Detailed Project Report (DPR) on cake gel

CAKE GEL

[CODE NO 3842]  

Cake gels are emulsifiers that are much used for the purpose of baking. Emulsifiers are found in nature and assist in improving food system stability. Cake gels have the best of technical ingredients with desired specifications. It needs to be understood well that cake gels are the best of emulsifiers for cake productions and have the best of function. These emulsifiers exist in white as well as yellow color. 

The abilities of emulsifiers include “foaming” wherein – foam is much produced through agitation making bubbles which have the tendency to burst. When an emulsifier is added, there is need of more aeration to foam. This in turn assists in provision of batter with increased volume and smooth texture. It needs to be well noted that cake gels are easy to use and the instructions of use are well mentioned on the packaging. Using cake gels are indeed cost effective when there is much of mass production. 

It needs to be well noted that cake gels are well designed to have a distribution that is uniform throughout the cake. A system needs to be created that keeps emulsifiers in the form of crystals. Cake gels have a kind of magic at every stage with the best of softening effects. It is important to understand the best of ingredients including water for producers of cake gels. It is important to have the right results and have a baking result that is much consistent. 

The key features and benefits of cake gels and emulsifiers need to be understood well and noted at the same time. There needs to be a provision of excellent texture, whippability and volume for cake batters. The emulsifiers are known to decrease the surface tension between fat phase and water. The cake gels ensure stable emulsion and homogenous provision in the end product. 

Cake gels are used in making of starch as well as bread emulsifiers. Cake gel is actually a kind of whipping active gel which consists of mono-layers of water. Emulsifiers are di-glycerides and polyglycerol esters and that too related to fatty acids. It needs to be well noted that the monoglycerides are mostly crystalline in alpha form. As mentioned before, cake gels are a kind of emulsifiers used for baking. In nature around, emulsifiers are discovered much having technical elements that give good food quality. 

Cake gels are known to improve the strength of the batter as well as gives much consistency. It is very simple to make cake gels and it is important to observe the directions on the packaging. The ingredients of cake gels are maida, vanilla essence, sugar, cocoa powder, tablespoon oil, eggs, salt as well as baking powder. It is price efficient to use cake gels particularly in mass manufacturing. Due to the fact that cake gels are easy to use, they should often be used as emulsifiers. Also, it needs to be noted that cake gels are very simple to make and it is advised that they are often used. 

COST ESTIMATION

Plant Capacity                                  600 Kg/Day  

Land & Building (6000 sq.ft.)         Rented    

Plant & Machinery                          Rs. 35 Lacs 

Working Capital for 2 Months    Rs. 58 Lacs 

Total Capital Investment                 Rs. 1.34 Cr 

Rate of Return                                 36%

Break Even Point                             63%

• INTRODUCTION
• FUNCTION OF CAKE GEL
• DIFFERENT TYPES OF GEL CAKES PRODUCED BY FOODVER CO.
• PROPERTIES OF EMULSIFYING AGENTS
• CHARACTERISTICS OF EMULSIONS
• CHARACTERISTIC OF SAMPLE
• PROPERTIES & CHARACTERISTICS OF CAKE GEL
• TEXTURE
• STABILITY
• USES AND APPLICATION
• B.I.S. SPECIFICATION
• DETAILS OF BAKERY GEL
• THE CAKE EMULSIFIERS ARE CLASSIFIED AS FOLLOW.
• VARIOUS EMULSIFIERS
• ESTIMATION BY HLB METHOD FOR EMULSIFIERS
• HLB RANGES AND THEIR APPLICATIONS
• APPROXIMATION OF BLB BY WATER SOLUBILITY
• METHOD OF HLB CALCULATION
• TABLE: H/L RANGES AND THEIR APPLICATION
• ANOTHER METHOD:-
• SORBITAN MONOSTEARATE:-
• CAKE GEL BENEFITS AND APPLICATION
• BENEFITS
• INSTANT CAKE GEL MARKET
• INNOVATIONS, TRENDS & CHALLENGES & ON BAKERY INDUSTRY IN INDIA
• INNOVATION
• TRENDS
• CHALLENGES
• CURRENT RESEARCH ON THE RETAIL BAKERY INDUSTRY
• MARKET OVERVIEW OF BAKERY INDUSTRY IN INDIA
• INDIAN BAKERY MARKET SUMMARY:
• BAKERY CAKE MARKET IN INDIA
• MANUFACTURING OF BAKERY GEL/CAKE GEL (TRANSLUIENT SEMI 
• SOLID PASTE)
• FORMULATION - 1 (NON-IONIC TYPE):-
• FATTY PHASE:
• FORMULATION - 2 (NON-IONIC TYPE):-
• FATTY PHASE:-
• FORMULATION - 3 (NON-IONIC TYPE):-
• FATTY PHASE:-
• DETAILS OF MANUFACTURING PROCESS
• STEP-1:-
• STEP - 2:-
• STEP - 3:
• STEP - 4:-
• STEP - 5:-
• STEP 1:-
• RECEIVING OF ETHYLENE OXIDE GAS AT PLANT:-
• ETHOXYLATION REACTION PROCESS:-
• REACTION:-
• STEP 2:-
• PREPARATION OF FATTY PHASE:-
• STEP 3:-
• PREPARATION OF WATER PHASE:-
• STEP 4:-
• MIXING OF WATER PHASE WITH FATTY PHASE:-
• STEP 5:-
• PACKAGING:-
• PROCESS FLOWSHEET FOR BAKERY GEL/ CAKE GEL MANUFACTURING
• FORMULATION 4:-
• FORMULATION 5:-
• PROCESS OF MANUFACTURING:-
• PROCESS FLOWSHEET OF SMOOTH PLASTIC GEL TYPE EMULSIFIER
• SHORTENING BASED EMULSIFYING FORMULATION FOR MAKING 
•    IMPROVED QUALITY CAKES
• POLYOXYETHYLENE (20) PROPYLENE GLYCOL MONOSTEARATE 
•    AND ALPHA-MONOGLYCERIDE BASED BAKERY GEL
• FORMULATION 1:-
• FORMULATION 2:-
• FORMULATION 3:-
• PREPARATION OF POLYOXYETHYLENE (20) PROPYLENE GLYCOLMONOSTEARATE
• STEP 1:-
• STEP 2:-
• STEP 3:-
• STEP 4:-
• DETAILS OF PROCESS
• STEP 1:-
• PREPARATION OF PROPYLENE GLYCOL MONOSTEARATE:-
• STEP 2:-
• ETHOXYLATION OF PROPYLENE GLYCOL MONOSTEARATE:-
• STEP 3:-
• STEP 4:-
• TESTING:-
• APPLICATION IN YEAST-RAISED BAKERY PRODUCTS
• CONCLUSION:-
• PROCESS FLOW SHEET OF POLYOXYETHYLENE (20) PROPYLENE 
•    GLYCOL MONOSTEARATE WITH ALPHA MONOGLYCERIDE
• METHOD OF PREPARATION OF EMULSIFIER SYSTEM
• EVALUATION OF CAKE BATTER AND CAKES
• A) EVALUATION OF CAKE BATTERS:
• B) EVALUATION OF CAKE:
• SCORE CARD FOR SENSORY EVALUATION OF CAKE
• EXAMPLE 1
• EXAMPLE 2
• EXAMPLE 3
• EXAMPLE 4
• TABLE 1
• TABLE 2
• THE ADVANTAGES OF THE PRESENT INVENTION:
• THE INVENTION CLAIMED IS:
• SATURATED DISTILLED MONOGLYCERIDES VARIANTS IN GEL 
•    FORM CAKE EMULSIFIER
• PRINCIPLES OF PLANT LAYOUT
• PLANT LOCATION FACTORS
• EXPLANATION OF TERMS USED IN THE PROJECT REPORT
• PROJECT IMPLEMENTATION SCHEDULES
• SUPPLIERS 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)