meat processing unit

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+--------------------------------+ | MARKET SURVEY CUM | | DETAILED TECHNO ECONOMIC | | FEASIBILITY REPORT | +--------------------------------+ O N +=========================================+ | | | MEAT PROCESSING (EOU) | | | +=========================================+ KAT INDUSTRIAL CONSULTANTS PVT.LTD. +---------------------------------------------------------------+ | HEAD OFFICE | | WORLD TRADE CENTRE (38, GROUND FLOOR), BARAKHAMBA LANE, | | CONNAUGHT PLACE, BABAR ROAD (NEAR BENGALI MARKET), | | ADJACENT TO HOTEL INTER CONTINENTAL, NEW DELHI-110001 (INDIA) | | ALSO AT:2/51, ROOP NAGAR, DELHI-110007 | | | |PHONE:41528137,23842632,23413183,23411360,9871231144,9868182357|

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Page 1: meat processing unit

+--------------------------------+ | MARKET SURVEY CUM | | DETAILED TECHNO ECONOMIC | | FEASIBILITY REPORT | +--------------------------------+

O N

+=========================================+ | | | MEAT PROCESSING (EOU) | | | +=========================================+

KAT INDUSTRIAL CONSULTANTS PVT.LTD.

+---------------------------------------------------------------+| HEAD OFFICE || WORLD TRADE CENTRE (38, GROUND FLOOR), BARAKHAMBA LANE, || CONNAUGHT PLACE, BABAR ROAD (NEAR BENGALI MARKET), || ADJACENT TO HOTEL INTER CONTINENTAL, NEW DELHI-110001 (INDIA) || ALSO AT:2/51, ROOP NAGAR, DELHI-110007 || | |PHONE:41528137,23842632,23413183,23411360,9871231144,9868182357|| FAX : 011 - 23413183 || E-mail : [email protected] || Website : www.katconsultants.net || || ******************************** || * * || * CODE : KAT/DPR/9662 * || * J.C. : 8540,9985,9210 * || ******************************** |+---------------------------------------------------------------+

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+------------------------------------------------------------------------+| || || | | C A U T I O N | | | | || || This project report has been prepared on the basis of || information available with M/S. KAT INDUSTRIAL CONSULTANTS || PVT. LTD. . The intention here is to provide preliminary | | information to the prospective entrepreneur. Prior to || making a firm decision for investment in the project the || entrepreneur must verify the various feasibility aspects together || along with the addresses for the procurement of plant & machinery | | and raw materials independently. The informations supplied in || this report is obtained from the reliable sources but it is not || guaranteed and the money once paid will not be refunded back in || any case. Claims for incomprehensiveness of the project report || will not be entertained and no legal action in this regard would || be entertained in any case (Subject to Delhi Jurisdiction only). || Any matter relating to our standard points covered in the report || may be modified with in 5 days time only from the date of || purchase. || || || _____________________________________________________________________ || +---+ || | C |K A T I N D U S T R I A L C O N S U L T A N T S P V T. L T D. || +---+ 38, WORLD TRADE CENTRE, G.F., BARAKHAMBA LANE, || CONNAUGHT PLACE, N. DELHI - 110 001. || |+------------------------------------------------------------------------+

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MEAT PROCESSING (EOU)

[KAT/DPR/9662]J.C.:8540,9985,9210

CONTENTS

PAGE

1. INTRODUCTION 42. USES & APPLICATION 63. STANDARD & QUALITY CONTROL 74. VARIOUS PROCESSING OF BUFFALO MEAT 85. MARKET SURVEY 156. PRODUCTION OF MEAT 177. DEMAND SUPPLY GAP 188. MANUFACTURING PROCESS OF BUFFALO MEAT 199. PROCESS FLOW SHEET 2110. ANNEXURE-A (REFRIGERATION AND PROCESSING PLANT) 2211. ANNEXURE-B (TECHNICAL DETAILS & PRICES OF SILENT- DG SET) 3012. ANNEXURE-C (ETP AND POLLUTION CONTROL EQUIPMENTS) 4313. ANNEXURE-D (ESTIMATE/COST OF BUILDING CONSTRUCTION- WORKS) 4414. PLANT LAY OUT 4715. PLANT & MACHINERY SUPPLIERS 4816. RAW MATERIAL SUPPLIERS 5317. GUIDELINES FOR APPLICANTS 5518. PROCESS OF QUALITY SYSTEMS CERTIFICATION 6519. SCHEDULE OF FEES FOR QUALITY SYSTEMS CERTIFICATION 6720. PRINCIPLES OF PLANT LAYOUT 6921. PLANT LOCATION FACTORS 7422. EXPLANATION OF TERMS 7823. ADDRESSES OF STATE INDL. DEV. CORPN. 8024. ADDRESSES OF FINANCIAL INSTITUTIONS 8825. ADDRESSES OF RELEVANT GOVERNMENT OFFICES 92

APPENDIX - A

1. COST OF PLANT ECONOMICS A 1 2. LAND & BUILDING A 2

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3. PLANT AND MACHINERY A 3 4. FIXED CAPITAL INVESTMENT A 5 5. RAW MATERIAL A 6 6. SALARY AND WAGES A 7 7. UTILITIES AND OVERHEADS A 8 8. TOTAL WORKING CAPITAL A 9 9. COST OF PRODUCTION A 1110. PROFITABILITY ANALYSIS A 1211. BREAK EVEN POINT A 1312. RESOURCES OF FINANCE A 1413. INTEREST CHART A 1514. DEPRECIATION CHART A 1615. CASH FLOW STATEMENT A 1716. PROJECTED BALANCE SHEET A 18

MEAT PROCESSING (EOU)

[KAT/DPR/9662]J.C.:8540,9985,9210

INTRODUCTION

Meat is a good source of high quality and readily digestable proteins, fats, phasphrous, iron vitamin A and B-vitamins, It is well balanced with regard to the relative amounts of the specific nutrientsit contains.

The composition of meat depends upon the species from which the cut of meat depends upon the species from which the cut of meat is obtained the degree of fatness to which the animal has been fed prior to slaughter, the curing and/or processing methods, and the cooking methods employed in preparing the meat for consumption.

Buffalo meat is composed of muscles, connective tissues, bone, fat water, organic extractives, enzymes, and pigments. All of these components make some contribution to the palatability of

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the consumed product. Dielectically, meat is an important source of protein, some vitamin A, a rich source of thiamin, riboflavin essential minerals, except calcium, are found in lean including phosphorus,iron copper and trace elements. Nutrients are usually distributed in both expensive and inexpensive cuts.

Buffalo meat is not only significant nutritionally, but is also popular as a food because it is attractive, aromatic, flavourful, and satisfying, cooking generally improves these attributes, contributing to flvour, tenderness and digestibility.

Buffalo meat processing can be divided into three categories : (1) muscle products, (2) codrse ground products and (3) emulsified products. The products in cach group share common process equipments. The goal of musele product processing is to keep an original intact tissue appearance inthe finished product. Buffalo flesh (Biltong) products are produced whole muscles or sectioned muscles. For coarse ground products, the meat particles are substantially reduced and are then restruared back to a different physical form. The finished products such as dry sausagae and smoked sausage, still present the recognizable meat particles.

Enmulsified products made from meats that are completely chopped and further reduced to a pastelike batter. The finished products are a smooth homogeneous mass. In the processed meat industry rave meats, either whole muscles or altered meat perticles, are restructured to the determined product characteristics.

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USES & APPLICATION

In some communities, through buffalo meat is eaten in a variety of ways, commonly cooked and seasoned with salt, oil and spices. It is used for properation of various dishes like (when cooked with rice ), chops eletlets and sheaks, curries, soups broths and sanduriches. The buffalo meat is processed for preservation.

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STANDARD & QUALITY CONTROL

The quality standard of buffalo meat processing products are guided and supervised as per BIS specification given in the following code :

Is : 1982-1971 ( First Revision) - Reaffirmed -1988 for and mortem inspection of meat animals.

Is : 6851-1973 (Reaffirmed 1991) - Meat extract, microbiological grade.

Is : 8182-1976 (Reaffirmed 1990 )- Code of hygenic conditions for processed meat products.

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VARIOUS PROCESSING OF BUFFALO MEAT

To protect the shelf life of buffalo meat wholesomeness and palatability, various techniques are employed depending on the desired type of end product. A number of barriers have been devised to block changes caused by bacteria, molds, spores and enzgrnes. Affective control can be achieved at tempratures ranging above freezing to 40*F. High relative humility asnd minimum volocity of air flow are important. The "butch bloom" on fresh out portions will remain bright for 2-3 days when the product is wrapped in MSAD 80 cellophone, suerose coated, which creates hydrostatic surface pressures. Shelflife upto as much as 4 to 5 meeks can be achieved with pvc -saran bags, vaccumized and shrunk over the product. The negative odour is dissipated shortly affer removal from the bag. Anaerabic bacteria unfortunately to souring of the product. The bag is almost impervious to gases, moisture and this precludes and oxygen source which account for the destruction of aerobic bacteria, a major shelf life problem.

After getting the buffalo flesh (Biltong) from slaughter houses, processing done in the follwing stops :

INJECTING

First of all, the mild curing is employed to improve eating equality more than for preservation. The common ingredients used in a pickling solution, or brine, asre salt, nitrite, phosphates, sodium erythrobatae, sugar and starch. Because of other different solibility of each ingredients should be mixed and dissoved first and then the other igredients should be added. The following preparation procedure is suggested :

1) Dissolve the sodium phosphates in cold water 40*F.

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2) Add the sodium erythrobate and dissolve.

3) Add the remaining ingredients like salt, nitrite, sugar etc.

Agitation is usually done to provent procipitation. Accurate pumping and uniform brive distribution in meat muscle are two major process control pionts. The amounnt of pumping determines the profitaility and legality of products. Uneven distributionof pickle can cause colour, flavour and texture prroblems. Small diameter needles, closely speced provide more uniform injecting and less muscle damage. Because small diameter needles are used for pickle injection, a filter system to prevent particles from plugging up the hole of the needles is vital for accuracy and uniformity. The pickle solution must be dept free of meat particles or other non- dissolved ingredients before coming into the needle manifold . The injection needle can be sigh - hole or multihole . The former can create a large brive pouch inside the must muscle and cause a leakage problem when the needle pulls out. The multihole is preferred for better distribution and less leakage. The amount of pumping is usually controlled by pressure, belt speed ands stitch sequence.

MASSAGING & TUMBLING

After pickle injection, muscle products require a massaging or tumbling process & facilitate the salt somble protection extraction and pickle diffusion. The desired result is to produce a product with and original intact tissue apperance after heat processing. The ascessive pickle carried over from the injecting process is usually massaged into the product in order to attain a disirable brine level.

A massager is comprised of as stationary vat having one or two shafts axtending therin with plurality of paddles. The meats in the vot are kneaded by slow rotation mixing of paddles, which forces the meats to rub against on another. A tumbler is a rotating drum with blades built longitrdinhally on the inner surface. As the drum rotates, the meat blades and fall on of one another. The tumber provides not only meat- on- meat friction but also falling impact to produce a gentle effect, similar to a massasge machine. If consists of a rotating drum with two

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interatate independently fromj the drum and hence do not cause tearing and shearing effects. In addition the flights are in helical arragnement, they do not lift and drop meat like straight blades.

There is no falling impact. As the drum rotates, the helical flights force the product into and elliptic motion and produce meat on- meat massaging action. The massageing or tumbling process produces a better cloured, more tender, and higher yuield product. The application of a vacum driving massaging can fruther improve the product clour, cohesion and sliceability. Appling a vacuum driving the massaging also gives 2 to 3% higher yield. The optimum massaging temperature is suggested to be 43-46F.

GRINDING

The grinder is the most commonly used piece of equipment in the meat indutry for reducing particle size. The size of the meat particle is determined by the diameter of the hole in the cutting knife. The grinding temperature is critical for obtaining clear particle definition and is found to be at or near the freezing point of meat, 28*F. An automatic bone elimination system is often built into a ginder to remove bofe gristle and any other hard to grind materials.

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CHOPPING & EMULSIFYING

Chopper is employed to reduce particle size, to extract salt- soluble protein, to disperse fat, and to mix meats and spices uniformly. The chopper is usually used as the first phase of size reduction before the emulsifying process. Chopping is one of the most important to control emuldifyed product quality. The chopping process determined the amount of available protein and the seze of fat particles. If the measts are not adequately chopped, there is as lack of soluble protein to coat the fat particles. If the meats are over chopped, the fat particle size is reduced and the surface area increases enormously. Eventually, the fat surface becomes so large that the protein solution cannot coat all the fat particles. In both cases, fat will render from emulseon during heat procssing. To determine the optimum chopping condition, emulsion temperature is generally used as the process control criterion. An omulsion temperature of 55*F. after chopping is found to ge most stable. The variables that can effect emulsion stability in a chopper asre chopping time, bowl speed, knife speed bowl size, knife size, number of knives and the mass of emulsion inside a chopper.

The emulsifier used in the meat industry is similar to a grinder, Because products that require an enmulsifying process are usually preechopped or preground to a veryflind mass, an emulsifier normally does not have a feed sereve to deliver product to the emulsifying plate. The cutting knives of the emulsifier function as impellers to suck meats from the hopper and to force them through the emulsifying plate simultaneosly. The hole in the emuslifying plate ranges from 1 to 3 mm. The meat temperature ountside the imulsifier should be kept below 70*F. to assure emulsion stability.

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MIXING

The mixing process is a necessary procedure for coarse- ground products. The only purpose of grinding to reduce particle size. Lean and fat meat extruded through the grinder must be throughly mixed in order to extract salt- soluble protein for fat holding and water binding. A mixer consists of a hopper and a pair of agitators. Ribbon paddle or solid flight agitators are commonly used for mixing. The agitators rotate in apposite directions to perform overlapping action. The optimum mixing temperature is suggested to be below 40*F. to prevent smear problems. Drygen, which exists in meast productss, accurates the spoilasge of finished product. a vacuum is often applied during the mixing process to evacuate air. To keep product cold during the mixing operation ice, chilled water, or liquid gas asre added into the mixer.

STUFFING

Meat product is usually stuffed into natural casings, cellulose casings callagen casings, wok - in bags or moulds to form the final geometric shape. Several types of pumps are used in stuffer, such as piston, gear vave, or worm geasr types. A highly automative co-extrusion of two meast ingredients: one is sausage meat and other a collagen paste that is derived from hide. Two meat ingredients are fed through Co. extrusion nozzle simultaneouly. The nozzle consists of a central tube surrounded narrow gap ending in an orifice circling thre tube. The cones spin in opposite direction. The gap and spun onto an endless rope of sausge meat. This rope is then passed through a brine bath to coagulaste the collagen and then through a crimper that separates and forms the individual links. The diameter of the saurage is determined by the size of the nozzle.

HEAT PROCESSING

The basic functions of smoking and heat processing are to inhibit bacterial growth, to provide desirable colour, and to

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impart specific flavour and texture. Heat processing in the meat industry covers smoking drying, cooking cooling, and freezing.

SMOKING

The smoking process is used to enhance favour and surface colour, the some of the main compounds of smoke like, phends, and carboryls are major contributors of smoke flavour and colour respectively. The acidic compounds accelerate the curing reaction and contribute to the pink colour of cured meats.

Smoke is produced from thermal decomposition of wood and is known as pyrolysis, corbon monorude, corbon dioxid, and some volatile short- change organe acids are released during the dehydration process. When the internal moisture is dried out the temperature rapidly rises of 300* - 400*c. (570* - 750* F). The heat source for thermal decomposition of wood can be hot plate, self burning, or friction. sawdust is loaded in a hopper and the feeding rate is controlled by the rotation speed of the feed plate. The find ash is discharged into a cold water stream ande carried to on ash collector.

DRYING & HEATING

The modern smoke houses are equipped with heating and drying system. The humidity is controlled by the amount of air intake and exhaust. Heat scheules are specifically desingned according to product quality requirement as well as nicrobial kill. The quality of processed meats is singificantly affected by the heat processing schedule. High humidity in a smokehouse can cause surface greave and poor colour problems.

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COOLING

The product shelf life strongly depends on product temperature. By loadring product growth can be sustically delayed. To reduce product temperature after smoking and cooking, air cooling and requird chilling are too of the more commonly used methods in the meat porcessing. The brive chilled air is passed through the cooling system.

PACKAGING

Packing is done at a vacuum level higher than 27 in. The product is heat sealed in film by melting the two sealant layers and weld them together under pressure. For some applications, such as a controlled atmosphere package, an inert gas or gas mixture is back flushed after the vacuumization before final sealing. The sealed packages are then trimmed and boxed.

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MARKET SURVEY

The demand for buffalow processed meat is increasing in some communitities. Since India is a country of Hidus,Muslims, Christians and sikh etc. Hindu do not prefer to take buffalo meat. But buffalo meat is usually used by Muslims, sikhs,and christians. As per consus of India their population is increasing at an average rate of 2.1% per year. Accordingly, the demand for buffalo meat is likely to increase in future.

Livestock and poultry are the main sources of meat and meat products, in India, the animal slaughtered for meat are sheep, goats, buffaloes, cattle and frigs, Fowls, duckus are also used for meat.

According to the type of animal slaughtered different varieties of fresh meat like beef, ham, pork, veal, bacon, mutton, offals, chicken meat etc. are available in the market. All these types of meat are processed many times with a view to preserve it for some time, fresh meat is even used to prepare meat product like sausages, pork laucheon meat, harn rolls, tikkas, salami, kemma, kabab etc.

The demand for meat is increasing at a little faster than it has increased in the past. In India as such Muslims, Christians and Sikhs eat meat more or less on regular basis. Most of the Hindu population is still vegetration and so is not a regular consumer of meat or meat products. However 20 to 25% of population is found eating meat and its products occasionally. The population of Muslims, Sikhs and Christian in total population is found to be 15.76%. As for the census of India their population is likely to increase at an average growth rate of 2.1% per annum, and to that extent the demand for meat is likely to increase.

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PROSPECTS OF THE INDUSTRY

The Industry has full support of the Government and doing very well for last two decades. The International Market for this product is very vast and has very good future in the years to come. Even the major two players in this field are exporting more than 150000 M.T. of Buffalo Meat Products per year and earning more than Rs. 1000 crores (approx.) worth foreign currency for the country. The Government of India has a very positive attitude towards this industry and providing lot of facilities to encourage the industry.

Therefore, the management is quite confident towards the future of this project.

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PRODUCTION OF MEAT

(Th Tons) ------------------------------------------------------ YEAR PRODUCTION ------------------------------------------------------

1996-97 7440

1997-98 7495

1998-99 7520

1999-00 7550

2000-01 7610

2001-02 7655

2002-03 7695

2003-04 7750

2004-05 7800

------------------------------------------------------

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DEMAND SUPPLY GAP

(Th.Tons)--------------------------------------------------------------YEAR DEMAND SUPPLY GAP--------------------------------------------------------------

2000-01 7800 7610 190

2001-02 7910 7655 255

2002-03 8020 7695 325

2003-04 8125 7750 375

2004-05 8230 7800 430

2005-06 8340 7850 490

2006-07 8450 7910 540

2007-08 8565 7965 600

2008-09 8675 8015 660

2009-10 8790 8070 720

--------------------------------------------------------------

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MANUFACTURING PROCESS OF BUFFALO MEAT

On the first point the Buffalo carcasses are purchased from the Government Approved Slaughter Houses and unloaded in the factory.

Then the carcasses are stored in chillers for an approximate period of 10 hours at a temperature ranging between +1 degree to -1 degree C. The capacity of the chiller is sufficient for 2000 carcasses or equivalent to 500 live animals.

After this carcasses from chilling room are brought to Deboning Hall through a conveyor belt system. As the carcass moves from one table to another, butches cut pieces from the carcass as per their area and debone that piece.

After deboning the products are brought to the Freezing section where these are kept in plate and Blast Freezers at -40 degree C. The company has planned to have two Blast Freezers and one Plate Freezer having a total capacity of 50 m.t. (Blast Freezers - 14 m.t. each and Plate Freezer 22 m.t.).

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From Freezing section the goods are sent to Packing Section, where it is packed in cartons in the packing of 18 kgs to 20 kgs as per the buyer's requirement. The Corrugated boxes are strapped and shrink wrapped before sending to the cold storage.

The freezed meat is kept in the cold storage at a temperature of- 40 degree C. The capacity of the cold Storage has been designed to be about 400 to 450 m.t.

From cold storage the goods will be stuffed in refrigerated trucks and sent to Mumbai for shipment at Mumbai port.

The Deboning, Fresh and Frozen packing halls are all fully air-conditioned.

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PROCESS FLOW SHEET

RAW MEAT / BUFFALOW MEAT (WITHOUT SKIN & HEAD IN 4 PIECES)

| | V CHILLING

| | V DEBONING

| | V FREEZING (BLAST & PLATEFREEZING)

| | V PACKING

| | V COLD STORAGE

| | V FREEZED MEAT FOR EXPORT

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ANNEXURE-A

REFRIGERATION AND PROCESSING PLANT

SECTION-A: HIGHSIDE EQUIPMENT:

A. FOR COLD STORAGE:

ONE KIRLOSKAR Model KC21 Three cylinder double stage enclosed type ammonia compound compressor complete with all standard accessories.

ONE KIRLOSKAR/CROMPTON 30 HP 1440 RPM Squirrel cage Induction Motor SPDP, suitable for operation on 3 phase. 50 Hz, 400-440 Volts AC.

ONE Sets of Drive accessories

ONE HP, LP & OP Cutout

ONE HP, LP & OP Gauges

TWO NEPTUNE High pressure oil separators complete with all standard accessories.

B. FOR BLAST FREEZER

TWO KIRLOSKAR Model KC42 Six cylinder double stage enclosed type ammonia compound compressor complete with all standard accessories.

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TWO KIRLOSKAR/CROMPTON 100 HP 1440 RPM Squirrel cage Induction Motor SPDP, suitable for operation on 3 phase. 50 HZ, 400-440 Volts AC

TWO Sets of Drive accessories

TWO HP, LP & OP Cutout

TWO HP, LP & OP Gauges

FOUR NEPTUNE High pressure oil separators complete with all standard accessories.

C. FOR PLATE FREEZER

ONE KIRLOSKAR Model KC31 Three cylinder double stage enclosed type ammonia compound compressor complete with all standard accessories.

ONE KIRLOSKAR/CROMPTON 75 HP 1440 RPM Squirrel cage Induction Motor SPDP, suitable for operation on 3 phase, 50 Hz, 400-440 Volts AC

ONE Sets of Drive accessories

ONE HP, LP & OP Cutout

ONE HP, LP & OP Gauges

TWO NEPTUNE High pressure oil separators complete with all standard accessories.

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D. FOR CHILLER/DEBONING HALL/FRESH PACKING/FROZEN PACKING

ONE KIRLOSKAR Model KC6 Six Cylinder single stage enclosed type ammonia compound compressor complete with all standard accessories.

ONE KIRLOSKAR/CROMPTON 120 HP 1440 RPM Squirrel cage Induction Motor SPDP, suitable for operation on 3 phase, 50 Hz, 400-440 Volts AC

ONE Sets of Drive accessories

ONE HP, LP & OP Cutout 3/4" MS Class pipe

ONE HP, LP & OP Gauges

ONE NEPTUNE High pressure oil separators complete with all standard accessories.

D. COMMON HIGH SIDE EQUIPMENT

TWO NEPTUNE Liquid Receiver of SIZE 30"+20' complete with all standard accessories.

TWO NEPTUNE Evaporative Condenser made from 3/4" MS Class pipe. No. of fans = 3 + 3hp Cladding = Precoated Gl

THREE Beacon/Kirloskar condensor water pumping sets (one to remain as standby).

ONE Lot of refrigerant pipes and fittings, the pipes shall be of TATA MS C Class, Ball valves and the fittings shall be of best Indian make.

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ONE Lot of condenser water pipes and fittings, the pipes shall be of ZENITH/JINDAL Gl B Class and the fittings shall be of best indian make.

ONE NEPTUNE Cubical type switch board powder coated from outside complete with main busbarof copper, switches and contractors of L & T, ampmeter, volt meter etc. - Main earthing and Main switch excluded.

ONE Lot of electrical materials such as copper cables of polycab/anchor, wires etc. For complete power wiring of the plant (illumination excluded).

ONE Lot of suction line insulation complete with Precoated Gl cladding.

FIRST Charge of Ammonia gas in our returnable cylinders.

FIRST Charge of refrigeration grade oil

TWO HERMETIC - GERMANY Ammonia liquid pumps One for operation and One to remain as standby.

ONE Low Pressure Reciever with precoated Gl Cladding from outside.

TWO NEPTUNE Electronic Liquid Level controller with solenoid valve and strainer.

ONE Digital Scanner to be connected to the Cold Storage, Plate Freezer, Blast Freezer etc

ONE Alarm System for Cold Storage

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SECTION-B: LOWSIDE EQUIPMENT

A. FOR COLD STORAGE

TWO NEPTUNE Finned Type Air Cooling units of the following specifications: Coil: CDW Fins: Galvanised Cladding: Precoated Gl

TWO NEPTUNE PUF Hinged Doors of size 2.1M + 1.2M Stainless Steel cladded from outside with Stainless Steel hardware

TWO Sets of Precoated GI Ducting with Powder coated Grills for uniform temperature maintenance.

ONE NEPTUNE Digital Temperature Indicator

B. FOR BLAST FREEZER

FOUR NEPTUNE Finned Type Air Cooling units of the following specifications: Type: Ceiling suspended Coil: CDW Fins: Galvanised Cladding: Precoated Gl

TWO NEPTUNE PUF Hinged Doors of size 2.1M + 1.2M Stainless Steel cladded from outside with Stainless Steel hardware.

TWO NEPTUNE Digital Temperature Indicator

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C. FOR PLATE FREEZER

ONE NEPTUNE Horizontal double contact Plate freezer of the following specifications: No. of plates: 19 Plate size: 76"+ 44" Hoses: Stainless Steel External cladding: Stainless Steel Doors: PUF Insulated Capacity: 180Trays/load

ONE NEPTUNE Digital Temperature Indicator

D. FOR CHILL ROOM

TWO NEPTUNE Finned Type Air Cooling units of the following specifications: Coil: CDW Fins: Galvanised Cladding: Precoated Gl

TWO NEPTUNE PUF Hinged Doors of size 2.1M+1.2M Stainless Steel cladded from outside with Stainless Steel hardware (One for Ante Room)

ONE NEPTUNE Digital Temperature Indicator

ONE NEPTUNE Electronic Liquid Level controller with solenoid valve and strainer.

E. FOR PRE-CHILLER

ONE NEPTUNE Finned Type Air Cooling units of the following specifications: Type: Ceiling Suspended Coil: CDW Fins: Galvanised Cladding: Precoated Gl

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ONE NEPTUNE PUF Hinged Doors of size 2.1M + 1.2M Stainless Steel cladded from outside with Stainless Steel hardware.

ONE NEPTUNE Digital Temperature Indicator

F. FOR DEBONING / FRESH / FROZEN PACKING

SIX NEPTUNE Finned Type Air Cooling units of the following specifications: Type: Ceiling suspended Coil: CDW Fins: Galvanised Cladding: Precoated Gl

SECTION-C: LABOUR CHARGES

JOB Complete installation of the plant including wiring, testing, charging and putting the plant into commission.

EXCLUSIONS

1. All civil, masonry, foundations, Making holes in walls, ceiling and repairing the same.

2. Insulation of cold storages, blast freezer, chill room etc.

3. Main power and water at a point required by us.

4. Living quarters for our workers at the plant site with minimum basic needs. If this cannot be provided, conveyance from the place they stay to the job site.

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5. Main switch and main earthing for the entire electrical installation.

6. Shifting of materials from your godown to the plant location and unskilled labourers for lifting the materials and placing on position.

7. Any other item not specifically mentioned above.

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ANNEXURE-B

TECHNICAL DETAILS & PRICES OF SILENT DG SET

PRICING SCHEDULE

-------------------------------------------------------------------------------SL. PARTICULAR QTY. RATE AMOUNTNO. (Rs.) (Rs.) -------------------------------------------------------------------------------

1. Supply of 250KVA, 415 Volts 01 No. 12,90,000.00 12,90,000.00 Silent D G Set Comprising of Cummins make engine model NT855G5-I/6CTAA8.3G4 developing 306/310BHP Coupled to 250KVA, 415V, Stamford make alternator both mounted on a common base frame, complete with

(a) Fuel tank

(b) Batteries & Leads

(c) Silencer

(d) Manual Control Panel

(e) First fill of lube oil

(f) Acoustic Enclosure

-------------------------------------------------------------------------------

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2. Supply of 380KVA, 415 Volts 01 No. 19,40,000.00 19,40,000.00 Silent D G Set comprising of Cummins make engine model NTA14G3 developing 450BHP Coupled to 380KVA, 415V, Stamford make alternator both mounted on a common base frame, Complete with

(a) Fuel with

(b) Batteries & Leads

(c) Silencer

(d) Manual Control Panel

(e) First fill of lube oil

(f) Acoustic Enclosure

-------------------------------------------------------------------------------

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3. Supply of 500KVA, 415 Volts Silent 01 No. 28,25,000.00 28,25,000.00 DG Set comprising of Cummins make engine model KTA19G9 developing 600BHP Coupled to 500KVA, 415V, Stamford make alternator both mounted on a common base frame, complete with

(a) Fuel tank

(b) Batteries & Leads

(c) Silencer

(d) Manual Control Panel

(e) First fill of lube oil

(f) Acoustic Enclosure

------------------------------------------------------------------------------- Total Rs. 60,55,000.00 -------------------------------------------------------------------------------

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TECHNICAL SPECIFICATION FOR 250/380 KVA DG SET

A. DIESEL ENGINE

Cummins make Diesel engine model NT855G5-1/6CTAA8.3G4 DEVELOPING 306/310 BHP & NTA14G3 developing 450 BHP, rated at 1500 RPM, water cooled, four stroke, electric start, six cylinder diesel engine conforming to BS : 5514 with capacity of 10% over loading for one hour in twelve hours duration having following accessories as scope of supply:-

AIR INTAKE SYSTEM

- Air intake manifold. - Dry type air cleaner.

- Vacuum indicator

EXHAUST SYSTEM

- Turbocharged-After Cooled. - Flexible Connection.

- Exhaust manifold.

- Exhaust silencer - residential type.

COOLANT SYSTEM

- Engine water pump.

- Radiator.

- Coolant additive concentrates.

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LUBRICATING SYSTEM

- Oil pan.

- Engine mounted lub oil pump.

- Full flow lub oil filter.

- Spin-on filters.

FUEL SYSTEM

- Fuel pump with Electronic Governor.

- PTD Injector.

- 24V DC Solenoid Coil.

- Replaceable fuel filter.

STARTING SYSTEM

- 24V DC Electric Starter.

- 24V DC battery charging alternator.

SAFETY CONTROLS

- Low lube oil pressure trip.

- High water temperature trip.

- Overspeed stop.

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ELECTRIC INSTRUMENT PANEL

- Start / stop key switch

- Lub oil pressure indication

- Water temperature indication

- RPM indication

- Engine Hours indication.

- Low lub oil trip indication.

- High water temperature trip indication.

- Overspeed trip indication.

- Battery Charging Indication.

OTHERS

- Vibration damper.

- Flexible coupling (only for double brg. Alternators).

- Flywheel with housing.

B. ALTERNATOR

Synchronous alternator of STAMFORD make of 250/380 KVA rating, suitable for continuous operation at 1500 RPM generation 415 volts at 0.8 p.f. (lag) suitable for 50 Hz, 3 phase, 4 wire system. The alternator shall be Brushless type, self excited & self regulated through an AVR. The alternator will be suitable for tropical climate and shall generally confirm to IS: 4722. The salient features of the alternator are:-

- + 1% voltage regulation (max) in static conditions.

- IP : 23 protection with class 'H' insulation.

- Permanent lubricating bearing.

- Permissible overload of 10% for one hour in 12 hours of

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operation.

C. CONTROL PANEL

The std. control panel is fabricated from 14 SWG sheet and Powder Coated after seven tank treatment process. The panel is equipped with:-

- One no.3 pole MCCB of suitable rating with inbuilt short

circuit and overload protection. - Ammeter with selector switch.

- Voltmeter with selector switch.

- Frequency meter.

- KW Meter.

- Current transformers

- Three nos. current transformers.

- Aluminium bus bars of suitable capacity with incoming & outgoing termination ends.

- Indication lamps for "Load On" and "Set Running".

- Instrument fuses.

D. BASE FRAME

Engine and alternator are mounted, coupled and aligned on a

common channel iron fabricated Base Frame with pre-drilled holes.

E. FUEL TANK

Daily service fuel tank of 8 hours running 520 Ltrs., fabricated from 14 SWG sheet metal complete with drain plug, air vent, level indicator,inlet and outlet connection.

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F. BATTERIES

Two no. STANDARD FURUKHAWA/ equivalent make batteries of 12 V, 180 AH capacity in dry and uncharged condition with its leads.

G. DOCUMENTATION

1 set of following documents shall be provides with each set

- O & M Manual of Diesel Engine

- Spare parts list of diesel engine

- Test Certificate of diesel engine

- Test Certificate of Alternator

TECHNICAL SPECIFICATION FOR 500 KVA SILENT DG SET

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A. DIESEL ENGINE

Cummins make Diesel engine model KTA-19-G9 developing 600 BHP at 1500 RPM, water cooled, four stroke, electric start, six cylinder, turbo-charged & after cooled model, conforming to BS : 5514 with capacity of 10% over loading for one hour in twelve hours duration having following accessories as scope of supply:-

AIR INTAKE SYSTEM

- Air intake manifold.

- Dry type air cleaner.

- Vacuum indicator.

EXHAUST SYSTEM

- Turbocharger After cooler

- Flexible connection.

- Exhaust manifold.

- Exhaust Silencer - Residential type.

COOLANT SYSTEM

- Engine water pump.

- Radiator.

- Coolant additive concentrate

- By Pass Thermostat

LUBRICATING SYSTEM

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- Oil Sump

- Engine mounted lub oil pump.

- Full flow lub oil filter.

- Lube oil by pass filter

- Bypass Thermostat

FUEL SYSTEM

- PT Fuel pump with Electronic Governor

- PTD Injector

- 24V DC Solenoid Coil

- Replaceable fuel filer

STARTING SYSTEM

- 24V DC Electric Starter

- 24V DC battery charging alternator

SAFETY CONTROLS

- Low lube oil pressure trip

- High water temperature trip.

- Overspeed stop

ELECTRIC INSTRUMENT PANEL

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- Start/Stop key switch

- Lube oil pressure indication

- Water temperature indication

- RPM indication.

- Engine Hours Indication.

- Battery Charging Indication

- Low lube oil trip indication

- High water temperature trip indication

- Overspeed trip indication.

OTHERS

- Vibration damper.

- Flexible coupling (for double bearing alternators only)

- Flywheel with housing.

B. ALTERNATOR

Synchronous alternator of STAMFORD make of 500 KVA rating, suitable for continuous operation at 1500 RPM generating 415 volts at 0.8 p.f. (lag) 50 Hz, 3 phase, 4 wire system. The alternator shall be Brushless type, self excited & self regulated through an AVR. The alternator will be suitable for tropical climate and shall generally confirm to BS : 2613 / IS : 4722. The salient features of the alternator are :-

- + 1% voltage regulation (max) in static conditions.

- IP: 23 protection with class 'H' insulation.

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- Permanent lubricating bearing.

- Permissible overload of 10% for one hour in 12 hours of operation.

C.CONTROL PANEL

The std. control panel is fabricated from 14 SWG sheet and Powder Coated after seven tank treatment process. The panel is floor mounted & equipped with :-

- One no.3 pole 800 Amps., fixed type breaker

- Ammeter with selector switch

- Voltmeter with selector switch.

- Frequency meter.

- KW meter.

- Three nos. current transformers.

- Aluminium bus bars of suitable capacity with incoming & outgoing termination ends.

- Indication lamps for "Load on" and "Set Running".

- Instrument fuses.

D. BASE FRAME

Engine and alternator are mounted, coupled and aligned on a common channel iron fabricated base Frame with pre-drilled holes.

E. FUEL TANK

Daily service fuel tank of 990 lts. Capacity fabricated for

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14 SWG sheet metal complete with drain valve, air vent, inlet and outlet connection.

F. BATTERIES

Two nos. STANDARD FURUKHAWA / equivalent make batteries of 12V, 180 AH capacity in dry and uncharged condition with its leads.

G. ACOSUTIC ENCLOSURE - 1 NO. (CPCB APPROVED)

H. DOCUMENTATION

1 set of following documents shall be provides with each set

- O & M Manual of Diesel Engine

- Spare parts list of diesel engine

- Test Certificate of diesel engine

- Test Certificate of Alternator

- Test Certificate of D.G. Set

ANNEXURE-C

ETP & POLLUTION CONTROL EQUIPMENTS

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(1) Installation of Effluent Treatment Plant for Meat Processing Section (40 KL/day capacity) L.S. Rs. 4,65,000.00/- (Rupees Four Lacs Sixty Five thousand only)

(2) Installation of Effluent Treatment Plant for Rendering Section (40 KL/day capacity) L.S. Rs. 5,10,000.00/- (Rupees Five Lacs Ten Thousand Only)

(3) Installation of Air Pollution Control System for Vent Gas from Rendering section. L.S. Rs. 1,05,000.00/- (Rupees One Lacs Five thousand only)

----------------------------------------- TOTAL L.S. Rs.10,80,000.00/- -----------------------------------------

ANNEXURE - D

ESTIMATE / COST OF BUILDING CONSTRUCTION WORKS:-

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Following are the detailed estimate / project cost for construction of factory building showing detailed specification and quantity, rate adopted are as per U.P. PWD schedule of rates for covered are basis as applicable at present for such type of building.

NO. PARTICULARS AMOUNT

1. CARCASS CHILLER RCC framed structure in M-20 cement concrete in coloumns, beams and roof slab with brick coba water proofing internal and external plaster in (1:5) cement mortar, kota stone in flooring over thermocloe insulation electrocal and sanitation work complete in all respects. 2450 sq.ft.@ Rs. 500/- 12,25,000.00

2. DEBONING AND PROCESSING HALL RCC framed structure in M-20 cement concrete in coloumns, beams and roof slab with brick coba water proofing internal and external plaster in (1:5) cement mortar, kota stone 40 mm thick in flooring over PCC in (1:4:8) glaze upto 7' height brick masonry work in walls.

9500 sq.ft@ Rs. 550/- 52,25,000.00

3. BLAST FREEZERS RCC framed structure in M-20 cement concrete in coloumns, beams and roof slab with brick coba water proofing internal and external plaster in (1:5) cement mortar, kota stone in flooring over thermocloe insulation electrocal and sanitation work complete in all respects.

2260 sq.ft.@ Rs. 500/- 11,30,000.00

4. FROZEN STORAGE & DISPATCH AREA RCC framed structure in M-20 cement concrete in coloumns, beams and roof slab with brick coba water proofing internal and external plaster in (1:5) cement mortar, 150 mm thick RCC in flooring over thermocloe insulation

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electrocal and sanitation work complete in all respects.

2300 sq.ft.@ Rs. 450/- 10,35,000.00

5. REFRIGERATION PLANT & D.G. ROOM RCC framed structure in M-20 cement concrete in coloumns, beams and roof slab with brick coba treatment internal and external plaster in (1:5) cement mortar, upto 15 mm thick IPS flooring with trimix vaccume dewatering cement concrete, machines foundation with RCC, cable trenches as per requirement electrical work, door windows and rolling shutter, white washing complete in all respects.

2000 sq.ft. @ Rs. 475/- 9,50,000.00

6. OFFICE BLOCK RCC framed structure in M-20 cement concrete waterproofing of roof with brick coba method internal and external plaster in ( 1:5) cement mortar, brick masonry work in wall in (1:6) white marble flooring over 100 mm thick PCC sanitary and plumbing work in toilet & bath, Glazed tiles upto 7' height, wooden work in doors

& windows, electrical and painting work complete in all respects.

1500 sq.ft. @ Rs. 600/- 9,00,000.00

7. UTILITY BLOCK RCC framed structure in M-20 cement concrete in coloums, beams and roof slab,waterproofing of roof with brick coba method internal and external plaster in (1:5) cement mortar, glazed tile of approved brand upto 7' height, brick masonry work in wall in (1:6) cement

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motor wooden work in doors & windows, electrical and painting work complete in all respects.

3500 sq.ft.@ Rs.600/- 21,00,000.00

8. PACKING MATERIAL STORE RCC framed structure in M-20 cement concrete waterproofing of roof with brick coba method internal and external plaster in (1:5) cement mortar, upto 15 mm thick IPS flooring with trimix vaccume dewatering cement concrete, wooden work in doors & windows, electrical and painting work complete in all respects.

1800 sq.ft. @ Rs. 450/- 8,10,000.00

9. BOUNDARY WALL Earth work in excavation, PCC in 1:4: brick masonry work in (1:6) cement morter, both side plaster in (1:6) cement morter.

450 R/M @ Rs. 2400/- 10,80,000.00

10. ROAD WORK Earth work in cutting and filling stone soling 200mm thick, compacted with road roller and 150mm thick RCC with trimix vaccume dewatering concrete.

25,375 sq.ft. @ Rs. 120/- 30,45,000.00

TOTAL = 1,75,00,000.00

PLANT LAY OUT

+--------------------------------------------------------------+

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| || || || || +----------------------------------------------+ || | | | || | - RAW MATERIALS - || | - STORAGE - || | | | || | | | || | WORKING AREA/SHED |---------------| || | | | || | - FINISHED - || | - PRODUCTS - || | | STORAGE | || | | | || | |---------------| || | | | || | | | || | |ADMINISTRATIVE | || | | BLOCK | || |-------+ - | || | - - | || |TOILET - | | || +----------------------| |------| |----------+ || || || || || || +---------------+ || | METER | GUARD | |+-----| GATE |-----------------------------------| GATE |--+

PLANT & MACHINERY SUPPLIERS

REFRIGERATION & COLD STORAGE PLANT

NEPTUNE REFRIGERATION COMPANY PVT LTD.

502, Arun Chambers,

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Tardeo Road,

Mumbai-34

Tel: 022-23523553/23516321

Fax: 022-23514363

E-mail: [email protected]

Website: www.neptunerefrigeration.com

Regd. Office:

153,Mount Road,

Chennai-600002

Tel: 2846-0422

Fax: 28460581

E-mail: [email protected]

SINGHSONS REFRIGERATION

115, Hiranandani Indl. Estate,

Kansur Marg,

Mumbai-400078

Tel: 25782450

Fax: 25791775

E-mail: [email protected]

SUPER SALES INDIA

2853, Peepal Mahadev,

Hauz Qazi,

Delhi-110006

Tel: 23264001

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Fax: 23243246

E-mail: [email protected]

EFFLUENT TREATMENT & POLLUTION CONTROL EQUIPMENTS

GLOBAL ENVIRO CONSULTANTS

C-15,

Sector-15,

IInd Floor,

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MILO Complex,

Vasundhara,

Ghaziabad,

(U.P.)

Tel-0120-3943689

Mobile: 9810317145

MEMBRANE FILTRATION SYSTEMS PVT LTD.

265, Udyog Vihar,

Phase-I,

Gurgaon-1221016

Tel: 0124-2343578

Fax: 0124-5005255

E-mail: [email protected]

AIRFILT TECHNOLOGIES PVT LTD.

C-51, Basant Bali Nagar,

New Delhi-15

Tel: 25162303

Fax: 25432191

E-mail: [email protected]

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ENVIRO ANALYSTS & ENGINEERS (P) LTD.

7/8, Divine Shereton Bhy,

Mumbai-105

Tel: 28163569

Fax: 28163461

E-mail: [email protected]

MEAT PROCESSING PLANT

CHEN GALVA ENGINEERS LTD.

405,

Shashank Residency Street,

No.11,

Tamaka,

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Hyderabad-17

Tel: 40-27017397

Fax: 40-27018517

E-mail: [email protected]

RAW MATERIAL SUPPLIERS

TO BE PROCURED FROM LOCAL SLAUGHTER HOUSE/PROCESSED HOUSE

AVI'S EXPORTS

D-9,

Jangpura,

Extn.-1,

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New Delhi-14

Tel: 24317100

Fax: 25532342

E-mail: [email protected]

FINE SEAFOODS & MEAT EXPORTS PVT LTD.

G-2,

Plot - A/84,

Rampuri,

Surya Nagar,

Ghaziabad

Tel: 120-2920536

Fax: 120-2614222

E-mail: [email protected]

MIKI EXPORTS INTERNATIONAL

Jail Road,

Meerut-250001

Tel: 121-2762416

Fax: 121-2763885

E-mail: [email protected]

UNITED EXPORTS

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22/24,

F-Block,

Sitaram Bldg.,

Mumbai-1,

Tel: 22-23473118

Fax: 22-23431844

E-mail: [email protected]

GUIDELINES FOR APPLICANTS FOR OBTAINING IS/ISO

INTRODUCTION

The Bureau of Indian Standards, the National Standards Body of India has been guiding the Indian industry for more than four decades by formulation of national standards and operation of product certification scheme. In the wake of international trends and competitiveness taken new dimensions, the Bureau of Indian Standards (BIS) has introduced the Quality Systems Certification Scheme according to IS/ISO 9000 family of

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standards. These standards are adoption of and identical to the internationally accepted ISO 9000 family of standards on quality management systems.

These guidelines contain useful information on processing of an application, procedure for grant of licence, obligations and responsibilities of the firms interested in obtaining licences to relevant model according to IS/ISO 9000 family of standards.

These guidelines are in the nature of extracted information from the applicable regulations. For complete details, reference is to be made to BIS (Certification) Regulations, 1988 - Amended upto 1991.

The Scheme envisage grant of Quality Systems Certification licence to firms according to three Quality systems Models, as under:

Model I - IS/ISO 9001

Quality Systems - Model for Quality Assurance in Design, Development, Production, Installation and Servicing

IS/ISO 9001 should be selected and used when the need is to demonstrate the supplier's capability to control the processes for design as well as production of conforming product. The requirements specified are aimed primarily at achieving customer satisfaction by preventing non-conformity at all stages from design through to servicing. IS/ISO 9001 specifies a quality

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assurance model for this purpose.

Model II - IS/ISO 9002

Quality Systems - Model for Quality Assurance in Production, Installation and Servicing

IS/ISO 9002 should be selected and used when the need is to demonstrate the supplier's capability to control the processes for production of conforming product. IS/ISO 9002 specifies a quality assurance model for this purpose.

Model III - IS/ISO 9003

Quality Systems - Model for Quality Assurance in Final Inspection and Test

IS/ISO 9003 should be selected and used when conformance to specified requirements is to be assured by the supplier solely at final inspection and test. IS/ISO 9003 specifies a quality assurance model for this purpose.

HOW TO OBTAIN LICENCE

Application and its Processing

Firms interested in obtaining licence for quality systems as per the IS/ISO 9000 family of standards should ensure that they are operating quality system in accordance with relevant standard. They should apply on the prescribed proforma in triplicate (Form-III) at the nearest Regional office of BIS alongwith prescribed application fee as applicable. The schedule of fee is given at Annexure 1. The application fee is non refundable.

The application is to be signed by the proprietor, partner or the Chief Executive officer (CEO) of the firm or any other person authorized to sign any declaration on behalf of the firm.

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The name and designation of the person signing the application must be recorded legibly in a space set apart for the purpose in the application form.

Each application must be accompanied by a supplementary questionnaire (Form-IV) duly filled in alongwith the documented quality system (such as quality manual, quality plan etc.0 prepared by the firm. The documented quality system shall be in line with the requirements of the relevant quality system standard.

If necessary, BIS shall provide to the applicant further information about the scheme and also ask for further information from the applicant.

BIS reserves the right to reject an application which is incomplete and does not fulfill one or more of following requirements:

i) Application fee not accompanying the applications;

ii) Application form is incomplete;

iii) Annexures to the application are not clear.

The reason for rejection of the application shall be communicated to the applicant by BIS.

BIS will acknowledge the receipt of the application and application fee. Every application will be given serial number to be known as `Application Number'. In all future correspondence, reference must be made to the `Application Number'.

Adequacy Audit

After the application has been accepted, the documented quality system (Quality Manual/Quality Plan etc.) shall be examined by the BIS for verifying the conformance to relevant standard. Any significant omissions or deviations from the prescribed requirements intimated by BIS will have to be corrected by the applicant and BIS advised accordingly to process the application further.

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Preliminary Visit

BIS official(s) may make a visit to the premises of the applicant to acquaint himself/themselves of the size, nature of the operation and firm's readiness for the audit. The number of the auditors for audit and its duration will vary according to the size and nature of operation of the firm being assessed.

Assessment Fee

Assessment fee will be payable in advance, estimate of which will be provided by BIS, depending upon the man-days expected to be spent on the audit of the firm and the anticipated expenses for travel/stay etc.

Assessment

An Audit team for BIS will visit the firms for assessment of the firm's compliance to the procedures and activities enumerated in the documented quality system and relevant quality systems standard.

The Assessment will comprise the following sequence:

a) Opening Meeting -- The meeting will be conducted by the leader of the audit team in which the Chief Executive Officer (CEO) of the company, the management representative and heads of all the departments being audited are expected to be present. During this meeting, the leader will explain the scope and extent of the audit and the important terms used in the assessment.

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b) Conduct of Assessment -- Each auditor should be accompanied by a guide who is conversant with the activities of the department(s) the auditor is auditing. Observations recorded by the auditors must be signed by the guide as a token of acceptance.

c) Closing meeting and report

i) All the members present in the opening meeting should preferably be present in the closing meeting as well when the audit team will present their findings to the firm.

ii) The non conformities observed by the audit team will be handed over to the firm at the end of each day for necessary corrective action.

iii) Time frame for the corrective action(s) will be decided by the firm.

iv) The non-conformity reports will be signed by Management Representative or authorized signatory as a token of acceptance.

RESPONSIBILITIES OF APPLICANT DURING THE AUDIT

The firm is expected to provide following assistance to the audit team during the audits:

a) Arrangements of stay, local guidance and travel arrangements etc.

b) The CEO and the Management Representative of he company must be present during the opening and closing meetings. As far as possible, all responsible personnel of the company whose departments are being audited should be present in these meetings.

c) In the interest of the firm, all efforts should be made that time of the audit team is not wasted on account of non availability of relevant personnel, documents, records, shut down of unit(s) being audited etc.

d) The firm will arrange a place/room where members of the audit team can meet and discuss during the day and at the

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end of the day to exchange their notes and findings.

Before grant of licence to the firm be considered, corrective actions taken by the firm on the non conformities observed during the audit will have to be verified by BIS. This may call for a follow up audit, full or partial, as the case may be.

Before a licence is granted to the applicant, they shall give the following undertaking:

"We shall make no claim direct or implied that the licence to be granted relates to any products or processes other than those that will be set out in the licence and the Schedule."

Based on the findings of the audit team and satisfactory report, firm will be granted a licence by BIS.

Grant of Licence

The licence shall be granted for a period of three years.

Grant of licence will be followed by surveillance visits once in six months by the auditor(s) of BIS to verify the effective implementation and maintenance of the quality system established by the firm.

During the operation of licence, when a licensee fails to observe the conditions of the Quality Systems Certification Scheme or where there have been significant changes in the organization of he licensee, licence of the firm is liable to be suspended and may call for special visits for which firm is liable to pay special visit charges, as set out in schedule of fees.

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RENEWAL, DEFERMENT, EXPIRY AND CANCELLATION O LICENCE

Any licence granted automatically expires at the end of he period for which it is granted. A renewal notice will be issued to the licensee by the concerned regional office of BIS about

four months before the expiry of he current operative period. The licensee is required to submit the renewal application along with the original copy of the licence atleast three months in advance before the expiry of the licence which will be followed by a complete audit of quality system of the firm.

If some discrepancies are found during the audit, the licensee will be asked to take corrective action. After the licensee has taken necessary action to remove discrepancies, the Quality Systems Certification licence will be renewed for a period of three years.

OBLIGATIONS OF LICENSEE

A licensee on grant of certification for quality system will:

a) Only claim that he is holding a licence in respect of the capability which is the subject of the licence and which relates to the products or process in accordance with the licence requirements.

b) Not use the licence in any manner to which the BIS may object and shall not make any statement concerning the authority of the licensee's use of the licence which in the opinion of the BIS may be misleading.

c) Submit to the BIS for approval the way in which he proposes to use the licence or proposes to make references to the licence.

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d) Not make any change to the Quality System which form the basis for the grant of the licence and which prevents it compliance with the Scheme without prior approval of the BIS.

e) Upon suspension or termination of the licence, however determined, discontinue its use forthwith and withdraw all promotional and advertising matter which contains any reference thereto.

f) Submit to the BIS any amendments to the Quality Manual and/or Quality Plan.

g) Document all changes made to the Quality System and make records of such changes available to Bureau's designated officers on request. A change in key personnel in relation to quality assurance, key technological functions or significant changes in the organization of the licensee, licence of the firm is liable to be suspended and may call for special visits for which firm is liable to pay special visit charges, as set out in schedule of fees.

h) Permit access to BIS officer(s)/team(s) appointed by the BIS for purposes of assessment, audit or surveillance. Licensee shall give full details of all actions taken in response to field problems arising from allegations of licence and allow BIS officers access to all relevant records and documents for the purpose of verifying such details.

j) Be required to produce evidence of continuing operations for the products or processes covered by the licence. Licensee shall notify the BIS in writing of discontinuance in such operations exceeding three months. Discontinuance of operations in excess of six months or more may lead to cancellation of the licence. In such cases, a fresh application shall be lodged with the BIS.

k) Pay all financial dues to the Bureau, as prescribed even for the period during which the operation of the licence remains discontinued by him or suspended by the BIS.

m) Operate and maintain procedures for handling and recording

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of complaints and shall report any complaints against the quality system operated and or licence to BISQSCS. Cooperate and assist BISQUSCS on the investigation and resolution of such complaints.

n) Operate within the provisions of he BIS Act 1986 Rules, 1987 BIS (Certification) Regulations, 1988 amended up to 1991 and Certification Scheme Procedure for grant of licence.

PRIVILEGES OF LICENSEE

The privileges enjoyed by BIS licensees include:

a) Original Quality System Certification licence which can be demonstrated by the licensees to anyone concerned. If need be it can be photocopied & displayed at various locations.

b) A very attractive plaque containing details of certification is presented as a compliment at the time of award of certificate. Additional plaques can also be provided by BIS on actual cost payment basis.

c) Use of Quality Systems Certification Mark on letter-heads in advertisements, brochures, complimentaries and for other promotional purposes. However, Standard Mark shall not be directly applied on the product and its packaging so as to imply that product itself is certified by BIS.

d) Each licensee shall be listed in the register of licensees maintained by BIS.

APPEALS

Under the Provisions of BIS Act 1986, any decision taken in respect of granting, withholding, renewal, suspension or cancellation of certification under the Bureau of Indian Standards Quality Systems Certification Scheme (BIS QSCS) can be appealed against. The appeal shall be made formally in writing not later than 90 days form the date of intimation of the decision by BIS QACS, to Appeals Committee. Verdict of the

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Appeals Committee shall be final. For the Procedure and guidelines for making an appeal contact Director (Quality Systems) at BIS Headquarters, 9 Bahadur Shah Zafar Marg, New Delhi - 110 002.

PROCESS OF QUALITY SYSTEMS CERTIFICATION

+-------------------+ +--------------->| APPLICANT | | +-------------------+ | | | V | +-------------------+ | | SUBMISSION | | | OF APPLICATION | | +-------------------+ | | | V | SEEK MORE +-------------------+ +----------------| SCRUTINY BY BIS |--------- REJECT INFORMATION +-------------------+ | V Accepted +-------------------+ | ADEQUACY AUDIT | +-------------------+

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| V +-------------------+ | PRELIMINARY VISIT | AFTER +-------------------+ +------------------------->| | CORRECTIVE V | ACTION +-------------------+ | | AUDIT TEAM | | | APPOINTMENT | | +-------------------+ | |+--------------+ V| APPLICANT | +-------------------++--------------+ | AUDIT | | +-------------------+ | | | V | CORRECTIVE +-------------------+ +----------------| AUDIT REPORT | ACTION REQD +-------------------+ |

CONT......

| V Satisfactory +-------------------+ | RECOMMENDATIONS | | FOR AWARD OF | | CERTIFICATE | +-------------------+ | V +-------------------+ | CERTIFICATE | | GRANTED | +-------------------+ | V +-------------------+ | SURVEILLANCE | +-------------------+ | V +-------------------+ | RENEWAL | +-------------------+ |

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V

ANNEXURE 1

SCHEDULE OF FEES FOR QUALITY SYSTEMS CERTIFICATION

Quality Systems Models : IS/ISO 9001

IS/ISO 9002

IS/ISO 9003

APPLICATION FEE

Application fee shall be 15,000/- (Rs. 10,000/- for each subsequent unit to first unit of an organization or a corporate body).

Small Scale Industry -- Application fee shall be Rs. 10,000/- for all units.

The application fee includes the adequacy audit of documented Quality System and preliminary visit fee. However,

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expenses for travel/stay of auditor(s) for preliminary visit will be charged at cost.

ASSESSMENT FEE & REASSESSMENT FEE

Rs. 3,000/- per auditor(s) per day towards assessment fee plus expenses for travel/stay of auditors which will be charged at cost. Normally assessment time would be six to nine mandays (for example three auditors for three days). However this is flexible and would depend upon the quality system model and the size & nature of operation of the company.

LICENCE FEE

For all the three models, the licence fee for a period of three years shall be Rs. 60,000/- (Rs. 40,000/- for each subsequent unit to first unit of an organization or a corporate body).

Small Scale Industry -- Licence fee for all three models for a period of three years shall be Rs. 40,000/- for all units.

The licence fee is payable at the time of grant of licence. However, charges for surveillance audits will be extra, towards mandays spent (Rs. 3,000/- per manday) plus expenses for travel/stay for auditors which will be charged at cost.

REASSESSMENT FEE FOR RENEWAL

The fee is payable once in three years and an amount of Rs. 3,000/- per auditor per day towards assessment fee plus expenses for travel/stay of auditors will be charged at cost.

SPECIAL VISIT FEES

Any other audit or special visit will be charged at Rs. 3,000/- per auditor per day towards fee plus expenses for

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travel/stay of auditors which will be charged at cost. Above charges will be leviable for any other visit covering additional requirement which cannot be assessed during routine visits.

EFFECTIVE DATE

This schedule of fees will be applicable to licences granted/renewed with effect from 11 March 1998.

REVIEW OF FEES

Fees are subject to review periodically.

NOTE : BIS reserves the right to revise the terms & conditions and fees as and when necessary, without notice

PRINCIPLES OF PLANT LAYOUT

Some of the guiding principles for detailed plant layout will be discussed for the benefit of those making layout decisions for the first time.

Storage Layout: Storage facilities for raw materials and intermediate and finished products may be located in isolated areas or in adjoining areas. Hazardous materials become a decided menace to life and property when stored in large quantities and should consequently be isolated. Storage in adjoining areas to reduce materials handling may introduce an obstacle toward future expansion of the plant. Arranging storage of materials so as to facilitate or simplify handling is also a point to be considered to design. Where it is possible to pump a single material to an elevation so that subsequent handling can be accomplished by gravity into intermediate reaction and storage units, costs may be reduced. Liquids can be stored in small containers, barrels,s horizontal or vertical tanks and vats, either indoors or out of doors.

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Equipment Layout: In making a layout, ample space should be assigned to each piece of equipment; accessibility is an important factors for maintenance.

It is extremely poor economy to fit the equipment layout too closely into a building. A slightly larger building

than appears necessary will cost little more than one that is crowded. The extra cost will indeed be small in comparison with the penalties that will be extracted if, in order to iron out the kines, the building must be expanded.

The operations that constitute a process are essentially a series of unit operations that may be carried on simultaneously. These include filtration, evaporation, crystallization, separation, and drying. Since these operations are repeated several times in the flow of materials,k it should be possible to arrange the necessary equipment into groups of the same kinds possible to arrange the necessary equipment into groups of the same kinds. This sort of layour will make possible a division of operation labor so that one or two operators can be detailed to tend all equipment of a like nature.

The relative levels of the several pieces of equipment and their accessories determine their placement. Although gravity flow is usually preferable, it is not altogether necessary because liquids can be transported by blowing or by pumping, and solids can be moved by mechanical means. Gravity flow may be siad to acost nothing to operate, whereas the various mechanical means of transportation involve the first cost of the necessary equipment and the cost of operation and maintenance. But material must be elevated to a level where gravity flow must start. However, gravity flow usually means a multistory layout, whereas the factors favoring a single-story plant may largely, if not entirely, compensate for the cost of mechanical transportation.

Access for intial construction and maintenance is a necessary part of planning. for example, overhead equipment must have space for lowering into place, and heat-exchange equipment should be located near access areas where trucks or hoist can be placed for pulling and replacing tube bundles. Thus, space should be provided for repair and replacement equipment, such as cranes and forked trucks, as well as access way around doors and underground hatches.

Safety: A great deal of planning is governed by local and national safety and fire code requirements. Fire protection consisting of reservoirs, mains, hydrant, hose houses, fire

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pumps, reservoirs, sprinklers in building, explosion barriers and directional routing of explosion forces to clear areas, and dikes for combvustible-product storage tanks must be incorporated to protect costly plant investment and reduce insurance rates.

Plant Expansion: Expansion must always be kept in mind. The question of multiplying the number of units or increasing the size of the prevailing unit merits more study than it can be given here. Suffice it to say that one must exercise engineering judgement; that as a penalty for bad judgement, scrapping of present serviceable equipment constitutes but one phase, for shutdown due to remodeling may involve a greater loss of money than that due to rejected equipment. Nevertheless, the cost of change must sometimes be borne, for the economies of larger units may, in the end, make replacement imperative.

Floor Space: Floor space may or may not be a major factor in the design of a particular plant. The value of land may be a considerable item. The engineers however, follow the rule of practicing economy of floor space, consistent with good housekeeping in the plant land with proper consideration given to line flow of materials, access to equipment, space to permit working on parts of equipment that need frequent servicing, and safety and comfort of the operators.

Utilities Servicing: The distribution of gas, air, water, steam, power, and electricity is not always a major item, inasmuch as the flexibility of distribution of these serivces permits designing to meet almost any condition. But a little regard for the proper placement of each of these services, practicing good design, aids in ease of operation, orderliness, and reduction in costs of maintenance. No pipes should be laid on the floor or between the floor and the 7-ft level, where the operator must pass or work. Chaotic arrangement of piping invites chaotic operation of the plant. The flexibility of standard pipe fittings and power-transmission mechanisms renders this problem one of minor diffculty.

Building: After a complete study of quantitative factors, the seletion of of the building or buildings must be considered.

Standard factory buildings are to be desired, but, if none can be found satisfactory to handle the space and process requirements of the chemical engineer, then a competent architect should be consulted to design a building around the process - not a beautiful structure into which a process must fit. It is fundamental in chemical engineering industries that the buildings should be built arount the process, instead of the process being made to fit building of conventional design.

In many cases only the control area requires housing, with the process equipment eracted outdoors. This is known as outdoor consturction and such layouts should be considered for

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many types of plants. What consideration must be given to buildings depends upon conditions. If the designer must adapt his design to fit an old building or building space already erected, his problem is cut out for him and he was limiting conditions. However, the selection of the design of a new building to meet the requirements of the process is more scientific. In this case, one finds before him practically all types of standard building, built in units, interlocking or otherwise, ready for shipment and erection.

Throughout chemical industry, much thought must be given to the disposal of waste liquors, fumes, dusts, and gases. Ventilation, fume elimination, and drainage may require the installation of extra equipment. This may involve the design of the individual pieces of operating equipment, or it may require the installation of isolated equipment. If the latter be the case, the location of such equipment where it will be interfere with the flow of materials in process should be practiced. The selection of the proper piece of equipment for doing this service is also an important point; the less attention the ventilating, fume, or waste-elimination systems require, the better service they may render. Sometimes air conditioning of the plant is called for an may required an elaborate setup. But the installation of such equipment, when needed, pays in better service from operators, less discomfort, greater production, and a better morale than when such conditions are left to nature.

It must be recognized that there is not only one solution to the problem of layout of the equipment. There are many rational designs. Which plant to adopt must be decided upon after exercise of engineering judgement and after striking a balance job the advantages and disadvantages of each possible choice.

Material-handling Equipment: Consideration of equipment for materials handling is only a minor factor in most cases of arrangement, owing to the multiplicity of available materials-handling devices. But where this operation is paramount in a process, serious thought must be given to it. Again it should be said that engineering judgement must be exercised. Whenever possible, one should take advantage of the topography of the site location, one should take advantage in the process.

Railroads and Roads: Existing or possible future railroads and highways adjacent to the plant must be known in order to plan rail siding and access roads within the plant. Railroad spurs and roadways of the correct capacity and at the right location should be provided for in a traffic study and over-all master track and road plan of the plant area. Some of the factors in rail-track planning are:

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1. Existing and future off-site main rail facilities

2. Permissible radius of curvature for spurs - consult local rail authorities.

3. Provision for traffic handling - arrangement of spurs and ladder track and switching.

4. Adequate spur facilities

a. Loading and unloading facilities for initial plant construction and subsequent operations.

b. Rack stations for liquid handling

c. Storage space for full and empty cars

d. Space for cleaning and car repairs.

Major provisions in road planning for multipurpose service are:

1. A means of interplant movement for road traffic, both pedestrian and vehicular

2. Heavier and wider roads for large-scale traffic

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3. Routing of heavy traffic outside the operational areas

4. Roadways for access to initial construction, maintenance, and repair points

5. Roadways to isolated points, storage tanks, and safety equipment, such as fire hydrants.

PLANT LOCATION FACTORS

Factors which generally apply to the economic and operability aspect of plant site location are classified into two major groups. The primary factors listed apply to choice of a region, whereas the specific factors looked at in choosing an exact site location within the region. All factors are important in making a site location selection.

Primary Factors

1. Raw-material supply:

a. Availability form existing or future suppliers

b. Use of substitute materials

c. Distance

2. Markets:

a. Demand versus distance

b. Growth or decline

c. Inventory storage requirements

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d. Competition - present and future.

3. Power and fuel supply:

a. Availability of electricity and various type of fuel

b. Future reservers

c. Costs

4. Water supply:

a. Quality - temperature, mineral content, bacteriological content

b. Quantity

c. Dependability - may involve reservoir construction

d. Costs

5. Climate:

a. Investment required for construction

b. Humidity and temperature conditions

c. Hurricane,a tornado, and earthquake history

Specific Factors

6. Transportation:

a. Availability of various services and projected rates

1. Rail - dependable for light and heavy shipping over all distances

2. Highways - regularly used for short distance and generally small quantities

3. Water - cheaper, but may be slow and irregular

4. Pipeline - for gases and liquids, particularly for

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petroleum products

5. Air - for business transportation of personnel

7. Waste disposal:

a. Regulations laws

b. Stream carry-off possibilities

c. Air-pollution possibilities

8. Labor:

1. Availability of skills

2. Labor relations - history and stability in area

3. Stability of labor rates

9. Regulatory laws:

a. Building codes

b. Zoning ordinances

c. Highway restrictions

d. Waste-disposal codes

10. Taxes:

a. State and local taxes

1. Income

2. Unemployment insurance

3. Franchise

4. Use

5. Property

b. Low assessment or limited term exemptions to attract industry

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11. Site characteristics:

a. Contour of site

b. Soil structure

c. Access to rail, highway, and water

d. Room for expansion

e. Cost of site

f. Site and facilities available by expansion on present company-owned property

12. Community factors:

a. Rural or Urban

b. Housing costs C. Cultural aspects - churches, libra ries, theaters

d. School system

e. Recreation facilities

f. Medical facilities - hospitals, doctors

13. Vulnerability to wartime attack:

a. Distance form important facilitics

b. General industry concentration

14. Flood and fire control:

a. Fire hazards in surrounding area

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b. Floor history and control

EXPLANATION OF TERMS USED IN THE PROJECT REPORT

1. DEPRECIATION:

This represents reduction in the utility and value of a capital asset because of wear and tear, lapse of time, obsolescence etc. The use of an asset helps in the generation of revenue for the business. A part of the cost of the asset, estimated to be equal to the reduction in the utility and economic life of the asset, because of its use, is charged off by way of depreciation charge against such revenue to arrive at the true profits.

2. FIXED ASSETS:

Represent those assets which remain permanently (till their useful lives) with the business and are not meant for resale. These assets are acquired for use in the operation of business and help in the generation of revenue for the business. These include land and building, plant and machinery etc.

3. WORKING CAPITAL:

This represents the total expenses on Raw materials, utilities & overheads, and salaries & wages, for a specified period of time.

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4. BREAK-EVEN POINT:

This represents the level of output and sales at which the firm is able to recover all its expenses-both fixed and variable. In other words it indicates the level of output and sales at which the firm is neither making profit nor incurring any loss. Level of output more than the Break-Even Level generates profit for the firm.

5. OTHER FIXED EXPENSES:

These represent expenses which remain fixed irrespective of changes in level of output. In other words these are the expenses which the firm has to incur whether there is production or not. These include expenses such as preliminary and Preoperative expenses, Insurance and Freight, Technical Know-how and Consultancy, Erection & Commissioning etc.building, insurance, etc.

6. MARGIN MONEY:

This represents that part of the cost pf project which the promoter has to meet from his own resources. This is the contribution which the promoter must make to the equity of the project for becoming eligible for assistance from financial institutions/Banks.

7. TERM LOANS: Represent Loans which are repayable over a long period of time. These loans are meant for meeting capital expenditure of the project.

8. TOTAL LOAD:

It is the ratio of the maximum power consumed in KWH in a particular period of time to the number operating hours of the unit in that particular period.

Power Consumed in KWH Total Load = (--------------------------) in a particular No. of operating hours of period of time the unit

9. LAND AREA/MAN POWER RATIO:

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It is the ratio of manpower utilised per unit area of land required for operating the unit. + + | Land Area | Land Area/Man Power Ratio = | ---------------- | | No. of persons | | Working on the unit| + +

ADDRESSES OF STATE INDUSTRIAL DEVELOPMENT CORPORATIONS

1. M/s. A P Industrial Development Corporation,

Parisrama Bhavanam, Basheerbagh, Hyderabad 500029.

2. M/s. A P Electronics Development

Corporation Ltd,

Parisrama Bhavanam,

Basheer Bagh,

Hyderabad 500029.

3. M/s. Assam Industrial Development Corpn Ltd , Zoo Road,

Gauhati 781021.

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4. M/s. Bihar State Industrial Development Corporation, Biscomaun Building,

West Gandhi Maidan,

Patna - 800001.

5. M/s. Delhi State Industrial Development

Corporation,

Life Insurance Building,

Connaught Place,

New Delhi - 110001.

6. M/s. GOA,DAMAN & DIU Industrial

Development Corporation,

Shree Saraswati Mandir Building,

18th June Road, Panaji,

Goa- 403001.

7. M/s. Gujrat Industrial Development

Corporation, Bhavani Chamber,

3rd floor, Ashram Road,

Ahmedabad - 380009.

8. M/s. Haryana State Industrial

Development Corporation,

SCO 40-41, Sector - 17 A

Chandigarh 160017.

9. M/s. Haryana State Electronics

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Development Corporation Ltd,

1556,Sector 18-D

Chandigarh - 160018.

10. M/s. H P Electronics

Development Corporation,

Saligram Bhavan,

Khalini, Shimla 171003.

11. M/s. J & K Industrial

Development Corporation Ltd,

(SIDCO) Drabu House,

Rambagh , Srinagar 190001

12. M/s. Karnataka State Industrial

Development Corporation Ltd,

36, Cunningham Road,

Banglore 560001.

13. M/s. Karnataka State Electronic

Development Corporation Ltd,

Emlyn Haven,

30, Race Course Road,

Banglore 560001.

14. M/s. Kerala State Electronics

Development Corporation,

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Vellayambalam,

Trivandrum 695001.

15. M/s. Maharashtra Electronics

Corporation Ltd,

Raheja Center, Nariman Point, Bombay 400021.

16. M/s. State Industrial and Investment

Corporation of Maharashtra Ltd,

`NIRMAL' , Nariman Point,

Bombay 400021

17. M/s. Maghalaya Industries

Development Corporation,

Shilong,

Meghalaya - 793001.

18. M/s. Orissa State Financial Corporation,

Government of Orissa,

Janpath Bhubneshwar,

Orissa 751001.

19. M/s. Sikkim Industrial Development &

Investment Corporation Ltd,

New Market, Gangtok,

Sikkim.

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20. M/s. U P Financial Corporation ,

14/88, Civil Lines,

Kanpur ,

(U.P) - 208001.

21. M/s. West Bengal Industries

Corporation Ltd,

3rd Floor, 6/A, Raja Subodh Mullick Sq.,

Calcutta 700001.

22. M/s. West Bengal Infrastructural

Development Corporation,

P-34, CIT Road,

Calcutta 700001.

23. M/s.West Bengal Financial Corporation,

12/A, Netagi Subhash Road, Calcutta,

West Bengal- 700001.

24. M/s. Bihar State Industrial

Development Corporation,

Bandar Bagicha,

Patna,

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Bihar - 800001.

25. M/s. Bihar State Electronic

Development Corporation,

Udyog Bhawan, 2nd Floor,

East Gandhi Maidan,

Patna - 800001.

26. M/s. Himachal Pradesh State Electronic

Development Corporation Ltd,

Salig RAm Bhawan, Khalini,

Simla - 171002.

27. M/s. Himachal Pradesh State Industrial

Development Corporation,

`NEW HIMRUS' Building,

Cart Road ,

Simla (H P) - 171001.

28. M/s. Karnataka State Electronics

Development Corporation Ltd,

`EMLYN HAVEN', 30,Race Course Road,

Bangalore

(Karanataka) - 560001.

29. M/s. State Industrial & Investment

Corporation of Maharashtra Ltd., (SICOM)

`NIRMAL'. First Floor,

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Nariman Point,

Bombay - 400021.

30. M/s. Maharashtra Electronics Corpn Ltd.,

Plot No 214, Backbay Reckanmation ,

Raheja Centre, 13th Floor,

Nariman Point, Bombay - 400021.

31. M/s. Industrial Development Corporation

of Orissa Ltd.,

Post Box Nos. - 78,

Bhubneshwar - 751007.

32. M/s. Punjab State Industrial

Development Corporation,

SCO 54,55,56, Sector 17A

Post Box NO 81,

Chandigarh - 160017.

33. M/s. Punjab State Electronics Dev &

Production Corpn Ltd.,

Bank of India Building,

Bank Square, Sector 17-B

Chandigarh - 160017.

34. M/s. Pondicherry Indl Promotion &

Investment Corpn Ltd.,

38 Romain Rolland Street,

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Pondicherry - 605001.

35. M/s. R I I C O,

Udyog Bhawan, Tilak Marg,

Jaipur

(Rajasthan) - 302005.

36. M/s. T N Industrial Investment

Corporation Ltd.,

`ARUL MANAI' , 27, Whites Road,

Madras - 600014.

37. M/s. U P State Industrial

Development Corporation,

117/130, Sarvodya Nagar,

Kanpur ,

(U.P) - 208005.

38. M/s. U P Electronics Corpn Ltd.,

Nav Chetna Kendra, 1st Floor,

10, Ashok Marg,

Lucknow - 226001.

39. M/s. West Bengal Industrial

Development Corporation Ltd.,

23A, Netagi Shubhash Road,

Calcutta - 700001.

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ADDRESSES OF FINANCIAL INSTITUTIONS

1. M/s. Andhra Pradesh State Financial

Corporation,

Chirag Ali Lane,

Hyderabad - 500001.

2. M/s. Assam Financial Corporation ,

R G Barooah Road,

Guwahati,

Assam - 781001.

3. M/s. Bihar State Financial Corporation,

Fraser Road,

Patna - 800001.

4. M/s. Delhi financial Corporation,

Saraswati Bhawan,

E -Block, Cannaught Place,

New Delhi - 110001.

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5. M/s. Haryana Financial Corporation,

17, 18 & 19,

Sector 17 A,

Chandigarh - 160017.

6. M/s. Himachal Pradesh Financial Corporation,

Himrus , Shimla,

Himachal Pradesh - 171003.

7. M/s. State Financial Corporation,

Durga Nag Road,

Opp. Partap Park Srinagar,

(J & K) - 190001.

8. M/s. Karnataka State Financial Corporation,

Shankaranarayan Building,

25, M G Road,

Banglore - 560001.

9. M/s. Kerala Financial Corporation,

Vellayyambalam,

Trivandrum,

Kerala - 695001.

10. M/s. M P Financial Corporation,

Finance House,

Bombay - Agra Road,

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Indore - 432001.

11. M/s. Maharashtra State Financial Corporation, Excelsior Building,

A. K. Nayak Marg,

Bombay - 400036.

12. M/s. Orissa State Financial Corporation,

OMP Square,

Cuttack - 753003.

13. M/s. Punjab Financial Corporation,

Sector 17-B, 95-98 Bank Square,

Chandigarh - 160017.

14. M/s. Rajasthan Financial Corporation,

Udyog Bhawan, Tilak Marg,

C - Scheme,

Jaipur - 302005.

15. M/s. P I C U P,

Jawahar Bhawan (Annexe), 2nd Floor,

Ashok Marg,

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Lucknow ,

(U P).

16. M/s. U P Financial Corporation,

14/88 Civil Lines,

Kanpur - 208001.

17. M/s. WEst Bengal Financial Corporation,

12-A, Netagi Subhash Road,

Calcutta - 700001.

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ADDRESSES OF RELEVANT GOVERNMENT OFFICES

1. M/s. Department of Electronics,

Electronics Niketan,

CGO Complex,

New Delhi - 110001.

2. M/s. Directorate of Technical Development,

Udyag Bhawan,

New Delhi - 110001.

3. M/s. Secretariat For Industrial Approvals,

Ministry of Industry,

Udyaog Bhawan,

New Delhi - 110001.

4. M/s. Directorate General of

International Trade (DGIT),

Ministry of Commerce,

Udyog Bhawan,

New Delhi - 110001.

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SUGGESTED STEPS

ECONOMIC ADVANTAGE IN SETTING UP THE PROJECT IN INDIA

SEQENCE OF EVENTS/CLEARENCES TO BE OBTAINED IN THE IMPLEMENTATION OF THE PROJECT

Preparation of Detailed Project Report

Submission of Memorandum to SIA

Procurement of Land

Tie-up with Collaboration Approval from Govt of India

Application for Import of Capital Goods

Obtaining Loan

Factory Construction

Order placement of plant and machinery

Recruitment of manpower

Marketing arrangements in India and abroad

Commissioning

Trail Run

Commercial Production

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We hope Market Survey Cum Detailed Techno Economic Feasibility Report in your possession at the time, must have conveyed you the elementary idea on process data, market and economics. We feel you must have now taken a decision to finalise your project plan for ultimate implementation in a successful manner. Before you go ahead, we suggest you to take our Practical Project ExecutionKnow-How Report.

"KAT" offer you

PRACTICAL PROJECT EXECUTION KNOW HOW REPORT

on this project. Brief contents of

PRACTICAL PROJECT EXECUTION KNOW HOW REPORT are as under :

---------------------------------------------------------------------------

INTRODUCTION: PLANT & MACHINERY/EQUIPMENTS: * Product Mix * Range of Machineries Required * Individual & Class Study * Detailed Specification of of Products Machineries and Equipments * Suitability Factors for Uses & * Functional Details of Applications Machineries Selected * Uses and Applications * Standard & Special Accessories * Property Assurance to Desired & Attachment Service Conditions * Level of Automation and Controls * Quality Control Measures & their * Manufacturers/Suppliers of Introduction for Attaining Machineries and Equipments Required Properties LAND & BUILDING: * Economy & Productivity Competence * Total Land Area Required MARKET SURVEY: * Covered Area Break-up with * Market Position Estimated Cost of Construction * Installed Capacity, Production * Sector-wise Plant Layout and Anticipated Demand * Locational Advantage * Present Manufacturers RAW MATERIALS: * Statistics of Imports & Exports * Productwise Break-up of * Estimated Demand Raw Materials Requirement * Demand and Supply Gap * Raw Material Specifications PROCESS OF MANUFACTURE: * Raw Material Prices * Inventory Controls & Tests * Manufacturers/Suppliers of * Comparative Study of Process for Raw Materials Manufacturing the Product * Process Detail in stage from Raw Materials to Finished Products * Process Flow Sheet Diagram

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PLANT ECONOMICS/COST ANALYSIS ANNEXURE OF CHARTS * Rated Installed Capacity & * Depreciation Chart Capacity Utilisation (Building, Machines & Other Loans) * Basis of Working 5 to 10 Yrs. * Land & Built-up Area Required * Interest Chart for 5 to 10 Yrs. with their Cost * Repayment Schedule for 5 to 10 Yrs. * Plant & Machinery and * Cash Flow Statement for Other Fixed Assets 5 to 10 Yrs. * Total Fixed Capital Investment * Projected Balance Sheet for * Working Capital Assessment 5 to 10 Yrs. * Raw Materials & Consumable Stores * Land Man Ratio * Staff Salaries & Wages SPECIAL CHAPTERS * Utilities and Overheads * I.S. Specification by Bureau of * Manufacturing Overheads & Utilities Indian Standard (BIS) * Administrative Overheads & * If Imports of Raw Materials/ Utilities Capital Goods/Technical Know-How * Marketing Overheads becomes necessary, Sources given * Marketing Related Staff & Expenses * Details of Foreign Collaborations * Break-up of Product-Mix and * Any Specific benefit intended to Other Receipts be taken (within existing Govt. * Provisions for Power, Water & Fuels Policy frame work) will be duly * Total Cost of Project introduced in the Special * Source of Finance Project Report * Profitability Analysis in view of Turn-Over & Cost of Manufacture * Ratios of Profit of Sales, T.C.I., Cost of Production, Total Fixed Capital etc * Break Even Point Determination ---------------------------------------------------------------------------

Price Rs. 26,250/- (Rs. Twenty Six Thousand Two Hundred & Fifty) only for PRACTICAL PROJECT EXECUTION KNOW-HOW REPORT

PLEASE SEND YOUR CONFIRMED ORDER TO :-

+---------------------------------------------------------------+| | | KAT INDUSTRIAL CONSULTANTS PVT. LTD. || | | HEAD OFFICE || WORLD TRADE CENTRE (38, GROUND FLOOR), BARAKHAMBA LANE, || CONNAUGHT PLACE, BABAR ROAD (NEAR BENGALI MARKET), || ADJACENT TO HOTEL INTER CONTINENTAL, NEW DELHI-110001 (INDIA) || ALSO AT:2/51, ROOP NAGAR, DELHI-110007 || | |PHONE:41528137,23842632,23413183,23411360,9871231144,9868182357|

Page 95: meat processing unit

| FAX : 011 - 23413183 || E-mail : [email protected] || Website : www.katconsultants || | +---------------------------------------------------------------+

MEAT PROCESSING (EOU) [KAT/DPR/9662]J.C.:8540 [W/C: 1 Month] J.C. 8540 Page A- 1

PLANT ECONOMICS

Rated Plant capacity = 25.00 MT/day = 7500.00 MT/annum MEAT

Basis

No. of working days = 25 days/month = 300 days/annum

No. of shifts = 2 per day

One shift = 8 hours

Currency - Rs.

MEAT PROCESSING (EOU) [KAT/DPR/9662]J.C.:8540 [W/C: 1 Month] J.C. 8540 Page A- 2

LAND & BUILDING

1. Land Required 1800 sq.mts. @ Rs. 700/- sq.mt. Rs. 12,60,000.00

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2. Total Builtup Area 1800 sq.mts. in 2-floors (GF+FF) incl.Working Shed, Stores,Office etc.@ Rs.4,000/-sq.mt Rs. 72,00,000.00

3. Boudary Wall,Gate etc. Rs. 5,00,000.00

------------------------ TOTAL Rs. 89,60,000.00 ------------------------

MEAT PROCESSING (EOU) [KAT/DPR/9662]J.C.:8540 [W/C: 1 Month] J.C. 8540 Page A- 3

PLANT & MACHINERY

1. Refrigeration & ProcessingUnit with Cold Storage,Blast & Plate Freezer, Chiller/Deboning,Frozen PackingUnit Rs. 75,00,000.00

2. Effluent Treatment Plant & Pollution Control Equipments Rs. 8,00,000.00

3. D.G. Sets 250 KVA each 2 No. Rs. 20,00,000.00

4. Insulation Cost Rs. 12,00,000.00

5. Other Miscellaneous Eqpts. Rs. 5,00,000.00

------------------------ TOTAL Rs. 1,20,00,000.00 ------------------------

MEAT PROCESSING (EOU) [KAT/DPR/9662]J.C.:8540 [W/C: 1 Month] J.C. 8540 Page A- 4

OTHER FIXED ASSETS

1. Office equipment, furniture plus other equipment & accessories Rs. 75,000.00

2. Installation costs for water, electricity, fuel etc. Rs. 50,000.00

3. Pre-operative & preliminary expenses Rs. 80,000.00

4. Fire Fighting Equipments Rs. 20,000.00

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5. Lab. Equipments Rs. 20,000.00

6. Refrigerated Van Rs. 4,00,000.00

7. Misc. Tools & Equipments Rs. 20,000.00

------------------------ TOTAL Rs. 6,65,000.00 ------------------------

MEAT PROCESSING (EOU) [KAT/DPR/9662]J.C.:8540 [W/C: 1 Month] J.C. 8540 Page A- 5

FIXED CAPITAL

1. LAND & BUILDING Rs. 89,60,000.00

2. PLANT & MACHINERY Rs. 1,20,00,000.00

3. OTHER FIXED ASSETS Rs. 6,65,000.00

------------------------ TOTAL Rs. 2,16,25,000.00 ------------------------

MEAT PROCESSING (EOU) [KAT/DPR/9662]J.C.:8540 [W/C: 1 Month] J.C. 8540 Page A- 6

WORKING CAPITAL REQUIREMENT/MONTH

RAW MATERIALS

1. Raw Meat 600 MT @ Rs. 35,000/- MT Rs. 2,10,00,000.00

2. Packing Materials & Other Consumables Rs. 6,00,000.00

------------------------ TOTAL Rs. 2,16,00,000.00 ------------------------

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MEAT PROCESSING (EOU) [KAT/DPR/9662]J.C.:8540 [W/C: 1 Month] J.C. 8540 Page A- 7

SALARY & WAGES / MONTH

1. Manager cum Food Technologist 1 No. Rs. 20,000.00

2. Supervisor 2 No. Rs. 16,000.00

3. Chemist 1 No. Rs. 6,000.00

4. Typist/Clerk cum Store Keeper 1 No. Rs. 5,000.00

5. Accountant 1 No. Rs. 7,000.00

6. Skilled Workers 8 No. Rs. 48,000.00

7. Semi/Un-skilled Workers 15 No. Rs. 67,500.00

8. Marketing Personnel/Executives 2 No. Rs. 16,000.00

9. Peon/Helpers 5 No. Rs. 17,500.00

10. Guards 3 No. Rs. 10,500.00

11. Misc. Staffs 2 No. Rs. 10,000.00

------------------------ TOTAL Rs. 2,23,500.00

------------------------

Plus perks @ 25% p.a. Rs. 55,875.00

------------------------ TOTAL Rs. 2,79,375.00 ------------------------

MEAT PROCESSING (EOU) [KAT/DPR/9662]J.C.:8540 [W/C: 1 Month] J.C. 8540 Page A- 8

UTILITIES AND OVERHEADS

1. Power Consumption of 80000 Kwatt hrs @ Rs. 5.00 per Kwatt hr. Rs. 4,00,000.00

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2. Water Consumption of 500 KLs @ Rs. 5.00 per KL Rs. 2,500.00

3. Stationery, Postage, Telephone etc. Rs. 5,000.00

4. Conveyance & Transportation etc. Rs. 20,000.00

5. Insurance Professional fees Rs. 3,000.00

6. Publicity & Sales Promotion Rs. 15,000.00

7. Repairs & maintenance Rs. 4,000.00

8. Miscellaneous Rs. 10,000.00

9. Fuel/Oil for D.G.Set, 5,000 ltrs @ Rs. 32/- ltr. Rs. 1,60,000.00

------------------------ TOTAL Rs. 6,19,500.00 ------------------------

Total load is 220 Kwatts

MEAT PROCESSING (EOU) [KAT/DPR/9662]J.C.:8540 [W/C: 1 Month] J.C. 8540 Page A- 9

TOTAL WORKING CAPITAL/MONTH

1. RAW MATERIAL Rs. 2,16,00,000.00

2. SALARY & WAGES Rs. 2,79,375.00

3. UTILITIES & OVERHEADS Rs. 6,19,500.00

------------------------ TOTAL Rs. 2,24,98,875.00 ------------------------

1. WORKING CAPITAL FOR 1 MONTHS Rs. 2,24,98,875.00

2. MARGIN MONEY FOR W/C LOAN Rs. 56,24,718.75

COST OF PROJECT

TOTAL FIXED CAPITAL Rs. 2,16,25,000.00

Page 100: meat processing unit

MARGIN MONEY Rs. 56,24,718.75

------------------------ TOTAL Rs. 2,72,49,718.75

------------------------

MEAT PROCESSING (EOU) [KAT/DPR/9662]J.C.:8540 [W/C: 1 Month] J.C. 8540 Page A- 10

TOTAL CAPITAL INVESTMENT

TOTAL FIXED CAPITAL Rs. 2,16,25,000.00

TOTAL WORKING CAPITAL FOR 1 MONTHS Rs. 2,24,98,875.00

------------------------ TOTAL Rs. 4,41,23,875.00

------------------------

MEAT PROCESSING (EOU) [KAT/DPR/9662]J.C.:8540 [W/C: 1 Month] J.C. 8540 Page A- 11

COST OF PRODUCTION/ANNUM

1. Working Capital for 1 year Rs.26,99,86,500.00

2. Interest @ 12.00% on T.C.I Rs. 52,94,865.00

3. Depreciation @ 6.50% on buildings Rs. 5,00,500.00

4. Depreciation @ 25.00% on Plant and Machinery Rs. 30,00,000.00

5. Depreciation @ 20.00% on office equipment & furnitures Rs. 15,000.00 ------------------------ TOTAL Rs.27,87,96,865.00 ------------------------

Page 101: meat processing unit

MEAT PROCESSING (EOU) [KAT/DPR/9662]J.C.:8540 [W/C: 1 Month] J.C. 8540 Page A- 12

TURN OVER/ANNUM

1. By sale of 7,500 MT of Processed & Packed Meat (Frozen) @ Rs. 40,000/- MT (avg.) Rs.30,00,00,000.00

------------------------ TOTAL Rs.30,00,00,000.00 ------------------------

PROFIT = RECEIPTS - COST OF PRODUCTION

= 30,00,00,000.00 - 27,87,96,865.00

= 2,12,03,135.00

PROFIT SALES RATIO = Profit / Sales x 100

2,12,03,135.00 = ------------------------------ X 100 30,00,00,000.00

= 7.07 %

RATE OF RETURN = Operating profit / T.C.I x 100

2,12,03,135.00 = ------------------------------ X 100 4,41,23,875.00

= 48.05 %

MEAT PROCESSING (EOU) [KAT/DPR/9662]J.C.:8540 [W/C: 1 Month] J.C. 8540 Page A- 13

BREAK EVEN POINT (B.E.P)

Fixed Costs of the plant are as under -

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1. Interests Rs. 52,94,865.00

2. Depreciation Rs. 35,15,500.00

3. 40.00% of salaries Rs. 13,41,000.00

4. 40.00% of overheads Rs. 29,73,600.00 ------------------------ TOTAL Rs. 1,31,24,965.00 ------------------------

FIXED COSTS B.E.P. = ------------------------------ X 100 FIXED COSTS + PROFIT

1,31,24,965.00 = ------------------------------ X 100 1,31,24,965.00 + 2,12,03,135.00

= 38.23 %

LAND MAN RATIO = Total land / Manpower

1800 : 41 :: 44 : 1

MEAT PROCESSING (EOU) [KAT/DPR/9662]J.C.:8540 [W/C: 1 Month] J.C. 8540 Page A- 14

RESOURCES FOR FINANCE

1. Term loans from Financial institutions ( 80.00 % of fixed capital ) at @12.00% p.a rate of interest Rs. 1,73,00,000.00

2. Bank loans for 3 months ( 75.00 % of working capital ) at @ 12.00% p.a rate of interest Rs. 1,68,74,156.25

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3. Self raised capital from even funds & loans from close ones to meet the margin money needs at a @ 12.00% p.a rate of interest Rs. 99,49,718.75

-------------------------- TOTAL Rs. 4,41,23,875.00 --------------------------

MEAT PROCESSING (EOU) [KAT/DPR/9662]J.C.:8540 [W/C: 1 Month] J.C. 8540 Page A- 15

INSTALMENT PAYABLE IN 5 YEARS

================================================================================ Year To Financial To Commercial To others Total institutions banks (Rs. 17300000) (Rs. 16874156) (Rs. 9949719) ================================================================================ 1 34,60,000.00 33,74,831.25 19,89,943.75 88,24,775.00 2 34,60,000.00 33,74,831.25 19,89,943.75 88,24,775.00 3 34,60,000.00 33,74,831.25 19,89,943.75 88,24,775.00 4 34,60,000.00 33,74,831.25 19,89,943.75 88,24,775.00 5 34,60,000.00 33,74,831.25 19,89,943.75 88,24,775.00 ================================================================================

INTEREST PAYABLE IN 5 YEARS

================================================================================ Year On term loans On bank loans On self loans Total (Rs. 17300000) (Rs. 16874156) (Rs. 9949719) @ 12.00 % P.A. @ 12.00 % P.A. @ 12.00 % P.A. ================================================================================ 1 20,76,000.00 20,24,898.75 11,93,966.25 52,94,865.00 2 16,60,800.00 16,19,919.00 9,55,173.00 42,35,892.00 3 12,45,600.00 12,14,939.25 7,16,379.75 31,76,919.00 4 8,30,400.00 8,09,959.50 4,77,586.50 21,17,946.00 5 4,15,200.00 4,04,979.75 2,38,793.25 10,58,973.00 ================================================================================

TOTAL REPAYMENT SCHEDULE FOR 5 YEARS

================================================================================ Year Interest Instalments Total ================================================================================ 1 52,94,865.00 88,24,775.00 1,41,19,640.00 2 42,35,892.00 88,24,775.00 1,30,60,667.00 3 31,76,919.00 88,24,775.00 1,20,01,694.00 4 21,17,946.00 88,24,775.00 1,09,42,721.00 5 10,58,973.00 88,24,775.00 98,83,748.00 ================================================================================

MEAT PROCESSING (EOU) [KAT/DPR/9662]J.C.:8540 [W/C: 1 Month] J.C. 8540 Page A- 16

DEPRECIATION CHART FOR 5 YEARS

================================================================================ Year Building costs Plant & Machinery fur. & office equip. Total

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( Rs. 7700000.00 ) ( Rs. 12000000.00 ) ( Rs. 75000.00 ) @ 6.50 % P.A. @ 25.00 % P.A. @ 20.00 % P.A. ================================================================================ 1 5,00,500.00 30,00,000.00 15,000.00 35,15,500.00 2 4,67,967.50 22,50,000.00 12,000.00 27,29,967.50 3 4,37,549.61 16,87,500.00 9,600.00 21,34,649.61 4 4,09,108.89 12,65,625.00 7,680.00 16,82,413.89 5 3,82,516.81 9,49,218.75 6,144.00 13,37,879.56 ================================================================================

MEAT PROCESSING (EOU) [KAT/DPR/9662]J.C.:8540 [W/C: 1 Month] J.C. 8540 Page A- 17

PROFIT ANALYSIS FOR 5 YEARS

================================================================================================ YR CAP. Sales Mfg. Gross Depre- Interest Net profit Net profit UTIL Expenses Profit ciation before tax after tax @ 30.00% ================================================================================================ 1 70% 210000000 188990550 21009450 3515500 5294865 12199085 8539360 2 80% 240000000 215989200 24010800 2729968 4235892 17044941 11931458 3 80% 240000000 215989200 24010800 2134650 3176919 18699231 13089462 4 90% 270000000 242987850 27012150 1682414 2117946 23211790 16248253 5 100% 300000000 269986500 30013500 1337880 1058973 27616647 19331653 ================================================================================================

CASH FLOW STATEMENT FOR 5 YEARS

================================================================================ YR CAP. Net profit Depre- Cash Repayment of Net surplus UTIL (after tax) ciation in hand Instalment ================================================================================ 1 70% 8539360 3515500 12054860 6834831 5220028 2 80% 11931458 2729968 14661426 6834831 7826595 3 80% 13089462 2134650 15224112 6834831 8389280 4 90% 16248253 1682414 17930667 6834831 11095836 5 100% 19331653 1337880 20669533 6834831 13834702 ================================================================================

MEAT PROCESSING (EOU) [KAT/DPR/9662]J.C.:8540 [W/C: 1 Month] J.C. 8540 Page A- 18

PROJECTED BALANCE SHEET FOR 5 YEARS

Construction 1 Yr. 2 Yr. 3 Yr. 4 Yr. 5 Yr. Period 70 % 80 % 80 % 90 % 100 % Cap. Cap. Cap. Cap. Cap. Util. Util. Util. Util. Util.

LIABILITIES LIABILITIES

1. Promoters capital 99,49,718 99,49,718 1,51,69,747 2,29,96,343 3,13,85,624 4,24,81,460 2. Net Surplus 0 52,20,029 78,26,596 83,89,281 1,10,95,836 1,38,34,703 3. Term loans 1,73,00,000 1,38,40,000 1,03,80,000 69,20,000 34,60,000 0 4. W/C loans 1,68,74,156 1,34,99,325 1,01,24,494 67,49,663 33,74,832 0 ------------------------------------------------------------------------------------------ TOTALS 4,41,23,874 4,25,09,072 4,35,00,837 4,50,55,287 4,93,16,292 5,63,16,163 ------------------------------------------------------------------------------------------

ASSETS ASSETS

1. W.D.V. of Fixed Asset

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1,97,75,000 1,62,59,500 1,35,29,533 1,13,94,884 97,12,471 83,74,593 2. Working Capital in stock 0 1,57,49,212 1,79,99,100 1,79,99,100 2,02,48,987 2,24,98,875 3. Surplus funds 2,43,48,874 1,05,00,360 1,19,72,204 1,56,61,303 1,93,54,834 2,54,42,695 ------------------------------------------------------------------------------------------ TOTALS 4,41,23,874 4,25,09,072 4,35,00,837 4,50,55,287 4,93,16,292 5,63,16,163 ------------------------------------------------------------------------------------------