Detailed Project Report on Dall Mill (Pulse Mill) (Cap: 30 TPD)

DALL MILL (PULSE MILL) (CAP: 30 TPD)

[EIRI/EDPR/1853] J.C. 720

INTRODUCTION

Dal milling industry is one of the major agro processing industries in India. Out of the total production of 13.19 million tones of pulse in the country, 75% is processed by these dal mills. There were about 2000 dal mills in the country in 1972. The numbers grew steadily to 6000 units in 1982, 12000 units in 1995 and 14000 units during the year 1999-2000.

Most of the dal mills in the country are concentrated in selected pockets of the country i.e. pulses producing areas such as Indore (MP), Jalgaon, Akola and Nagpur (Maharashtra) and in or near major consumption centres such as Kolkata, Mumbai, Chennai, Hyderabad and Delhi. The units are mostly traditional ones. They are capital intensive and energy sapping in nature. The dehusking efficiency in traditional mills is quite low. Moreover, the yield of dehusked and splitted pulses in traditional mills is about 65-70 % in comparison to 88-89% maximum potential recovery of splits.

Thus, there is excessive loss of pulse cotyleadons and embroyos in the form of brokens and powdered grains (5- 15%). The industry is also besieged with other problems such as low domestic availability of pulses, high block capital and working capital requirement and presence of large number of intermediaries in pulses procurement and marketing of finished products.

Need for improved Dal Mills:

The present losses being encountered by the milling industry can be minimized to a great extent by the use of improved dal mills. These dal mills are highly versatile and energy efficient. Many agricultural universities , ICAR institutions in the country have developed modern improved dal mills . Some of these institutes are PKV Akola, CFTRI- Mysore, GBPUAT- Pantnagar, CIAE- Bhopal, IIPR-Kanpur, TNAU- Coimbatore and IARI- New Delhi. The improved dal mills have dehusking efficiency of about 95% and the yield of split pulses is about 80-85% depending on the variety of pulse and conditioning of the pulse grain. 

COST ESTIMATION

Plant Capacity            30 MT/Day

Land & Building (1800 sq.mt.)    Rs. 2.70 Cr

Plant & Machinery                    Rs. 1.50 Cr

Working Capital for 1 Month    Rs. 5.76 Cr

Total Capital Investment          Rs. 10.13 Cr

Rate of Return                          39%

Break Even Point                      37%

CONTENTS

INTRODUCTION

USES AND APPLICATIONS

PROPERTIES

B.I.S. SPECIFICATION

MARKET SURVEY

PROCESSING DETAILS OF DAL MILL

PRODUCTION PROCESS IN PULSE MAKING MILLS

PROCESS FLOW DIAGRAM OF A TYPICAL PULSE MILL

CONVENTIONAL PULSE MILLING METHODS

FLOW DIAGRAM OF WET MILLING OF PULSES

FLOW DIAGRAM FOR DRY MILLING OF PULSES

UNIT OPERATION IN DAL MILLING

ENVIRONMENTAL POLLUTION IN PULSE MILL (DAL MILL)

PFD OF A TYPICAL PULSE MILL SHOWING POLLUTION SOURCES & CONTROL SYSTEMS

PROCESS FLOW DIAGRAM

PRINCIPLES OF PLANT LAYOUT

PLANT LOCATION FACTORS

EXPLANATION OF TERMS USED IN THE PROJECT REPORT

SUPPLIERS OF RAW MATERIALS

SUPPLIERS OF PLANT AND 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)