Detailed Project Report (DPR) on Biscuit Production Unit (Cap: 35 Tons/Day)

BISCUIT PRODUCTION UNIT (CAP: 35 TONS/DAY)

[EIRI/EDPR/4648] 

Baking industry is the most stable sector in the food manufacturing industries. The principal basis for most products in this range is wheat flour. Addition of water and various other ingredients give us variety of products like cookies, crackers, cakes, pastries and biscuits. Biscuits are flat, crisp, baked good, whereas cookies are softer and thicker. Cracker means biscuits of a low sugar and fat content, frequently bland or savory.

Biscuit is a low moisture bakery product. Moisture content of biscuit is typically below 4% depending upon its weight, thickness and shape. Biscuit dough can be made from soft wheat flour with a high amount of sugar (25-55%) and shortening (20-60%). They are classified based on the way the dough is placed on the baking band e.g. rotary molded, wire-cut, cutting machine, etc.

The same Biscuit is made up from the word 'BIS' which means twice and 'Cut' means Balled suggesting that product should be twice balled. The Biscuit were originally developed to meet the requirement of longer life of the barley products and for this, purpose, the dough were made up and twice balled to make them moisture free to improve their keeping qualities. The Biscuit manufacturing was started a century ago mainly to meet the requirement of European Travellers. The industry was located near the sea port but today we have a large number of factories situated in various parts of the country. Producing best quality biscuits equivalent to international standards. 

COST ESTIMATION

Plant Capacity            35 MT/Day  

Land & Building (10,000 sq.mt.)    Rs. 6.31 Cr    

Plant & Machinery                    Rs. 7.00 Cr 

Working Capital for 1 Month    Rs. 6.07 Cr 

Total Capital Investment          Rs. 20.54 Cr 

Rate of Return                          35%

Break Even Point                      53%

CONTENTS

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 BE 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 – 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)