Detailed Project Report on biscuit manufacturing unit

BISCUIT MANUFACTURING UNIT

[CODE NO.4216] 

Baking industry is the most stable sector in the food manufacturing industries. The principal basis for most products in this range is wheat flour. Addition of water and various other ingredients give us variety of products like cookies, crackers, cakes, pastries and biscuits. Biscuits are flat, crisp, baked good, whereas cookies are softer and thicker. Cracker means biscuits of a low sugar and fat content, frequently bland or savory.

Biscuit is a low moisture bakery product. Moisture content of biscuit is typically below 4% depending upon its weight, thickness and shape. Biscuit dough can be made from soft wheat flour with a high amount of sugar (25-55%) and shortening (20-60%). They are classified based on the way the dough is placed on the baking band e.g. rotary molded, wire-cut, cutting machine, etc.

The same Biscuit is made up from the word 'BIS' which means twice and 'Cut' means balled suggesting that product should be twice balled. The Biscuit were originally developed to meet the requirement of longer life of the barley products and for this, purpose, the dough were made up and twice balled to make them moisture free to improve their keeping qualities. The Biscuit manufacturing was started a century ago mainly to meet the requirement of European Travelers. The industry was located near the sea port but today we have a large number of factories situated in various parts of the country. Producing best quality biscuits equivalent to international standards. 

India at present processes mainly following varieties of Biscuits:

1. Plain Biscuit

2. Slightly Sweet Biscuits 

3. Sweet Biscuits,

4. Short Biscuits and a small extent fermented biscuit. The plain type includes cheese milk and water biscuits. These contain little if any sweeting agents and a small proportion of fat. Slightly, Sweet Biscuits such as thin arrowroot, marie and petilpeurre contains 20-25 percent of sugar and 16-18 percent of fat. The sweet type contains a much higher proportion of sugar, these are cream Sandwich, the sugar coated and the Ginger Nut Biscuit. Short biscuits contain a high percentage of fat and sugar.

Biscuits are one of the important bakery items and can be used whole day irrespective of time. It is very common for morning breakfast and also used as snacks.

Biscuits are generally classified into soft biscuits, hard biscuits and crackers. Biscuit dough’s are made mainly from flour, fat, sugar and water with minor amounts of flavor, colors, and aerating agents and possibly eggs and fruits.

Obtained from the milling of wheat by the gradual reduction system. The object of milling process is to separate as cleanly as possible, the endosperm of the grain from the enveloping skins and embryo. The flour for biscuit should be weak and low in protein content; the protein content may be 8.5 per cent of less.

Fat is used in biscuit to remove hardness and to improve the shortness of the biscuits - that is to lower the Millard reaction and polymerization particularly in alkaline conditions and invert sugar is effective in diminishing checking in biscuits. Sugars also affect the heat denaturation of flour protein. Aerating agents commonly used are ammonium bicarbonate by itself and sodium bicarbonate with either sodium pyrophosphate or calcium hydrogen phosphate. 

Ammonium bicarbonate has the advantage that it leaves no residue and evolves a greater volume of gas per unit weight than any of the others but, in the absence of phosphate and sodium ions, it leaves a raw taste in the biscuits. Sodium pyrophosphate residues give a burning taste and excess sodium bicarbonate gives a fine granular texture to the biscuit (which is desired) but only at the expense of a burning taste. 

The doughs are prepared using above mentioned ingredients and formed to the regulated shape by one of various processers and baked in traveling ovens to moisture content of 1 to 4 percent. 

INGREDIENTS

Flour

Soft wheat flour is the main component in most recipes. Wheat flour consists of 65 ? 75% starch and 7- 16% protein. When water is added, during the makeup of dough, starch absorbs a significant amount of water and may act as filler in the continuous protein network with the proteins. During baking, starch granules get gelatinized, which is a major part of the dough. Cookies, crackers flours are normally not treated with additives. For cookies to be premium quality, soft wheat flour containing 8 to 10% protein and less than 0.4% ash content is ideally suited.

Water

Water affects textural properties of baked products. Water acts as a plasticizer, and the amount of water used is adjusted to produce a batter or dough of acceptable consistency for processing. Water is needed for hydrating the proteins, gelatinizing the starch, making leavening agent function, activating the enzymes, dissolving sugar and salt, as well as acting as major heat transfer mechanism during baking through evaporation and condensation.

Fat

Fat provides shortness character to the products, like soft, pleasant and crumbly texture. Fats and oils are used in dough and batters, in surface sprays and in cream fillings and coatings such as chocolates. Bakery fats are often premixed with or used in conjunction with emulsifiers. The function of emulsifier is to promote formation and stabilization of water/fat/air emulsions.

Sugar

Sugar is most important ingredient after flour in soft wheat products such as biscuits, cookies, cakes, etc. Apart from providing sweetness to the product, sweeteners provide one or more of the following functions: tenderizing, texture, yeast nutrient and fermentation control, stabilizing, bulking agent, humactancy, flavour, crust colour and shelf-life extension. Sucrose, corn syrup solids, invert sugar, honey, glucose syrup and certain permitted intense sweeteners are used in manufacture of soft wheat products.

Salt

Salt is added to dough as a seasoning or as flavour enhancer. Salt also inhibits yeast growth and thus help in controlling the fermentation.

COST ESTIMATION

Plant Capacity                               7.2 Ton/Day

Land & Building (3000 sq.mt.)  Rs. 1.80 Cr

Plant & Machinery                              Rs. 1.50 Cr

Working Capital for 2 Months    Rs. 1.88 Cr

Total Capital Investment                    Rs. 5.45 Cr

Rate of Return                                      44%

Break Even Point                                 49%

• INTRODUCTION
  
• INDIA AT PRESENT PROCESSES MAINLY FOLLOWING VARIETIES OF BISCUITS:
• INGREDIENTS
• FLOUR
• WATER
• FAT
• SUGAR
• SALT
• OTHER INGREDIENTS
• TYPES OF BISCUIT
• COMPOSITION OF BISCUITS
• USES AND APPLICATION
• B.I.S. SPECIFICATIONS
• INGREDIENTS OF BISCUITS WITH THEIR B.I.S. SPECIFICATIONS
• 1. ESSENTIAL INGREDIENTS:-
• 2. OPTIONAL INGREDIENTS:-
• PROPERTIES OF RAW MATERIALS
• MARKET POSITION
• BISCUIT CAN HE BROADLY CATEGORIZED INTO THE FOLLOWING SEGMENTS:
• KEY TAKEAWAYS
• BY TYPE - SEGMENT ANALYSIS
• BY DISTRIBUTION CHANNEL - SEGMENT ANALYSIS
• BY GEOGRAPHY - SEGMENT ANALYSIS
• DRIVERS – BISCUITS MARKET
• THE RISING DEMAND FOR HEALTHY COOKIE REGIONAL INSIGHTS
• HEALTHY BISCUITS MARKET SHARE INSIGHTS
• INCREASING DEMAND FOR “READY TO GO” FOOD
• THE HIGH COST OF RAW MATERIALS
• BISCUITS INDUSTRY OUTLOOK:
• ACQUISITIONS/PRODUCT LAUNCHES:
• RISING DEMAND FOR HEALTHY COOKIES
• NORTH AMERICA TO DRIVE THE MARKET
• COMPETITIVE LANDSCAPE
• MAJOR PLAYERS
• EMBRACING INNOVATION TO OVERCOME CHALLENGES
• BISCUITS-BAKERY SECTOR LOOKS LIKE A BATTLEFRONT
• TRENDS
• THE PREMIUM COOKIE MARKET
• LOCATION AND REACH
• QUALITY AND TASTE
• RISING COSTS
• PACKAGING
• TECHNOLOGY, INFRASTRUCTURE
• COMPETITION
• MANPOWER
• PRESENT MANUFACTURERS OF BISCUITS
• RECIPE FOR VARIOUS TYPES OF BISCUITS
• 1. ARRAROOT BISCUIT:
• 2. DIGESTIVE BISCUITS:
• 3. HONEY COMB BISCUITS:
• 4. ALMOND FRUIT BISCUITS:
• 5. SODA BISCUIT:
• 6. COCONUT BISCUIT:
• 7. NICE BISCUIT
• 8. SALTISH BISCUIT:
• 9. MARIE BISCUIT:
• 10. MARIE BISCUIT:
• 11. SANDWICH TYPE BISCUITS:
• 12. CHEESE BISCUIT:
• 13. RICE BISCUITS:
• 14. CORN FLOUR BISCUITS:
• 15. COFFEE BISCUIT:
• 16. VICTORIA BISCUIT:
• 17. EDINBURG BISCUIT:
• 18. SNOW DROP BISCUIT:
• 19. LUNCHEON BISCUITS:
• 23. SOOJEE BISCUIT:
• 24. SPECIAL NUT BISCUITS:
• 25. SIMPLE ALL PURPOSE BISCUITS:
• 26. PEPPERMINT CREAM BISCUIT:
• 27. CORN FLOUR COCONUT BISCUIT:
• 28. CHOCOLATE VANILLA BISCUIT:
• RECEIPE OF BATTER FOR WAFER SHEETS
• SPECIAL VARIETY OF BISCUITS
• MACAROON BISCUITS
• EASTER BUNNY BISCUITS
• BRANDY SNAPS
• ACO BISCUIT
• TYPICAL BISCUITS MIX
• RECIPES FOR BISCUIT COATINGS
• 1. WHITE COATING:
• 2. DESK CHOCOLATE COATING:
• 3. LEMON COATING:
• 4. ORANGE COATING:
• 5. MALT MILK COATING:
• GOOD QUALITY BISCUITS
• SOME IMPORTANT REQUIREMENT FOR BISCUITS ARE AS FOLLOWS:
• MANUFACTURING PROCESS
• ACCORDING TO TEXTURE AND HARDNESS
• ACCORDING TO THE RECIPE ENRICHMENTS WITH INGREDIENTS LIKE FAT AND SUGAR
• PLANT & MACHINERY DESCRIPTION
• THE UNIT WISE DESCRIPTION OF THE PLANT IS GIVEN BELOW:-
• ELECTRIC OVEN
• THE STANDARD CAPACITY OVENS, AVAILABLE INDIGENOUSLY ARE AS UNDER:-
• OTHER UNITS OF A BISCUIT PLANT COMPRISE OF
• THE STEPS INVOLVE IN THE PRODUCTION OF BISCUIT IS AS FOLLOWS:-
• PRODUCTION PROCESS OF BISCUIT
• THE STEPS INVOLVED ARE AS FOLLOWS:
• PROCESS FLOW SHEET
• STEPS IN INVOLVED IN BISCUIT MAKING
• QUALITY CONTROL OF BISCUIT
• TYPES OF BISCUITS
• PREPARATION OF SAMPLE
• PROCEDURE
• APPARATUS
• PROCEDURE
• DETERMINATION OF ACIDITY OF EXTRACTED FAT
• PROCEDURE
• 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:
• 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:
• SUPPLIERS OF RAW MATERIALS
• YEAST
• SUPPLIERS OF CHEMICALS
• BAKING POWDER
• MILK POWDER
• FOOD FLAVOURS/ESSENCES
• WHEAT FLOUR
• SUPPLIER OF SUGAR
• VANASPATI GHEE
• COMPLETE PLANT SUPPLIERS FOR BISCUIT MAKING
• SUPPLIERS OF PLANT AND MACHINERY
• BISCUIT/WAFER MAKING PLANT MACHINE
• MACHINERY PHOTOGRAPHS
• MIXING EQUIPMENT
• HORIZONTAL MIXTURE 
• VERTICAL MIXTURE
• CONTINUOUS MIXTURE
• FORMING & MOULDING EQUIPMENT
• SHEETING LINE 
• MOLDING
• DOUGH FEEDING SYSTEM
• BAKING & COOLING
• BAKING OVEN
• PRODUCTS PHOTOGRAPHS
• RAW MATERIAL PHOTOGRAPH

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)