Detailed Project Report (DPR) on dairy processing unit (50,000 ltr/day)

DAIRY PROCESSING UNIT
(CAP: 50,000 LTR/DAY)
[CODE NO. 2087]  


India has the highest livestock population in the world with 50% of the buffaloes and 20% of the world’s cattle population, most of which are milch cows and milch buffaloes. India’s dairy industry is considered as one of the most successful development programmes in the post-Independence period.

In the year 2006-07the total milk production in the country was over 94.6 million tonnes with a per capita availability of 229 gms per day. The industry had been recording an annual growth of 4% during the period 1993-2005, which is almost 3 times the average growth rate of the dairy industry in the world. Milk processing in India is around 35%, of which the organized dairy industry account for 13% of the milk produced, while the rest of the milk is either consumed at farm level, or sold as fresh, non-pasteurized milk through unorganized channels.

Dairy Cooperatives account for the major share of processed liquid milk marketed in the India. Milk is processed and marketed by 170 Milk Producers’ Cooperative Unions, which federate into 15 State Cooperative Milk Marketing Federations. Over the years, several brands have been created by cooperatives like Amul (GCMMF), Vijaya (AP), Verka (Punjab), Saras (Rajasthan). Nandini (Karnataka), Milma (Kerala) and Gokul (Kolhapur).

Uttar Pradesh, Punjab, Haryana, Rajasthan, Gujarat, Maharashtra, Andhra Pradesh, Karnataka and Tamil Nadu are the milk surplus states in India. The manufacturing of milk products is obviously high in these milk surplus States. Exports of dairy products have been growing at the rate of 25% per annum in the terms of quantity terms and 28% in terms of value since 2001. Significant investment opportunities exist for the manufacturing of value-added milk products like milk powder, packaged milk, butter, ghee, cheese and ready-to-drink milk products.

India has emerged as the largest milk producing country in the world with present level of annual milk production estimated as 94.5 million tonnes. We expect a production level of 135 million tonnes by the year 2015. India has a large livestock population base constituting 278 million livestock including 180.5 million cattle, 82.8 million buffaloes, 4 million sheep and 9.2 million goats. The livestock population is projected to increase to 322 million by the year 2015. The large livestock population is raised primarily on crop residues and grazing in the common property including basement. The forest area, which was a major source of grazing, is no longer available to livestock breeders especially landless people. As a consequence, the available feed resources fall short of the nutritional requirement. The shortfall is estimated as 59.9 million tonnes for the green fodder and 19.9 million tonnes for dry fodder. This shortfall is likely to increase by 2015 to 63.5 million tonnes of green fodder and 23.56 milli
on tonnes of dry fodder.

The landless people are, therefore, likely to face severe shortage of resources to raise cattle and other species of livestock. There is a real danger that in the absence of resources to maintain their stock, these under-privilege rural people may give up livestock farming. This could be a serious setback to lakhs of rural families who derive income as well as employment opportunities from livestock sector.

India prepares to tackle the international market following Japan, where milk consumption today, has more than trebled to 70 kg per capita from a mere 20 kg in the 'sixties - the consumption of dairy products in other Asian 'tiger' nations is also growing. As a consequence - creating excellent export opportunities for India, as these nations are deficient in milk by at least 3 million tones per year. India, with some 27 per cent of Asia's population, accounts for more than half of the milk output with enough growth potential to explore foreign markets. In anticipation of the export opportunities and in view of the post GATT scenario, India is gearing up to tackle the demands of the international market.

Indian companies are preparing themselves to meet international standards and other non-tariff barriers. Planners are taking measures to meet the sanitary and phyto-sanitary specifications - prescribed by Office International des Epizooties (OIE) under the auspices of the World Trade Organization (WTO) -, which range from the quality assurance of processed dairy products to the health status of livestock.

     In  modern  times,  Milk products  viz  Ghee,  Butter,  Mava (Khoa),  Penda,  Paneer,  Curd  (Dahi),  Butter  milk,  Srikhand, Basundi,  Flavoured  milk,Cheese, Rabri,  Kheer,  Cream,  Mattha, Lassi  etc.  are  gaining  great eminence  and  their  demand  is increasing at a considerable pace.

     Milk   as  well  as  Milk  products  are  mostly  of   daily consumption  in our  day to day life, and their nutritious  value for health promoting cannot be underestimated.      

     Milk  is very salubrious for the health of our  human  body, which contains lactose vitamins, etc.

     The importance of milk in human diet especially for children and  expectant and nursing matters is vital.  To meet the  demand of  the increasing population milk production in India has to  be increased  upto about 84 million tons by 2010 Ad.  It is  neither possible  nor  desirable  to  increase  the  cattle  and  buffalo population to achieve this target.  This can only be achieved  by stepping  up  milk production of our bovine population  by  cross breeding of cows and use of improved cows and buffaloes.
          
     Dairying  in India is a subsidiary occupation of almost  all the  farmers.  More than 60 per cent of the families involved  in dairying  belong  to  the  small  or  marginal  farmers  or  even agricultural labourers.


COST ESTIMATION

Plant Capacity                                               50000.00 Ltr./day
Land & Building (67786  Sq.ft)                   Rs. 1.25     Cr
Plant & Machinery                                         Rs. 6.35   Cr
W.C. for 1 Month                                           Rs. 5.00     Cr
Total Capital Investment                            Rs.  17. 25  Cr
Rate of Return                                             104%
Break Even Point                                        21%

INTRODUCTION    
PROPERTIES OF GHEE    
PROPERTIES OF BUTTER    
USES AND APPLICATION    
SPECIFICATION OF PACKAGED, PASTEURIZED MILK    
B.I.S SPECIFICATIONS    
MARKET SURVEY    
MILK PRODUCTION IN INDIA    
EMERGING NEW TECHNOLOGIES IN THE DAIRY INDUSTRY IN INDIA    
NEW PRODUCTS AND PROCESSING    
KHOA AND KHOA BASED SWEETS    
BUYING AND COLLECTION OF MILK    
CHILLING AND TRANSPORTATION OF MILK TO PROCESSING STATION    
MANUFACTURING PROCESS    
FLOW DIAGRAM    
PROCESS FLOW DIAGRAM OF MILK PROCESSING    
MANUFACTURING PROCESS OF GHEE    
GHEE MANUFACTURING PROCESS    
BUTTER MANUFACTURE PROCESS    
PANEER MANUFACTURING PROCESS    
FLOW DIAGRAM FOR GHEE    
FORMULATION OF FLAVOURED MILK    
TECHNOLOGY AND PROCESS OF BUTTER    
SUPPLIERS OF RAW MATERIALS    
SUPPLIERS OF PLANT  
COMPLETE PLANT & MACHINERY SUPPLIERS FOR DAIRY PRODUCTS    


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