![Detailed Project Report (DPR) on Cocoa Products [Cocoa Couverture (Liquor), Cocoa Butter, Cocoa Powder, Chocolate Spread, Chocolate Syrup]](https://www.eiriindia.org/image/project-report/detailed-project-report-cma-data.png)
COCOA PRODUCTS [COCOA COUVERTURE (LIQUOR), COCOA BUTTER, COCOA POWDER, CHOCOLATE SPREAD, CHOCOLATE SYRUP]
[EIRI/EDPR/4270] J.C. 2451XL
INTRODUCTION
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 2525.84 Kg/Day
Land & Building (3300 sq.mt.) Rs. 3.88 Cr
Plant & Machinery Rs. 7.38 Cr
Working Capital for 3 Months Rs. 6.35 Cr
Total Capital Investment Rs. 18.46 Cr
Rate of Return 79%
Break Even Point 29%
CONTENTS
INTRODUCTION
COCOA POWDER AND COCOA BUTTER
COMPLEX FACTOR
PROPERTIES/USES/APPLICATION
MARKET OVERVIEW
GLOBAL COCOA PRODUCTS MARKET SCOPE AND MARKET SIZE
EXPORT
IMPORT
BIS SPECIFICATION
RAW MATERIAL
PACKING AND MARKING
FORMULATION-COCOA PRODUCTS
THE RAW MATERIALS INPUTS FOR THE FOLLOWING PRODUCTS
THE COMPOSITION OF VARIOUS PRODUCTS IS TABLED BELOW
RAW MATERIAL DETAILS
RAW MATERIAL
MANUFACTURING PROCESS STEPS
PROCESS FLOW DIAGRAM
CHOCOLATE SPREAD
CHOCOLATE SYRUP
PRODUCTION PROCESS OF COCOA
PROCESSING DETAILS OF COCOA BUTTER AND COCOA POWDER
COCOA BEAN TO COCOA LIQUOR
BLENDING, MIXING, CLEANING
ROASTING
WINNOWING/SHELLING
NIB ROASTING
GRINDING
COCOA LIQUOR FLAVOUR IMPROVEMENT
COCOA LIQUOR REFINEMENT
COCOA LIQUOR TO COCOA BUTTER AND COCOA POWDER
PRESSING
CRUSHING, COOLING, GRINDING
PRINCIPLES OF PLANT LAYOUT
MAJOR PROVISIONS IN ROAD PLANNING FOR MULTIPURPOSE SERVICE ARE:
PLANT LOCATION FACTORS
PRIMARY FACTORS
RAW-MATERIAL SUPPLY:
MARKETS:
POWER AND FUEL SUPPLY:
WATER SUPPLY:
CLIMATE:
TRANSPORTATION:
WASTE DISPOSAL:
LABOR:
REGULATORY LAWS:
TAXES:
SITE CHARACTERISTICS:
COMMUNITY FACTORS:
FLOOD AND FIRE CONTROL:
PROJECT IMPLEMENTATION SCHEDULE
PROJECT HANDLING
PROJECT SCHEDULING
PROJECT CONSTRUCTION SCHEDULE
TIME SCHEDULE
RAW MATERIALS SUPPLIER
PLANT & MACHINERY SUPPLIER
BUCKET ELEVATOR
SILO
STEAM BOILERS
STORAGE TANKS
FILTER PRESS
LABORATORY EQUIPMENT AND LAB TESTING EQUIPMENT
BROAD PLANT MACHINERY/EQUIPMENT DETAILS
WASTE MANAGEMENT
GREEN BELT
WASTE WATER
WASTE
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)
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