.) | Rs. 1.80 Cr |
| Plant & Machinery | Rs. 1.50 Cr |
| Working Capital for 2 Months | Rs. 1.88 Cr |
| Total Capital Investment | Rs. 5.45 Cr |
| Rate of Return | 44% |
| Break Even Point | 49% |
Content Index
- INTRODUCTION
- INDIA AT PRESENT PROCESSES MAINLY FOLLOWING VARIETIES OF BISCUITS:
- INGREDIENTS
- FLOUR
- WATER
- FAT
- SUGAR
- SALT
- OTHER INGREDIENTS
- TYPES OF BISCUIT
- COMPOSITION OF BISCUITS
- USES AND APPLICATION
- B.I.S. SPECIFICATIONS
- INGREDIENTS OF BISCUITS WITH THEIR B.I.S. SPECIFICATIONS
- 1. ESSENTIAL INGREDIENTS:-
- 2. OPTIONAL INGREDIENTS:-
- PROPERTIES OF RAW MATERIALS
- MARKET POSITION
- BISCUIT CAN HE BROADLY CATEGORIZED INTO THE FOLLOWING SEGMENTS:
- KEY TAKEAWAYS
- BY TYPE - SEGMENT ANALYSIS
- BY DISTRIBUTION CHANNEL - SEGMENT ANALYSIS
- BY GEOGRAPHY - SEGMENT ANALYSIS
- DRIVERS – BISCUITS MARKET
- THE RISING DEMAND FOR HEALTHY COOKIE
- REGIONAL INSIGHTS
- HEALTHY BISCUITS MARKET SHARE INSIGHTS
- INCREASING DEMAND FOR “READY TO GO” FOOD
- THE HIGH COST OF RAW MATERIALS
- BISCUITS INDUSTRY OUTLOOK:
- ACQUISITIONS/PRODUCT LAUNCHES:
- RISING DEMAND FOR HEALTHY COOKIES
- NORTH AMERICA TO DRIVE THE MARKET
- COMPETITIVE LANDSCAPE
- MAJOR PLAYERS
- EMBRACING INNOVATION TO OVERCOME CHALLENGES
- BISCUITS-BAKERY SECTOR LOOKS LIKE A BATTLEFRONT
- TRENDS
- THE PREMIUM COOKIE MARKET
- LOCATION AND REACH
- QUALITY AND TASTE
- RISING COSTS
- PACKAGING
- TECHNOLOGY, INFRASTRUCTURE
- COMPETITION
- MANPOWER
- PRESENT MANUFACTURERS OF BISCUITS
- RECIPE FOR VARIOUS TYPES OF BISCUITS
- 1. ARRAROOT BISCUIT:
- 2. DIGESTIVE BISCUITS:
- 3. HONEY COMB BISCUITS:
- 4. ALMOND FRUIT BISCUITS:
- 5. SODA BISCUIT:
- 6. COCONUT BISCUIT:
- 7. NICE BISCUIT
- 8. SALTISH BISCUIT:
- 9. MARIE BISCUIT:
- 10. MARIE BISCUIT:
- 11. SANDWICH TYPE BISCUITS:
- 12. CHEESE BISCUIT:
- 13. RICE BISCUITS:
- 14. CORN FLOUR BISCUITS:
- 15. COFFEE BISCUIT:
- 16. VICTORIA BISCUIT:
- 17. EDINBURG BISCUIT:
- 18. SNOW DROP BISCUIT:
- 19. LUNCHEON BISCUITS:
- 23. SOOJEE BISCUIT:
- 24. SPECIAL NUT BISCUITS:
- 25. SIMPLE ALL PURPOSE BISCUITS:
- 26. PEPPERMINT CREAM BISCUIT:
- 27. CORN FLOUR COCONUT BISCUIT:
- 28. CHOCOLATE VANILLA BISCUIT:
- RECEIPE OF BATTER FOR WAFER SHEETS
- SPECIAL VARIETY OF BISCUITS
- MACAROON BISCUITS
- EASTER BUNNY BISCUITS
- BRANDY SNAPS
- ACO BISCUIT
- TYPICAL BISCUITS MIX
- RECIPES FOR BISCUIT COATINGS
- 1. WHITE COATING:
- 2. DESK CHOCOLATE COATING:
- 3. LEMON COATING:
- 4. ORANGE COATING:
- 5. MALT MILK COATING:
- GOOD QUALITY BISCUITS
- SOME IMPORTANT REQUIREMENT FOR BISCUITS ARE AS FOLLOWS:
- MANUFACTURING PROCESS
- ACCORDING TO TEXTURE AND HARDNESS
- ACCORDING TO THE RECIPE ENRICHMENTS WITH INGREDIENTS LIKE FAT AND SUGAR
- PLANT & MACHINERY DESCRIPTION
- THE UNIT WISE DESCRIPTION OF THE PLANT IS GIVEN BELOW:-
- ELECTRIC OVEN
- THE STANDARD CAPACITY OVENS, AVAILABLE INDIGENOUSLY ARE AS UNDER:-
- OTHER UNITS OF A BISCUIT PLANT COMPRISE OF
- THE STEPS INVOLVE IN THE PRODUCTION OF BISCUIT IS AS FOLLOWS:-
- PRODUCTION PROCESS OF BISCUIT
- THE STEPS INVOLVED ARE AS FOLLOWS:
- PROCESS FLOW SHEET
- STEPS IN INVOLVED IN BISCUIT MAKING
- QUALITY CONTROL OF BISCUIT
- TYPES OF BISCUITS
- PREPARATION OF SAMPLE
- PROCEDURE
- APPARATUS
- PROCEDURE
- DETERMINATION OF ACIDITY OF EXTRACTED FAT
- PROCEDURE
- PRINCIPLES OF PLANT LAYOUT
- MAJOR PROVISIONS IN ROAD PLANNING FOR MULTIPURPOSE SERVICE ARE:
- PLANT LOCATION FACTORS
- PRIMARY FACTORS
- 1. RAW-MATERIAL SUPPLY:
- 2. MARKETS:
- 3. POWER AND FUEL SUPPLY:
- 4. WATER SUPPLY:
- 5. CLIMATE:
- 6. TRANSPORTATION:
- 7. WASTE DISPOSAL:
- 8. LABOR:
- 9. REGULATORY LAWS:
- 10. TAXES:
- 11. SITE CHARACTERISTICS:
- 12. COMMUNITY FACTORS:
- 13. VULNERABILITY TO WARTIME ATTACK:
- 14. FLOOD AND FIRE CONTROL:
- EXPLANATION OF TERMS USED IN THE PROJECT REPORT
- 1. DEPRECIATION:
- 2. FIXED ASSETS:
- 3. WORKING CAPITAL:
- 4. BREAK-EVEN POINT:
- 5. OTHER FIXED EXPENSES:
- 6. MARGIN MONEY:
- 7. TERM LOANS:
- 8. TOTAL LOAD:
- 9. LAND AREA/MAN POWER RATIO:
- SUPPLIERS OF RAW MATERIALS
- YEAST
- SUPPLIERS OF CHEMICALS
- BAKING POWDER
- MILK POWDER
- FOOD FLAVOURS/ESSENCES
- WHEAT FLOUR
- SUPPLIER OF SUGAR
- VANASPATI GHEE
- COMPLETE PLANT SUPPLIERS FOR BISCUIT MAKING
- SUPPLIERS OF PLANT AND MACHINERY
- BISCUIT/WAFER MAKING PLANT MACHINE
- MACHINERY PHOTOGRAPHS
- MIXING EQUIPMENT
- HORIZONTAL MIXTURE
- VERTICAL MIXTURE
- CONTINUOUS MIXTURE
- FORMING & MOULDING EQUIPMENT
- SHEETING LINE
- MOLDING
- DOUGH FEEDING SYSTEM
- BAKING & COOLING
- BAKING OVEN
- PRODUCTS PHOTOGRAPHS
- RAW MATERIAL PHOTOGRAPH
Appendix
- 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)
Frequently Asked Questions
The main ingredients used in biscuit manufacturing are flour, water, fat, sugar, and salt. Soft wheat flour provides the primary structural base, while water supports hydration, starch gelatinization, and processing. Fat contributes tenderness and the characteristic short texture, and sugar provides sweetness while also influencing texture, colour, flavour, and shelf life. Salt primarily enhances flavour and can influence fermentation. Depending on the product formulation, other ingredients such as flavouring agents, colours, aerating agents, eggs, fruits, and coatings may also be incorporated.
Soft wheat flour with relatively low protein content is generally suitable for biscuit production. The report identifies flour containing 8 to 10% protein and less than 0.4% ash content as ideally suited for premium-quality cookies. Biscuit flour should be relatively weak because the desired product texture differs from products that require strong gluten development. Flour quality also affects dough handling, spreading, texture, colour, and the final structure of the baked biscuit, making raw-material selection an important part of production planning.
Industrial biscuit manufacturing generally involves ingredient preparation, dough mixing, forming or moulding, baking, cooling, quality control, and packaging. The ingredients are combined to produce dough with the required consistency, after which forming equipment produces the specified shape. The shaped dough is transferred to a travelling or continuous oven for baking and moisture reduction. After baking, biscuits are cooled before further handling and packing. The exact equipment arrangement and processing conditions vary according to biscuit type, recipe, production capacity, and required product characteristics.
Fat helps produce the soft, pleasant, crumbly, and short texture associated with many biscuits. Fats and oils can be incorporated into dough and batters and may also be used in surface sprays, cream fillings, and coatings. Fat influences the eating quality and processing characteristics of the product, while emulsifiers may be used to support stable water, fat, and air emulsions. The quantity and type of fat are adjusted according to the recipe and the desired characteristics of the finished biscuit.
Common biscuit categories include soft biscuits, hard biscuits, and crackers. The report also identifies plain, slightly sweet, sweet, short, and fermented biscuits among the varieties processed in India. Plain biscuits generally contain little or no sweetening agents and relatively small amounts of fat, while slightly sweet and sweet biscuits contain progressively higher proportions of sugar. Short biscuits are characterized by comparatively higher levels of fat and sugar. Individual products may also differ in their forming method, ingredients, coatings, flavours, and texture.
Key biscuit plant location factors include raw-material availability, market access, power and fuel supply, water availability, climate, transportation, waste disposal, labour, regulatory requirements, taxes, site characteristics, community factors, and provisions for flood and fire control. A suitable location should support reliable procurement and efficient distribution while providing adequate utilities and infrastructure. These factors influence operating continuity, logistics, production efficiency, compliance, and the overall suitability of the site for establishing and operating a biscuit manufacturing facility.
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