Bakery Premix (Cake, Bread, Muffins, Rusk etc.)

BAKERY PREMIX (CAKE, BREAD, MUFFINS, RUSK ETC.)

[EIRI/EDPR/4416] J: 2617NPR, 2618INR, 2618US$

INTRODUCTION

Cake mix is a premix containing all the ingredients normally used for the preparation of cake, except egg and fat. Cakes could be easily prepared from such premix by adding required quantity of egg, hydrogenated fat/butter and water to the premix and mixing for a specified period of time and baking the batter in a baking oven. It adds variety to snack foods prepared in the household. The advantage of using such mix is the convenience, it offers as it eliminates the drudgery of purchasing ingredients in small quantities, weighing them and creaming them separately for a longer duration during the preparation of batter which is a very cumbersome procedure. This will find extensive use in urban middle class families, restaurants, bakeries, industrial canteens and armed forces.

COST ESTIMATION

Plant Capacity            10 MT/Day

Land & Building (2 Acres)    Rs. 4.56 Cr

Plant & Machinery                    Rs. 1.30 Cr

Working Capital for 2 Months    Rs. 3.54 Cr

Total Capital Investment          Rs. 9.71 Cr

Rate of Return                          55%

Break Even Point                      34%

CONTENTS

INTRODUCTION

MARKET POTENTIAL

MARKET OVERVIEW

GLOBAL BAKERY PREMIXES MARKET INTRODUCTION AND MARKET SCENARIO:

GLOBAL BAKERY PREMIXES MARKET SEGMENT OVERVIEW:

BY APPLICATION, THE BREAD SEGMENT IS PROJECTED TO DOMINATE THE MARKET DURING THE FORECAST PERIOD.

KEY MARKET PLAYERS

BASIC RAW MATERIAL REQUIRED

PROCESS FLOW DIAGRAM FOR MANUFACTURING OF CAKE PREMIX

NEW PRODUCT DEVELOPMENTS& FORMULATIONS

TABLE 1-DIFFERENT FORMULATIONS FOR VANILLA SPONGE CAKE:

TABLE 2-RESULT AND OBSERVATIONS (ON BASIS OF SENSORY EVALUATION):

SENSORY EVALUATION OF VANILLA CAKE (T9): SENSORY EVALUATION OF THE PRODUCT WAS DONE BY 10 SEMI TRAINED PANELLISTS ON THE BASIS OF 9-POINT HEDONIC SCALE

TABLE 3-OVERALL SCORE CARD OF SENSORY EVALUATION:

TABLE 4-RESULTS OF PROXIMATE ANALYSIS OF CAKE:

FIG-1.1 PRODUCT IMAGE (FORMULATION 9)

STANDARDIZATION OF FORMULATION FOR GLUTEN FREE AND SUGAR FREE INSTANT CAKE PREMIX

TABLE 5-DIFFERENT FORMULATION TO STANDARDIZE GLUTEN FREE BUCKWHEAT CHOCOLATE CAKE:

TABLE 6-RESULTS (IN TERMS OF SENSORY ANALYSIS):

FIG-1.2 PRODUCT IMAGE (FORMULATION 6)

SENSORY EVALUATION OF GLUTEN FREE BUCKWHEAT CHOCOLATE

CAKE (FORMULATION 6): SENSORY EVALUATION OF THE PRODUCT WAS DONE BY 10 SEMI TRAINED PANELLISTS ON THE BASIS OF 9-POINT HEDONIC SCALE

TABLE 7-OVERALL SCORE CARD FOR GLUTEN FREE STEVIA BASED CAKE:

DEVELOPMENT AND STANDARDIZATION OF BUCKWHEAT AND STEVIA BASED LOW SUGAR CHOCO CAKE BALLS

TABLE 11-FORMULATIONS FOR CAKE OF CAKE BALLS:

TABLE 12-EVALUATION

TABLE 13-SENSORY SCORE CARD OF CAKE BALLS

TABLE 14-RESULT OF PROXIMATE ANALYSIS OF CAKE BALL:

QUALITY CONTROL PROCEDURE/ PARAMETERS

TESTS TO BE DONE FOR FINAL PRODUCT:

A) QUALITY TESTS:

MOISTUREANALYSIS:

ASHTESTING:

PROTEIN ESTIMATION:

NUTRITIVE VALUE TESTS:

SUGAR ESTIMATION:

REDUCING SUGARS:

TOTAL SUGARS:

MICROBIOLOGICAL ANALYSIS:

MICROBIOLOGICAL TEST STOBE PERFORMED:

STANDARD PLATE COUNT:

COMPOSITION OF MEDIA:

NUTRIENT AGAR (FORBACTERIA)

SABOURAUD’S AGAR (FORMOLD)

GYE (FORYEAST)

SENSORY EVALUATION:

MUFFINS FORMULATIONS

MAJOR PLAYER’S

KEY PLAYERS OPERATING IN THE GLOBAL BAKERY PREMIXES MARKET

AVAILABILITY OF TECHNOLOGY/KNOW HOW

PACKAGING TYPES

SPECIFICATION (MULTILAYER POUCH PACKS) OF PACKAGING

MATERIAL FOR BAKERY PREMIX

A) LAMINATES:

B) CO-EXTRUDED FILMS:

PERFORMANCE:

(2) A) THICKNESS TOLERANCE – (LOWER LEVEL PERMISSIBLE)

B) THICKNESS TOLERANCE – (UPPER LEVEL)

PRODUCT APPLICATIONS

BY APPLICATION

BAKERY PREMIX MANUFACTURERS

FOREIGN EQUIPMENT MANUFACTURERS

LIST OF MACHINERY & EQUIPMENTS PHOTOS

W.R.T. BAKERY PREMIX PROJECTS

BUCKET ELEVATOR:

INSPECTION CONVEYOR:

PLANT PROJECT LOCATION

DOCUMENTS REQUIRED FOR LICENSES

LIST OF DOCUMENTS:

PRINCIPLES OF PLANT LAYOUT

MAJOR PROVISIONS IN ROAD PLANNING FOR MULTIPURPOSE SERVICE ARE:

PLANT LOCATION FACTORS

PRIMARY FACTORS

1. RAW-MATERIAL SUPPLY:

2. MARKETS:

3. POWER AND FUEL SUPPLY:

4. WATER SUPPLY:

5. CLIMATE:

SPECIFIC FACTORS

6. TRANSPORTATION:

7. WASTE DISPOSAL:

8. LABOR:

9. REGULATORY LAWS:

10. TAXES:

11. SITE CHARACTERISTICS:

12. COMMUNITY FACTORS:

13. VULNERABILITY TO WARTIME ATTACK:

14. FLOOD AND FIRE CONTROL:

EXPLANATION OF TERMS USED IN THE PROJECT REPORT

1. DEPRECIATION:

2. FIXED ASSETS:

3. WORKING CAPITAL:

4. BREAK-EVEN POINT:

5. OTHER FIXED EXPENSES:

6. MARGIN MONEY:

7. TERM LOANS:

8. TOTAL LOAD:

9. LAND AREA/MAN POWER RATIO:

MANUFACTURES PROCESSING MACHINES

SOME OTHER SUPPLIERS OF PLANT AND MACHINERY CONVEYOR BELT

BUCKET ELEVATORS

WEIGHING MACHINES

BAG SEALING MACHINE

D.G. SET

LABORATORY TESTING EQUIPMENTS

EFFLUENT TREATMENT AND DISPOSAL

THE WASTE FROM THE FOOD PROCESSING OPERATIONS MAYBE CLASSIFIED ON THE BASIS OF:

STANDARDS

TOLERANCE LIMITS FOR INDUSTRIAL EFFLUENT DISCHARGE

WASTE TREATMENT

PRIMARY TREATMENT

ANAEROBIC TREATMENT

METHANE FERMENTATION IS FAVORED BY A WARM CLIMATE. HOWEVER, ITS MAIN DISADVANTAGES ARE:

SECONDARY TREATMENT

TERTIARY TREATMENT

SOLIDS CONCENTRATION

TYPICAL WASTE SOLIDS CHARACTERISTICS

EQUIPMENT REQUIREMENT

EQUIPMENT REQUIREMENTS

MANPOWER

GENERAL

BASIS OF ESTIMATION

UTILITIES

UTILITIES

WATER

WATER QUALITY PARAMETERS FOR PROCESSED WATER:

STEAM

UTILITIES (EQUIPMENTS)

WATER TREATMENT PLANT

REFRIGERATION SYSTEM:

POWER

WORKING

TOTAL MANPOWER AND PAYROLL

FINAL PRODUCTS PHOTOGRAPHS

SWOL ANALYSIS

STRENGTHS

OPPORTUNITIES

WEAKNESS

LIMITATIONS

ADDRESSES OF RELEVANT GOVERNMENT OFFICES

CLEARANCE REQUIRED

TURNKEY CONSULTANT

ORGANIZATION CHART

PLANT LAYOUT

IMPLEMENTATION SCHEDULE

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)