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    Detailed Project Report on liquor bottling plant

    Detailed Project Report on liquor bottling plant
    Detailed Project Report on liquor bottling plant
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      LIQUOR BOTTLING PLANT
      [CODE NO.3913] 
       
       
      Alcohol has been widely consumed since prehistoric times by people around the world, as a component of the standard diet, for hygienic or medical reasons, for its relaxtant and euphoric effects, for recreational purposes, for artistic inspiration, as aphordisiacs, and for other reasons. Some drinks have been invested with symbolic or religious significance suggesting the mystic use of alcohol, e.g. by Greeo-Roman religion in the ecstatic rituals of dionysus (also called Bacchus), god of wine and revelry; in the christian eucharist, and on the Jewish Shabbat and Festivals.
       
      Humans have been drinking alcohol for thousands of years. Alcohol is both a chemical and a psychoactive drug. In chemistry, an alcohol exists when a hydroxy group, a pair of oxygen and hydrogen atoms, replaces the hydrogen atom in a hydrocarbon. Alcohols bind with other atoms to create secondary alcohols. These secondary alcohols are the three types of alcohol that humans use every day: methanol, isopropanol, and ethanol.
       
       In India, ' drinking ' has remained a bad word, clubbed with the other vices. While the beer and liquor market continuous to grow at an impressive rate even against an impressive rate even against an economic reassion, the social stigma remains in place which manifests itself in anti-growth state policies. United Breweries (UB), shaw Wallacs and McDowell Cpart of UB group) presently dominate the liquor and beer market. The structure of the industry is clearly influenced by the regulatory environment and the consequent fragmentation of markets. The regulatory framework covers all these categories.
       
       
      Besides these, there is a significant presence of illicitly brewed alcoholic beverages, which escapes the tax and regulatory net. We can have a look at an overview of Alcoholic beverage industry
       
       
      The Potable Sector Market 
       
      1. Indian Made Foreign Liquor (IMFL) –Whisky, Rum, Brandy, Gin & Vodka -180 million cases p.a.
       
      2. Country Liquor –222 million cases p.a. 
       
      3. Beer (made from Barley and Malt)-170 million cases p.a. 
       
      4. Wine Domestic –1.5 million cases p.a.
       
      IMFL and country liquor goes through the same manufacturing process and is distilled from the same agricultural source (molasses). The differences are in strength (the percentage of alcohol) and flavours. Add whisky or brandy flavours, for instance, and it becomes IMFL. Take the flavour to a tangier side, it’s desi daru.
       
       
      “Both IMFL and country liquor use the same commercial reactive enzymes and multi-column distillation process. At a basic level, it’s the same. That’s the standard distillation equipment that gives rectified spirit.
       
      Extra Neutral Alcohol (ENA) is the primary raw material for making alcoholic beverages. It is a colourless food-grade alcohol that does not have any impurities. It has a neutral smell and taste, and typically contains over 95 per cent alcohol by volume. It is derived from different sources — sugarcane molasses and grains — and is used in the production of alcoholic beverages such as whisky, vodka, gin, cane, liqueurs, and alcoholic fruit beverages.
       
      Neutral spirits, also known as neutral alcohol, rectified spirits, rectified alcohol or ethyl alcohol is highly concentrated ethanol distilled until it reaches a min. ABV of 95% (190 proof). Neutral spirits can be made from grains, grapes, molasses, potatoes, and other agricultural origins. As the name suggests, neutral spirits are considered neutral in flavour, odour and are colourless. Having said that, there are some slight “flavour” variations among the neutral spirits, leading some to question if neutral spirits are truly flavourless.
       
      Neutral spirits are widely used to make spirits such as vodka and gin, as well as to ‘cut’ liqueurs and make bitters, besides from its use in the spirits production the neutrality of rectified spirits also makes it useful in other industries such as the food, non-alcoholic beverage, pharmaceutical, perfumery, and cosmetics industry. It is common for neutral spirits intended for cosmetics and perfumes use to have denaturing agents added to it to reduce tax and to prevent human consumption.
       
      Though consumption is still low, pattern of alcohol consumption vary widely through the country. Punjab, Andhra Pradesh, Goa and the north eastern states have a much higher proportion of male alcohol consumer than the rest of the country. Women tend to drink more in the state of Arunachal Pradesh. Assam and Sikkim in north-east; Madhya Pradesh, Chhattisgarh, Orissa and Andhra Pradesh in central and east India, and Goa in the west, compared to other states. Alcohol also provides and ‘excuse’ to behave in an uncontrolled manner, which make ‘controlled’ societies, like in many Asian countries, including India, even more at risk, where alcohol consumption tend to done without the knowledge of parents and family.
         
      COST ESTIMATION
       
       
      Plant Capacity            24,000 Nos/Day  
      Land & Building (8000 sq.mt.)  Rs. 5.90 Cr    
      Plant & Machinery                    Rs. 3.20 Cr 
      Working Capital for 1 Month    Rs. 7.40 Cr 
      Total Capital Investment          Rs. 17.40 Cr 
      Rate of Return                          58%
      Break Even Point                      28%
       
       
      INTRODUCTION
      THE POTABLE SECTOR MARKET
      PROJECT LOCATION
      CITY MAP OF GUWAHATI
      CLIMATE
      TRANSPORTATION
      BY PLANE
      BY TRAIN
      BY CAR
      BY BUS
      BY BOAT
      TYPES OF NEUTRAL SPIRITS
      DIFFERENT GRADES AND TYPES OF NEUTRAL SPIRITS
      EXTRA-NEUTRAL ALCOHOL
      GRAIN NEUTRAL SPIRITS (GNS)
      POTATO-BASED NEUTRAL ALCOHOL
      GRAPE NEUTRAL SPIRITS
      MOLASSES-BASED ENA
      SPECIFICATION OF EXTRA NEUTRAL ALCOHOL
      DIFFERENT TYPES ALCOHOL
      THE THREE TYPES OF ALCOHOL
      DISTILLED AND UNDISTILLED ALCOHOL
      DIFFERENT TYPES OF ALCOHOLIC DRINKS BY ALCOHOL CONTENT
      UNDISTILLED DRINKS
      BEER
      WINE
      HARD CIDER
      MEAD
      SAKÉ
      GIN
      BRANDY
      WHISKEY
      RUM
      TEQUILA
      VODKA
      ABSINTHE
      EVERCLEAR
      ETHANOL FERMENTATION
      MOLASSES
      MOLASSES – FERMENTATION
      THEORETICAL YIELD OF 37.5 GRAMS OF MOLASSES:
      SUCROSE - FERMENTATION
      THEORETICAL YIELD OF 37.5 GRAMS OF SUCROSE:
      GLUCOSE – FERMENTATION
      MATERIALS NEEDED
      METHODOLOGY A. PREPARATION OF WORT
      METHODOLOGY B. PREPARATION OF YEAST INOCULUM AND FERMENTATION
      METHODOLOGY C. DISTILLATION OF ETHANOL
      FLOWCHART
      FLOW CHART SHOWING PRODUCTION OF IMFL FROM ENA
      MARKET SURVEY
      EXTRA NEUTRAL ALCOHOL MARKET: KEY SEGMENTS
      EXTRA NEUTRAL ALCOHOL MARKET: REGIONAL OUTLOOK
      EXTRA NEUTRAL ALCOHOL MARKET: KEY PLAYERS
      CHOICE OF THE MASSES
      EXPANDING CONSUMER BASE: ~40% OF POPULATION
      INDIAN SPIRITS INDUSTRY
      INDIAN MADE INDIAN LIQUOR (IMIL) INDUSTRY
      INDIAN MADE FOREIGN LIQUOR (IMFL) INDUSTRY
      BUSINESS OVERVIEW
      MANUFACTURING BUSINESS
      CONSUMER BUSINESS
      RATIONALE FOR INVESTMENT
      BOTTLING & PACKAGING
      BEVERAGE ALCOHOL LABELING REQUIREMENTS
      PROCESS OF LIQUOR MANUFACTURING
      THE MAKING OF MALT WHISKY
      1. MALTING
      2. MASHING
      3. FERMENTATION
      4. POT STILLS
      5. DISTILLATION
      6. SPIRIT SAFE
      THE MAKING OF GRAIN WHISKY
      THE MATURATION PROCESS
      THE ART OF BLENDING
      LIQUOR LICENSE
      DOCUMENTS REQUIRED
      ELIGIBILITY (IN CASE OF INDIVIDUAL)
      DISTILLATION METHODS AID IMIL QUALITY IMPROVEMENT
      SCENARIO 10 YEARS BEFORE
      PRESENT SCENARIO
      PROCEDURE AND INSTRUCTIONS FOR PROCUREMENT
      EXTRA NEUTRAL ALCOHOL - PROCEDURE AND INSTRUCTIONS FOR PROCUREMENT
      E N A APPROVAL
      ENA STORAGE
      ENA ISSUE
      QUALITY CONTROL TEST:
      PLANT LOCATION FACTORS
      PRIMARY FACTORS
      1. RAW - MATERIAL SUPPLY:
      2. MARKETS:
      3. POWER AND FUEL SUPPLY:
      4. WATER SUPPLY:
      5. CLIMATE:
      6. TRANSPORTATION:
      6. WASTE DISPOSAL:
      8. LABOR:
      9. REGULATORY LAWS:
      10. TAXES:
      11. SITE CHARACTERISTICS:
      12. COMMUNITY FACTORS:
      13. VULNERABILITY TO WARTIME TTACK:
      14. FLOOD AND FIRE CONTROL:
      RAW MATERIAL SUPPLIERS
      RECTIFIED SPIRIT/ ENA FROM DISTILLERY
      INS 150 A NATURAL COLOURS
      MACHINERY SUPPLIERS
      RAW MATERIAL PHOTOGRAPHS
      MACHINERY PHOTOGRAPHS
      ALCOHOL TANK
      ALCOHOL BOTTLING PLANT
      INDUCTION BOTTLE SEALING MACHINE
      LIQUOR BOTTLING LINE MACHINE
      PRODUCT PHOTOGRAPHS
       
      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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