Detailed Project Report (DPR) on cocoa butter and cocoa powder

COCOA BUTTER AND COCOA POWDER
[CODE NO.3192]


Cocoa is the product of the fruit of the cocoa tree (lat. Theobroma cacao), which requires a hot, wet climate, a mean shade temperature of 27°C, and well-distributed rainfall. This is why it can only be grown in regions within 20º latitude of the Equator.

Although the cocoa tree is indigenous to Latin America, Africa today accounts for 70% of the world’s cocoa bean production. Cocoa farming is mostly manual, requiring significant expertise and most cocoa in Africa is grown on small family farms of 2-5 hectares. Next to the Ivory Coast and Ghana, other major cocoa producing countries are Nigeria, Cameroon, Indonesia, Papua New Guinea, Malaysia, Ecuador, Brazil and Colombia.

The cocoa is a very unusual looking tree, with yellow, green and red coloured fleshy fruit pods, about 25 cm long, hanging directly from its trunk and branches. The cocoa beans are embedded within a sticky, white, sweet tasting pulp. At harvest, the cocoa bean has to have reached the proper level of ripeness as under-ripe or over-ripe pods will have a negative impact on the bean’s cocoa flavour.

Raw cocoa beans are bitter and quite inedible. Two processes are required to turn the raw bean into the raw material for chocolate: fermentation and drying. Once the beans have been removed from the pods they are stacked, covered and left to ferment for 3-9 days. The process generates high temperatures of about 50ºC activating enzymes in the beans to form compounds that produce the chocolate flavour when the beans are roasted. The fermentation process must have been concluded properly. Too little fermentation and the desired cocoa taste does not develop fully, too much fermentation and undesirable “off tastes” develop.

COST ESTIMATION

Plant  Capacity                                                       :    5.00 TONS/day
land & Building (4000 Sq.Mtr)                             :    Rs. 2.27 Cr
Plant & Machinery                                                  :    Rs. 5.23 Cr
Working Capital for 2 Months                              :    Rs. 7.32 Cr
Total Capital Investment                                       :    Rs. 15.10 cr
Rate of Return                                                        :    36%
Break Even Point                                                   :    42%


PROPERTIES, USES & APPLICATION                            
B.I.S. SPECIFICATION                                        
TABLE-1 REQUIREMENTS FOR COCOA BUTTER                    
DETERMINATION OF REFRACTIVE INDEX:-                        
DETERMINATION OF MELTING POINT:-                            
DETERMINATION OF FREE FATTY ACIDS:-                        
DETERMINATION OF SAPONIFICATION VALUE:-                    
DETERMINATION OF UNSAPONIFIABLE MATTER:-                    
SAMPLING OF COCOA BUTTER:-                                
PREPARATION OF TEST SAMPLES AND REFEREE SAMPLE:-            
RAW MATERIALS                                            
MARKET SURVEY                                            
EXPORT DATA OF COCOA POWDER                            
EXPORT DATA OF COCOA BUTTER                                
GLOBAL COCOA PRODUCTION (1000 MT)                            
GLOBAL SCENARIO OF COCOA AND COCOA PRODUCTS                
OVERVIEW OF BISCUIT INDUSTRY IN INDIA                        
MANUFACTURING PROCESS OF COCOA BUTTER AND POWDER (NATURAL PROCESS)                        
PROCESS FLOW DIAGRAM                                    
PRODUCTION PROCESS OF DUTCH COCOA                        
PROCESSING DETAILS OF COCOA BUTTER AND POWDER                
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 AND MACHINERIES (IMPORT)                    
SUPPLIERS OF PLANT AND MACHINERIES                        


APPENDIX – A:

 1.      COST OF PLANT ECONOMICS      
 2.      LAND & BUILDING                                      
 3.      PLANT AND MACHINERY                                  
 4.      FIXED CAPITAL INVESTMENT                             
 5.      RAW MATERIAL                                         
 6.      SALARY AND WAGES                                     
 7.      UTILITIES AND OVERHEADS                              
 8.      TOTAL WORKING CAPITAL                                
 9.      COST OF PRODUCTION                                   
10.      PROFITABILITY ANALYSIS                               
11.      BREAK EVEN POINT                                     
12.      RESOURCES OF FINANCE                           
13.      INTEREST CHART                                       
14.      DEPRECIATION CHART                                   
15.      CASH FLOW STATEMENT                                   
16.      PROJECTED BALANCE SHEET