French Fries Manufacturing Plant (Cap: 120 MT/Day)

FRENCH FRIES MANUFACTURING PLANT (CAP: 120 MT/DAY)

[EIRI/EDPR/4617] J.C.: 2834XL

The global frozen food market comprises retail as well as business customers. Retail customers of frozen food are individuals and households, whereas business customers include hotel chains, fast-food outlets, caterers, and other business buyers. Retail customers mostly prefer cooked and semi-cooked ready-to-eat food, meat, and soups amongst the class of available products in the market. While business customers majorly use frozen meat, sea food, frozen pizza crust, bread, frozen dough, potatoes, and vegetables as the key ingredients for preparing food for end customers. Based on geography, Europe is the largest market, closely followed by North America.

The growth of the frozen food market would primarily be driven by the growing demand and consumption of frozen foods in the developing markets across the Asian countries such as India and China. Increase in disposable incomes coupled with change in lifestyle and food habits are major factors that boost the market growth in these regions. Moreover, a rapid increase in number of large retail chains including hypermarkets and supermarkets has bolstered the demand of frozen food in the developing Asian countries. However, lack of proper refrigeration facility in retail stores and inadequate distribution facility in semi-urban and rural areas are the major challenges for the industry in developing markets. The developed markets are expected to continue their growth at a moderate pace, majorly driven by the mounting consumer preference for healthy frozen foods.

COST ESTIMATION

Plant Capacity            120 MT/Day  

Land & Building (5 Acres)    Rs. 15.99 Cr    

Plant & Machinery                    Rs. 52.66 Cr 

Working Capital for 3 Months    Rs. 52.48 Cr 

Total Capital Investment          Rs. 127.05 Cr 

Rate of Return                          99%

Break Even Point                      23%

CONTENTS

INTRODUCTION

FROZEN FOOD INDUSTRY MARKET OVERVIEW:

FRENCH FRIES

CONTRIBUTION TOWARDS THE GDP

GROWTH AND TREND OF THE INDUSTRY

ABOUT POTATO

NUTRITIONAL SIGNIFICANCE OF POTATO

VALUE ADDITION AND PROCESSING OF POTATO

POTATOES PROCESSING – GLOBAL

GROWING CONDITIONS FOR FRENCH FRIES POTATOES

POTATOES IN INDIA

POTATO PRODUCTION IN INDIA 2021-22

INDIAN PRODUCTION OF POTATO

FSSAI SPECIFICATION

STYLES

THE DIMENSION OF CROSS SECTION

STANDARDS ARE AS FOLLOWS

MAJOR PLAYER

MAJOR PRODUCTS

HERE ARE SOME FROZEN FOOD MAJOR PRODUCTS:

POTATO FARMING

VARIETIES

SOIL

CLIMATE

POTATO PROPAGATION

SELECTION OF SEED TUBER

TRUE POTATO SEED (TPS)

LAND PREPARATION

SEASON OF PLANTING

METHOD OF PLANTING

INTERCULTIVATION

WEED CONTROL

EARTHING UP

CROP ROTATION

INTERCROPPING

MANURE AND FERTILIZERS

IRRIGATION

PLANT PROTECTION

HARVESTING AND YIELD

POTATO HARVESTING

YIELD

PROCESSING OF FRENCH FRIES

1. POTATOES RECEIVING

2. SIZING

3. STEAM PEELER

4. DE-SKINNER/WASHER

5. PRE HEATER/METERING TANK

6. SORTING/CUTTING

7. DEFECT REMOVAL

8. BLANCHING

9. FLUMES

10. DRYER

11. FRYER

FLOW DIAGRAM FOR MAKING FRENCH FRIES

AUTOMATIC FROZEN FRENCH FRIES PLANT LAYOUT

LIST OF MACHINERY & EQUIPMENTS

1. POTATO WASHING AND PEELING MACHINE

2. FRENCH FRIES CUTTING MACHINE

3. MESH BELT POTATO BLANCHING MACHINE

4. VIBRATION DEWATERING MACHINE

5. AIR BLOWING POTATO DEHYDRATING MACHINE

6. FRENCH FRIES CONTINUOUS FRYING MACHINE

7. VIBRATION FRENCH FRIES DE-OILING MACHINE

8. FRENCH FRIES PRE-COOLING DEOILING MACHINE

9. TUNNEL TYPE FRENCH FRIES FREEZING MACHINE

10. AUTOMATIC FROZEN FRENCH FRIES PACKING MACHINE

11. LIFTING BELT OF LIFTING MACHINE

12. HIGH-PRESSURE BUBBLE WASHING MACHINE

ADVANTAGES OF TUNNEL QUICK-FREEZER

1. RAW MATERIAL

2. SPECIAL COLD STORAGE DOOR

3. INSIDE OF FREEZER

4. DRIVING MOTOR

5. EVAPORATOR AND FAN

6. IN AND OUT OF THE FREEZER

7. ELECTRIC CONTROL PART

INTRODUCTION OF FRENCH FRIES BLAST FREEZER

PLANT LOCATION: STATE

LICENSES REQUIRED

LIST OF DOCUMENTS:

OTHER LICENSES REQUIRED FOR THE SETUP:

PRINCIPLES OF PLANT LAYOUT

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:

A. AVAILABILITY OF VARIOUS SERVICES AND PROJECTED RATES

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

DEPRECIATION:

FIXED ASSETS:

WORKING CAPITAL:

BREAK-EVEN POINT:

OTHER FIXED EXPENSES:

MARGIN MONEY:

TERM LOANS:

TOTAL LOAD:

LAND AREA/MAN POWER RATIO:

FRENCH FRIES PRODUCTS

PACKAGING TYPES

FROZEN FOOD PACKAGING MARKET SEGMENTATION:

ON THE BASIS OF FOOD TYPE, THE GLOBAL FROZEN FOOD PACKAGING MARKET IS SEGMENTED INTO:

ON THE BASIS OF PRODUCT TYPE, THE GLOBAL FROZEN FOOD PACKAGING MARKET IS SEGMENTED INTO:

LIST OF FRENCH FRIES MANUFACTURERS

SUPPLIERS OF PLANT AND MACHINERY

CONVEYOR BELT

BUCKET ELEVATORS 

WEIGHING MACHINES 

BAG SEALING MACHINE

D.G. SET

LABORATORY TESTING EQUIPMENTS

EFFLUENT TREATMENT AND DISPOSAL

STANDARDS

TOLERANCE LIMITS FOR INDUSTRIAL EFFLUENT DISCHARGE

WASTE TREATMENT

PRIMARY TREATMENT

SECONDARY TREATMENT

TERTIARY TREATMENT

SOLIDS CONCENTRATION

TYPICAL WASTE SOLIDS CHARACTERISTICS

EQUIPMENT REQUIREMENTS

EQUIPMENT REQUIREMENTS 

MANPOWER

GENERAL

BASIS OF ESTIMATION

UTILITIES

WATER

WATER QUALITY PARAMETERS FOR PROCESSED WATER:

STEAM

UTILITIES (EQUIPMENTS)

WATER TREATMENT PLANT

STEAM GENERATING SYSTEM

REFRIGERATION SYSTEM:

POWER

WORKING 

TOTAL MANPOWER AND PAYROLL 

QUALITY CONTROL OF FRENCH FRIES

MACHINERY PHOTOGRTAPHS

RAW & FINAL PRODUCTS PHOTOGRAPHS

SWOL ANALYSIS

STRENGTHS:

WEAKNESSES:

OPPORTUNITIES:

THREATS:

ORGANIZATION CHART

PLANT LATOUT

CONSULTANT

ADDRESSES OF RELEVANT GOVERNMENT OFFICES

ADDRESSES OF FINANCIAL INSTITUTIONS

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)