Detailed Project Report on Manufacturing Plant for Chapati, Thepla and Other Snacks (Chakri, Puri and Khakhra)

MANUFACTURING PLANT FOR CHAPATI, THEPLA AND OTHER SNACKS (CHAKRI, PURI AND KHAKHRA)

[EIRI/EDPR/ 3223] J.C.: 1279, 1327

INTRODUCTION

DRY SNACKS/NAMKEEN

Dry Snacks or Namkeen products are in demand from over many years in India and are being exporting to many countries. Dal Moth, Chanachur & Bhujia are the important names enhancing the flavour & taste as processed foods. These are food products having no historical background & becomes in market and in social & cultural synonym as the society became more advanced.

Chakli a spiral shaped crisp deep fried snacks is one of the traditional Indian snacks item enjoyed during festival like Dewali. The snacks is known with different names and is prepared with wheat flour. It is known as Chakri in Gujarat, Chakli in Maharashtra and Northern India. To make crisp yet melt in mouth. Chakli, whole wheat flour is first steam cooked and then mixed with se same seeds, green chilli - ginger paste, spices and curd into dough. Raw chaklis are made from its dough by using a chakli maker and then they are deep fried until light brown.

Thepla are an inherent part of gujarati meals and are used for regular meals travelling and picnics eaten with pickles & curds. Theplas can be enjoyed hot or otherwise sometimes whole Jeera or til can be added to enhance the flavor of theplas.

Initially in long-long ago, people did not heard the name of Dal moth, chur or Bhujia like food products. But now days it is well known not in India but world wide. These are mainly consumed during breakfast period & are very much during social & cultural periods.  These are used as tasty & flavored food as well  as  in medicinal  way,  however,  a  little it  may  be,  according  to ayurveda)  because  of their  carminative  stimulative  digestive properties.  India  produces  almost all  these  types  of  salty processed  food  products  of grains all  these  types  of  salty

processed food products of grains like Grams, Pulses etc.

The main raw materials for these products are Gram pulses & spices.  The various food additives & colours may be used to provide sophistications in the products. the raw  material  are frequency available in India.

These salty food products get a broad market in foreign countries. These products are very much popular not only in India but also overseas countries. Hence, there are a lot of scope and market of these products & therefore, it will provide a very much profitable business.

COST ESTIMATION

Plant Capacity            80,000 Kg Chakli/Year,

80,000 Kg/Year Ganthia, 

8,00,000 No. Roti/Year, 

40,000 Kg/Yr. Puri. 48,000 Khakra

Land & Building (450 sq.mt.)    Rs. 57.70 Lac

Plant & Machinery                    Rs. 49.50 Lac

Working Capital for 2 Months    Rs. 49.61 Lac

Total Capital Investment          Rs. 1.60 Cr

Rate of Return                          29%

Break Even Point                      58%

CONTENTS

INTRODUCTION

DRY SNACKS/NAMKEEN

B.I.S. SPECIFICATIONS

OVERVIEW OF INDIAN FOOD INDUSTRY

MARKET SURVEY

SNACKS FOODS AND TRENDS

MARKET POSITION OF SNACKS

MARKETING STRATEGIES OF HALDIRAMS

OBJECTIVES

COMPETITORS OF HALDIRAM’S

MANUFACTURING PROCESS

MARKETING

EXPORT POTENTIAL

FORMULATION OF CHAKLI

FORMULATION OF KHAKHRA

FORMULATION OF GUJARATI METHI THEPLA

FORMULATION OF GHANTHIYA (TIKHA)

FORMULATION OF PURI (ROASTED)

FORMULATION PROCESS OF MASALA KHAKHRA

MANUFACTURE OF GANTHIA

PROCESS FLOW DIAGRAM

MANUFACTURING PROCESS OF CHAKLI

PROCESS FLOW DIAGRAM

FORMULATION & PROCESS OF BAKED PURI

MANUFACTURING PROCESS OF BIKANERI BHUJIA

PROCESS FLOW DIAGRAM

MANUFACTURING PROCESS OF GANTHIA

PROCESS FLOW DIAGRAM

FORMULATION AND PROCESS OF ALOO BHUJIA

BIKANERI BHUJIA

GANTHIA

TIKHA GANTHIA

RETORT PACKAGING

RETORT PACKAGING AND PROCESSING

DETAILS OF RETORT STERILIZATION PROCESS

COMEUP VENT OPEN – SATURATED STEAM

COME UP VENT CLOSED – SATURATED STEAM

COOK – SATURATED STEAM

PRESSURE COOL FILL – SATURATED STEAM

PRESSURE COOL – SATURATED STEAM

ATMOSPHERIC COOL – SATURATED STEAM

DRAIN – SATURATED STEAM

VERTICAL FORM FILL SEAL (VFFS)

SUPPLIERS OF RAW MATERIALS

SUPPLIERS OF PLANT AND MACHINERIES

FILLING & SEALING MACHINE

PACKAGING MACHINERY FOR DRY SNACKS PRODUCTS

SUPPLIERS OF RAW MATERIALS

SUPPIERS OF FLAVOURS AND OTHER RAW MATERIALS

PLANT & MACHINERY SUPPLIERS

FOR KURKURE TYPE DRY SNACK FOOD

KURKURE MAKING MACHINE

PACKING MACHINE

RAW MATERIAL SUPPLIERS FOR KURKURE TYPE SNACK FOOD

KURKURA MASALA SUPPLIERS

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)