Detailed Project Report (DPR) on Pan Masala & Zarda Manufacturing Unit (Capacity: 100 Kg/Day)

PAN MASALA & ZARDA MANUFACTURING UNIT 

[EIRI/EDPR/4440] J.C.: 2644XL 

INTRODUCTION

Pan Masala is a balanced mixture of areca nuts (also known as supari), catechu, cardamom, lime, flavoring agents and some natural perfuming materials. It is widely used to remove the bad odor of the mouth by providing a fresh breath and comes in attractive user-friendly packets and containers.

A herb, nut, and seed mixture that is commonly served in India. Pan Masala is most often considered to be an item to aid digestion or used as a breath freshener for use after consuming highly spicy meals. 

A typical mixture of Pan Masala will contain fennel seeds as the base ingredient as well as sugar coated seeds that may include sesame, fennel, and coriander seeds. Mint leaves, cardamom, powdered lime, pure menthol, catechu, betel nuts, areca nuts, and other flavorings may also be added to the mixture. When eaten following a meal, chewing the ingredients releases flavors that are refreshing to the mouth and digestive system.

Zarda if taken in high dose is injurious to health and gives the feeling of laziness and unconsciousness. 

Kimam is the sweetened masala, usually taken by peoples who are not in regular routine of chewing tobacco. It is generally a mouth freshener and believed to increase appetite by improving digestion system.

Gutka or betel quid is a chewing tobacco preparation made of crushed areca nut (also called betel nut), tobacco, catechu, paraffin wax, slaked lime and sweet or savory flavouring, in India, other Asian countries, and North America. Manikchand Group is a group of industries in India that primarily started out as a company that produced chewable tobacco products called 'Gutka'.

Now a days Pan Parag, Prince Gutka, Pan Mayur, Darbari type, Tambul, Maruti, Pan Bahar, Rajni Gandha, Manik Chand and number of other brands pan masalas are commonly used. The sale and marketing of Pan Masala is increasing day by day. It is very clear from the fact that wherever you go in the market, in the town, in a village you will find some panwari shops around everywhere in every mohalla and in every street. As the sale of pan and Pan Masala is increasing there is enough scope for starting the manufacture of Pan Masala on a small scale. It is being manufactured by various trade names like Pan Bahar, Pan Parag, Pan Mayur, Darbari Pan Masala, Manoranjan pan Masala, Tambul Pan Masala, Rajni Gandha Pan masala Santoor Pan masala etc. Powder form pan masala is made under various trade names now a day and are widely used. Uses of Pan Masala Pan Masala is widely used for removing bad odour to impart a pleasant feeling, For scenting the breath in order to impart a pleasant feeling, For serving the guests, friends and in the parties and functions, As a substances for tobacco chewing and for smoking, It can be used in the Hotel and restaurants. Properties of Pan Masala It should not produce irritation effects in the mouth, It should cool the mouth, It should have scented affect in the mouth & NO excess of lime should be in the pan Masala. Market Survey Now days pan Masala has very good market demand due to customer's habit. There is very good scope of pan masala. Actually on pan masala market data is not available but tobacco based product has market survey data. Basically pan masala is a substitute of tobacco products. Users of tobacco products largely converted to use pan Masala. The major factors contributing to tobacco consumption have been global population and income growth. Tobacco is consumed mainly by the adult population and about 70 percent of world population is over 15 years of age. Per adult tobacco consumption, however, is on the decline in both the developing and developed countries. This significant development, however, is concealed by the fact that overall world tobacco use is expanding with population.

COST ESTIMATION

Plant Capacity            100 Kg./Day

Land & Building (300 sq.mt.)    Rs. 46.00 Lac

Plant & Machinery                    Rs. 7.00 Lac

Working Capital for 1 Month    Rs. 36.89 Lac

Total Capital Investment          Rs. 92.90 Lac

Rate of Return                          62%

Break Even Point                      58%

CONTENTS

INTRODUCTION

THE INITIAL STARTUP CAPACITY UTILIZATION IS 80%

USES & APPLICATION

PAN MASALA

ZARDA

KIMAM (QIWAM)

CHEWING TOBACCO (BETEL QUID TOBACCO)

FIGURE-BETEL QUID CONSTITUENTS

FIGURE-PLAIN TOBACCO LEAVES USED IN BETEL QUID

SPECIFICATIONS

EACH PACKET OF CHEWING TOBACCO SHALL BE MARKED WITH THE FOLLOWING:

MARKET OVERVIEW  

THE INDIA PAN MASALA MARKET IS DIVIDED ON THE BASIS OF TYPE INTO:

ON THE BASIS OF PRICE, THE INDUSTRY IS BIFURCATED INTO:

ON THE BASIS OF PACKAGING, THE INDUSTRY IS SEGMENTED INTO:

TOP PLAYERS

PRESENT MANUFACTURER OF PAN MASALA AND RELATED PRODUCT

INSTALLED CAPACITY, PRODUCTION AND CAPACITY UTILIZATION OF PAN MASALA 

APPARENT CONSUMPTION OF PAN MASALA 

ESTIMATED DEMAND

PRESENT MANUFACTURERS/EXPORTERS 

FORMULATION 

FLAVOURED PAN MASALA 

PAN MASALA (MEETHA)

ZARDA

RAW MATERIALS

BETAL NUT (PROCESSED) 

LIME PURIFIED POWDER

CATECHU

CARDAMOM SEED (SMALL)

MULETHI

SANDAL WOOD OIL

KEWRA OIL

ROSE OIL

SAFFRON ESSENTIAL OIL

PERFUME

MANUFACTURING PROCESS STEPS/PROCESS SCHEMATIC

FLAVOURED PAN MASALA 

PAN MASALA (MEETHA)

PROCESS FLOW

ZARDA

PROCESS FLOW

PLANT & MACHINERY

BETELNUT CUTTING MACHINE     

ROASTER WITH DIGITAL TEMPERATURE   

MICRO PULVERISER 

TRAY DRYER 

DEHUMIDIFIER                           

BIBBON BLENDER MADE OF SS-316

VIBRATORY SIEVING MACHINE 

TOBACCO PROCESSING MACHINE WITH CUTTER, VIBRATORY SIEVE ETC

ROTOGRAVURE PRINTING MACHINE   

SOAKING TANK

POUCH FILLING & SEALING 

WEIGHING MACHINE (PLATFORM TYPE)      

SUPPLIERS OF RAW MATERIALS

SUPPLIERS OF MENTHOL

SUPPLIERS OF FLAVOURS/COLOURS/PRESERVATIVES/ESSENCE & EMULSIONS

SUPPLIERS OF FOOD COLOURS

MANUFACTURER OF SUGAR

MANUFACTURERS OF SMALL TIN CONTAINERS

SUPPLIERS OF KATHA FOR PAN MASALA

SUPPLIERS OF SANDALWOOD OIL

SUPPLIERS OF PERFUMES/FLAVOURS

SUPPLIERS OF PLANT & MACHINERY

SUPPLIERS OF MIXER 

SUPPLIERS OF PAN DRYER

SUPPLIERS OF TESTING EQUIPMENT

SUPPLIERS OF PULVERISER

SUPPLIERS OF WEIGHING BALANCE

SUPPLIERS OF POUCH PACKING MACHINE

SUPPLIERS OF TANKS

SUPPLIERS OF PAN MASALA MACHINE

SUPPLIERS OF SUPARI MACHINE

SUPPLIERS OF COMPLETE FOOD PACKAGING MACHINERY

SUPPLIERS OF SIEVE SUPPLIERS

SUPPLIERS OF FOOD MIXER

SUPPLIERS OF DRYER

SUPPLIERS OF FILTERS

PLANT LOCATION FACTORS

RAW-MATERIAL SUPPLY:

MARKETS:

POWER AND FUEL SUPPLY:

WATER SUPPLY:

WASTE DISPOSAL:

LABOR:

SITE CHARACTERISTICS:

WASTE GENERATION & MANAGEMENT/GREEN BELT

GREEN BELT

ANTICIPATED ENVIRONMENTAL IMPACTS 

CONSTRUCTION PHASE 

OPERATION PHASE 

MITIGATION MEASURES (PROPOSED)

HSE REQUIREMENTS

SAFETY & OCCUPATIONAL MEASURE (STORAGE/HANDLING OF RAW MATERIAL & PRODUCT)

PROPOSED IMPLEMENTATION SCHEDULE

PROJECT FINANCIALS 

BASIS & PRESUMPTIONS (FOR PROFITABILITY WORKINGS)

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)