Detailed Project Report on Baby Cereal Food & Milk Powders

BABY CEREAL FOOD & MILK POWDERS (BABY FOOD PRODUCTS)

[EIRI/EDPR/1610]  (J.C.: 411)

INTRODUCTION

Food is composed of three main groups of constituents i.e., carbohydrates, fat & protein. In addition to this there must be some inorganic minerals & organic substances e.g. Vitamins, Iron, Mg, etc.

There may be some foods which contain less or higher of these essential nutritional components depending upon the nutritional value. They are enriched or fortified by other components to attain the required level of utrition.

The Baby-cereal-foods is that enriched food which has a requisite level of nutrition. This requisite level is prescribed by various dieticians & physicians for children. Various experts fixed a definite calorific value for infant food & based on this the various mixtures or formulae of foods are developed. This formula of infant food contains essential amino-acids, fats, proteins, vitamins & other essential minerals etc. which are necessary for the normal growth of child.

Food products are derived from single grains or blends of mixed grains combined with other ingredients for flavour and nutritional fortification.    Materials used by various manufacturers in addition to the  grains  include  malt,  milk powder, vegetable oil, wheat germ, sugar, cotton seed flour, tri-or  dicalcium  phosphate, dried yeast, a form of iron such as sodium iron pyrophosphate and the B vitamin thiamin, riboflavin and niacin. The formulae and manufacturing  processes are carefully controlled so that the vitamins and minerals are present   in sufficient quantity to satisfy certain level declarations.

Infant cereal labels, in most instances list a complete proximate analysis as well as a section stating the percentage of minimum daily requirements for some of the vitamins and minerals present in a certain portion of the product.

COST ESTIMATION

Plant Capacity            7 MT/Day

Land & Building (15,000 sq.mt.)    Rs. 16.88 Cr

Plant & Machinery                    Rs. 2.56 Cr

Working Capital for 3 Months    Rs. 11.00 Cr

Total Capital Investment          Rs. 31.01 Cr

Rate of Return                          29%

Break Even Point                      42 %

CONTENTS

INTRODUCTION

APPROXIMATE ANALYSIS OF OATMEAL CEREAL:

USES AND APPLICATIONS

NUTRITIVE VALUE OF DRY MILK:

USES OF SKIM-MILK POWDER

BREAD:

CHAPATI:

TOFFEE:

COMPOSITIONS AND PROPERTIES

COMPOSITION OF DRY MILK & MILK PRODUCT

1. SOLUBILITY:

2. COLOUR:

3. HYDROSCOPIC PROPERTIES:

4. TASTES:

COMPOSITION OF MILK-POWDER

THE AVERAGE COMPOSITION OF MILK POWDERS:-

MARKET POSITION

MANUFACTURING MILK POWDER ON COMMERCIAL SCALE:-

WHOLE MILK POWDER (WMP):

COWS MILK: SUMMARY FOR SELECTED COUNTRIES

COWS MILK: SUMMARY FOR SELECTED COUNTRIES

PRESENT MANUFACTURERS AND DEALERS

MILK POWDER

B.I.S. SPECIFICATIONS

FORMULATIONS

1. MALTED FOOD

2. EGG CONTAINING FORMULA

3. MILK BASED

EXAMPLES OF COMMERCIALLY PREPARED MILK-BASED FORMULAS MARKETED IN THE UNITED STATES

IF VEGETABLE PROTEIN BASED

CONTENTS OF `CERELAC' TYPE. INFANT FOOD

CONSTITUENTS OF `CERELAC' TYPE INFANT FOOD

DETAILED PROCESS OF MANUFACTURE OF BABY CEREAL FOOD

2. APPEARANCE:

3. RECONSTITUTION PROPERTIES

4. NET WEIGHT AND FILLING OF CONTAINER

5. REFERENCE SAMPLES

6. TRADE SAMPLES

7. COMPETITIVE TESTING

DETAILED MANUFACTURING PROCESS OF MILK POWDER

SEPARATION/STANDARDIZATION

PREHEATING

EVAPORATION

SPRAY DRYING

THE STAGES IN SPRAY DRYING ARE ESSENTIALLY THE FOLLOWING:

ROLLER OR DRUM DRYING OF MILK POWDERS

PACKAGING AND STORAGE

AGGLOMERATED POWDERS

INSTANT WHOLE MILK POWDER

ENERGY AND ENVIRONMENTAL CONSIDERATIONS

INSTANT WHOLE MILK POWDER

FIG. 1 PROCESS DIAGRAM. INSTANT WHOLE MILK POWDER

FIG. 2  TWO-STAGE LECITHINATION PLANT

FIG. 3  LECITHIN DOSING EQUIPMENT

FIG. 4  COMPLETE PLANT FOR PRODUCTION OF INSTANT WHOLE MILK POWDER (MSD)

PROCESSING CONSIDERATIONS IN THE MANUFACTURE OF MILK PROTEIN CONCENTRATE

MPC 42-85 % POWDER PRODUCTION

CHEMICAL

ENZYMATIC

ULTRAFILTRATION

LABORATORY CONTROL

MOISTURE:

SOLUBILITY:

WETTABILITY:

BACTERIOLOGY OF MILK POWDER:

FREEZING DRYING:

KEEPING QUALITY:

NUTRITIONAL VALUE:

SOLUBILITY OF DRIED MILK:

C) HOWAT AND WRIGHT'S METHOD:-

SELECTION OF PROCESS OF MANUFACTURE

DESIGN

MILK BASED FORMULAS (CONTAINING MILK COMPONENTS SUCH AS CASEIN OR WHEY PROTEIN)

ANIMAL OR VEGETABLE FAT BASED FORMULAS (CONTAINING VEGETABLE AND/OR MILK COMPONENTS)

NON-MILK BASED (CONTAINING NO MILK COMPONENTS AT ALL)

RAW MATERIALS

PROTEINS

FATS AND CARBOHYDRATES

DILUENTS

MINERALS

VITAMINS

EMULSIFIERS/STABILIZERS

THE MANUFACTURING PROCESS

MIXING INGREDIENTS

PASTEURIZATION

HOMOGEN IZATION

GRINDING AND MILLING:

STANDARDIZATION

PACKAGING

STERILIZATION

QUALITY CONTROL

THE FUTURE

PRODUCTION OF POWDERED BABY FOOD

SECTION OF RAW MATERIALS

THE TYPES ARE:

TABLE 1: COMPOSITION OF DIFFERENT BABY FOODS

WET MIXING PLANT

FAT

LIQUID MILK CONCENTRATE

RAW MATERIALS IN POWDER FORM

MIXING TANKS - PASTEURIZER – HOMOGENIZER

EVAPORATION

SPRAY DRYING

PRODUCTION TIME BETWEEN CIP CLEANING

POWDER STRUCTURE

DRYING PARAMETERS

AS A RULE OF THUMB THE FOLLOWING APPLIES:

AUTOMATION

CIP PLANT

CONCLUSION

MILK SELECTION

COMPOSITION OF MILKS OF COWS, BUFFALOES, GOATES & SHEEP

PROCESS FLOW SHEET

MILK POWDER

BABY CEREAL FOOD

COMPLETE PLANT SUPPLIERS

MANUFACTURERS/SUPPLIERS OF PLANT & MACHINERY

BLENDING TANK

FLAKING MACHINES

SIEVES

CHILLING PLANT

MILK PASTEURIZER

SPRAY DRYERS

VACUUM DRYER

VACUUM EVAPORATORS

AIR CONDITIONING SYSTEM

BOILERS

GEN SET

ELEVATORS & ESCALATORS

RAW MATERIAL SUPPLIERS

PURE MILK

WHEY PROTEIN

VEGETABLE FAT

MALTODEXTRIN POWDER

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)