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Detailed Project Report on biscuit manufacturing unit

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Description
How to Start Business

BISCUIT MANUFACTURING UNIT

[CODE NO.4064]

The term ‘Biscuit’ refers to the small round bread leavened with baking powder or soda and covers a large variety of sweet, salted, filled and coated biscuits. Biscuits are eaten by all sections of people across the board round the year.

They are, thus, mass consumption items with number of varieties and shapes. The market is scattered. There are some dominant national and regional brands. Biscuits can be manufactured at a location which is close to the market. The basic ingredients of biscuit are flour, baking powder, salt, baking soda, sugar, shortening and milk solids.

Around the world Biscuits is the principal food and provides more nutrients than any other single food source. The value of grain in the world used for human consumption is over 2, 3 times of the value of the world iron and steel production. Although only 14% of the grain in the world is handled through international channels, cereal grains make up more than half of all the goods in overseas trade.

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 Travellers. 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 petil peurre 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 give a fine granular texture to the biscuit (which is desired) but only at the expense of a burning taste.

The dough’s 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.

COST ESTIMATION

Plant Capacity 20 MT/Day

Land & Building (4000 sq.mt.) Rs. 5.9 Cr

Plant & Machinery Rs. 4.70 Cr

Working Capital for 1 Month Rs. 5.17 Cr

Total Capital Investment Rs. 14.21 Cr

Rate of Return 42%

Break Even Point 67%

INTRODUCTION

INDIA AT PRESENT PROCESSES MAINLY FOLLOWING VARIETIES OF BISCUITS:

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

BY TYPE - SEGMENT ANALYSIS

BY DISTRIBUTION CHANNEL - SEGMENT ANALYSIS

BY GEOGRAPHY - SEGMENT ANALYSIS

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

BISCUITS-BAKERY SECTOR LOOKS LIKE A BATTLEFRONT

RAVI FOODS TO SCALE HIGHER IN EXPORT MARKET

TRENDS

THE PREMIUM COOKIE MARKET

CHALLENGES IN THE PREMIUM COOKIE SEGMENT DEMOGRAPHICS

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 IS AS FOLLOWS:

MANUFACTURING PROCESS

PLANT & MACHINERY DESCRIPTION

THE UNIT WISE DESCRIPTION OF THE PLANT IS GIVEN BELOW:-

ELECTRIC OVEN

OTHER UNITS OF A BISCUIT PLANT COMPRISE OF

THE STEPS INVOLVE IN THE PRODUCTION OF BISCUIT IS AS FOLLOWS:-

PRODUCTION PROCESS OF BISCUIT

PROCESS FLOW SHEET

QUALITY CONTROL OF BISCUIT

TYPES OF BISCUITS

PREPARATION OF SAMPLE

DETERMINATION OF ACID INSOLUBLE ASH

DETERMINATION OF ACIDITY OF EXTRACTED FAT

SUPPLIERS OF RAW MATERIALS

YEAST

SUPPLIERS OF CHEMICALS SUPPLIERS

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)

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