Detailed Project Report on automatic bakery business to produce puffs, croissant etc.

AUTOMATIC BAKERY BUSINESS TO PRODUCE PUFFS, CROISSANT ETC. [3547]

Puff pastry is the main example of a laminated paste and there are related products such as Danish pastry, croissant, and crackers which are yeast raised. Puff pastry is lighter, flakier, and more delicate than standard short crust or flan pastry. It contains a higher fat level and has a unique preparation method that is critical for preparation of a successful product. This pastry can be used for a wide variety of products, including turnovers, shells filled with whipped cream,  custards or fruit, vol au vents, and sausage rolls, and is considered a staple in commercial bakeries. The pastry is prepared with high protein flour (bread), water, salt and shortening. A firm, plastic shortening, equal to 50% of the dough weight and containing some moisture, is optimum. Other ingredients, such as eggs and acids (cream of tartar, vinegar, or lemon juice) can be used. There are three commonly used methods for mixing and handling the puff pastry dough the French (roll-in). English (roll-in), and the Scottish (all in) method. The French method involves rubbing a portion of pastry fat into the flour to lubricate the gluten. A portion of the water, acid, and eggs is placed into the center of a ring made from the mixed flour and shortening. The dough is mixed well, and the procedure is repeated until all the ingredients, with the exception of the remaining fat, have been added. The dough is rolled into a  rectangle, 1.25 cm thick  with a thinner outside border, and the fat is rolled to the size of the thicker dough. After the fat is placed on the thicker dough, the thinner dough is folded over on the thicker dough and the thinner dough is folded over, making a type of pocket. The fat and dough is then rolled into a rectangle. One half turn of the dough is formed by folding one end of the dough two thirds of the way down the rectangle and folding the opposite end to cove the first fold. The English method is the most popular in the USA. The dough is sheeted into a rectangular shape, and the roll in fat is spread uniformly over two thirds of the area. Three fold pastry preparation is used to form three dough layers separated by two layers of fat. The Scottish method is similar to pie-crust preparation, simple, and widely used commercially. All the pastry fat is broken into lumps (5 cm) and mixed loosely in the flour. The remaining ingredients are then added to form a lumpy dough. The rolling procedure is the same as the  French method with the addition of one extra half turn. After the final rolling, the dough is shaped and relaxed before baking. For maximum volume, puffed pastries should be baked at high temperatures (204-212oC) The Blitz method is a modification of the Scottish method that partially develops the gluten prior to adding the firm shortening. To mechanical mixers are commonly used in batch commercial pastry production. The low speed, double arm mixing machine with a large dough bowl and slow mixing produces a good quality commercial puffed pastry. The Scotch pastry method must be followed when the high speed mixer is used in large scale, high product capacity operations, Careful timing is critical  with these mixers to prevent over mixing that results in an intimate mixing of fat with the dough  and  formation of a short rather than a puffed pastry. After mixing the dough any of the methods described in the commercial pastry preparation section can be applied. Continuous puff pastry dough production equipment extrudes the dough and shortening into a double layer continuous tube with the shortening in the center layer. This is flattened and reduced by a dough stretcher. The sheet is folded, stretched, and thinned. Pieces are cut into their final shape for pastry shells, cheese or savory sticks, napoleons(mile feuilles), turnovers, sugar crisps, etc. Products prepared with this continuous process are usually intended for wholesale distribution. Thus, their size and flakiness are limited to prevent breakage during shipping. Crescent-shaped roll made from yeasted dough layered to make fl aky puff pastry. May be fl avoured with almond paste, chocolate or cheese. Should be light and fl aky in texture and melt in the mouth. Croissants are thought to have originated in Austria. In 1683 when the Turks were secretly digging tunnels under Vienna to make a surprise attack on the city they were heard by bakers working early in the morning. The bakers who raised the alarm and saved Vienna from being defeated by the Turks then baked a special commemorative roll in the shape of the crescent, as seen on the Turkish fl ag. Marie Antoinette introduced the roll to France where it became known as the croissant, the French word for crescent. The bread industry in India, valued at INR 33bn (~USD 0.53 bn) in FY 2015(E), grew at a CAGR of ~9% over the last three years. Value Notes estimates that the industry will be worth approximately INR 53bn (~USD 0.86bn) by FY 2020, growing at a CAGR of ~10%. ? Demand for brown and fruit breads is estimated to increase further due to an increasing urban consumer base and a rise in health awareness about nutritional food. ?    Growing disposable incomes, changing lifestyles and preferences of consumers supported by an increase in the youth population, female work participation as well as a widening scope of the Indian retail market will drive the industry growth. ? Latest trends witnessed in the industry reveal that companies manufacturing bread products are likely to increase their manufacturing capacities to expand their foothold in different regions. With a change in eating habits and preferences of consumers, the bread industry is coming up with innovative products and flavors, and a variety of breads. Chocolate confectionery value sales are expected to see a constant value CAGR of 8% over 2016-2021, to reach INR162 billion. Increasing availability in rural India and an expanded offer will contribute to chocolate confectionery growth during the forecast period. Pastries, Rusks, Bread, Cakes, and Toffees etc. come under the bakery product. Now the advancement of age food habits of the ready-made food. Most of all the bakery items are under the category of ready-made food. Now school going children are like to have the items like parties cakes, breads etc. for their tiffin use office going peoples like to take breads and parties products, in our daily break fast table also take. The share of bakery products even daily wages laborers also habituated to spend their lunch by taking bread or like that baking product. By the large utilities of baking products in our life takes part the programme of progress of bakery unit itself. Small scale production of baking item can be achieved by cary professional ways of life.

COST ESTIMATION

Plant Capacity                                       500 Kgs/Day  
Land & Building (20000 sq.ft)            Rs. 1.12 Cr
Plant & Machinery                                Rs. 1 Cr
Working Capital for 2 Months            Rs. 38 Lacs
Total Capital Investment                     Rs. 2.69 Cr
Rate of Return                                      23%
Break Even Point                                  67%


INTRODUCTION    
PROPERTIES    
BAKERY PRODUCTS    
A. BREAD    
B. BISCUITS    
B.I.S. SPECIFICATION    
FOR WHITE BREADS    
INGREDIENTS OF BISCUITS WITH THEIR B.I.S. SPECIFICATIONS    
1.   ESSENTIAL INGREDIENTS    
2.   OPTIONAL INGREDIENTS    
PROPERTIES OF RAW MATERIALS    
FLOUR    
YEAST    
YEAST FOOD    
SUGAR    
SHORTENING    
EMULSIFIERS    
MILK AND MILK SUBSTITUTE    
SALT    
ENZYMES    
MARKET OVERVIEW OF BAKERY INDUSTRY    
BAKERY MARKET IN INDIA COMPARISON WITH GLOBAL MARKETS    
BAKERY MARKET IN INDIA    
BAKERY - KEY PLAYERS IN INDIA    
INDIAN MARKET HAS HUGE POTENTIAL FOR BAKERY PRODUCTS    
POTENTIAL FOR BAKERY PRODUCTS    
FACTORS INFLUENCING GROWTH    
LARGE CUSTOMER BASE    
FACTORS DRIVING GROWTH    
SPENDING, CONSUMING CLASS    
BAKERY- SUB-SECTOR OF FOOD PROCESSING    
BREAD    
BISCUITS    
CAKE AND OTHER BAKERY PRODUCTS    
TRENDS    
INNOVATION    
INGREDIENTS FOR CROISSANT    
TYPES OF PUFF PASTRY    
STRUCTURE AND INGREDIENTS OF PUFF PASTRY    
TABLE SHOWS THE INGREDIENTS USED IN PUFF PASTRY.    
RECIPES OF PASTRIES    
DANISH PASTRY    
PUFF PASTRIES    
METHODS OF MAKING PUFF PASTRY    
THESE METHODS ARE AS FOLLOWS    
THREE FOLD OR SINGLE TURN    
BOOK FOLD OR DOUBLE TURN    
COMBINATION METHOD    
FRENCH METHOD    
ENGLISH METHOD    
MAKING OF PUFF PASTRY BY ENGLISH METHOD FROM THE
FOLLOWING STEPS    
SCOTCH METHOD    
INVERTED PUFF PASTRY    
SOME OF THE POINTS THAT NEED TO BE KEPT IN MIND ARE AS FOLLOWS    
PROCESSING DETAILS OF PUFF PASTRIES    
THE PROCESSING STEPS ARE AS FOLLOWS.    
DOUGH MIXING    
LAMINATION    
FOLDS AND FAT LAYER IN LAMINATED DOUGH    
MAKE UP
FILLING    
PROOFING    
BAKING    
PROCESSING DETAILS AND TROUBLE SHOOTING IN CROISSANTS
MANUFACTURE    
TROUBLE SHOOTING    
FILLING FOR DANISH PASTRIES    
BURGER MASTER PASTE.    
REMONCE.    
BAGECREME.    
MACHINE-MADE SHORT PASTE SUGAR IN PASTE    
SUGAR IN PASTE    
RUBBED-IN-METHOD    
CREAMED BATTER METHOD    
RUSK    
MANUFACTURE    
RUSK MANUFACTURING PROCESS -STAGES    
RUSK MANUFACTURING PROCESS FLOW CHART    
FORMULATION OF BREAD RUSK    
PROCESS MANUFACTURING OF BREAD    
GENERAL RAW MATERIAL    
NORMAL BREAD    
MILK BREAD    
SOME APPROVED RECIPE OF THE MAJOR MANUFACTURING PLAYER IN INDIA    
PROCESS    84
FLOW CHART FOR BREAD MANUFACTURING PROCESS    
PROCESS MANUFACTURING OF BUNS    
SWEET BUNS    
BATH BUNS    
SAFFRON BUNS    
HAMBURGER BUNS    
GENERAL PROCESS
BUN MANUFACTURING PROCESS STAGES    
MANUFACTURING PROCESS OF CAKES    
NAME OF THE INGREDIENTS    
MANUFACTURING PROCESS    
CAKE PRODUCTION LINE    
DIFFERENT FORMULATIONS OF CAKES    
ORIDINARY YELLOW CAKE    
HIGH RATIO YELLOW LOAVES    
HIGH RATIO YELLOW LAYERS    
POUND CAKE    
ORDINARY WHITE CAKE    
HIGH RATIO WHITE LAYERS    
LIST OF MAJOR MACHINERY USED DURING MANUFACTURING
OF BISCUIT & ALLIED PRODUCTS    
BUCKET ELEVATORS    
AUTO LOADING CONVEYOR    
INSPECTION/GRADING CONVEYOR    
TRAY DRYER    
CABINET
AIR CIRCULATION    
HEATERS    
COOLING TUNNEL    
WEIGHMETRIC FILLER MACHINE    
BAND SEALER FOR STANDY POUCH    
PROCESS FLOW BLOCK DIAGRAM FOR PRODUCTION OF BISCUIT
(MOULDING VARIETY)    
IMPLEMENTATION SCHEDULE    
WORKSHOP EQUIPMENT    
LABORATORY EQUIPMENT    
FIRE FIGHTING EQUIPMENT    
OFFICE EQUIPMENT    
SWOT ANALYSIS OF FOOD PROCESSING INDUSTRIES IN INDIA    
STRENGTHS    
WEAKNESS    
OPPORTUNITIES    
THREATS    
PLANT LAYOUT    
BAKERY & ALLIED PRODUCT CONSULTANT IN INDIA    
SUPPLIERS OF RAW MATERIALS    
BAKING POWDER    
BAKING ENZYMES    
CRATES, BUCKETS, DRUMS, ETC.    
CAKE GEL    
EGG POWDER    
BAKERY CHEMICALS    
SUPPLIERS OF PLANT AND MACHINERY    
PACKAGING MACHINERY    
    
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)