Thispprimariin order

[Weca

M/SInstiAunitof27/1/BGLucknow

P

particularprilytofacilitartoservedevelopm

anmodifythep

ituteforIndu

GokhleMargw226001

Mail:iidincubator17@gmail.comWeb:www.entrepreneurindia.tv industryincubator.co.in

PROJEC

PUR

re‐feasibilitatepotentiathisobjectiment,startu

projectcapacirepo

ustrialDeveloM/SSamadhan Samiti

g

CTPRO

RPOSEOFT

tyis regardalentreprenve;thedocuup,marketin

ityandprojecortonanysub

opment

OFILE

HEDOCUM

ding‘Bread’neursinproumentcoveng,andfinan

tcostasperybjectasperyou

ONBR

MENT

.Theobjectojectidentiersvariousanceandbus

yourrequiremurrequiremen

READ

tiveofthepificationforaspectsoftsinessmana

ment.Wecanant.]

pre‐feasibilirinvestmenheprojectcagement

alsopreparep

ityisntandconcept

roject

DIFFERENTTYPEOFBREADS

Whitbread

Themostcommonvarietyofbread iswhitebread. It ismade fromwheat flour

(extraction rate of 77%)and is made into many different sizes, shapes and

textures. Ingredients such asother cereal orvegetable flours, seeds, herbsor a

mixtureofthesecanbeadded

WholemealorWholeWheatBread

Madefromwholemealflour(containsallthecomponentsofthegrain‐closeto

100%extractionrate),ithasbecomemorepopularwithincreasingknowledgeof

thehealthbenefitsofbranandwheatgerm.

Mixedgrainbread

Maybemadefromanycombinationofflours(e.g.wholemealorwhiteflour,rye

mealorflour),grains(e.g.kibbledgrains,wheatgerm,wholegrainsorwheatand

othercereals)andseeds(e.g.sesameseeds).

Kibbledwheatandcrackedwheatbread

Containsorisrolledinkibbled(cracked)wheatgrains.Fibre‐increasedwhitebreads

Madewiththeadditionofbranorotherfibre‐containingmaterial.

Ryebread

Madefromacombinationofryeflourandwheatflour.Darkryebreadcontainsahigherproportionofryeflourandryemealthanlightryeandisconsequentlydenser,heavyandhasastrongerflavor.Pumpernickelisheavy,darkbreadmadefromryeflour,ryemealandkibbledorcrackedryegrains.

Sourdoughbread

Sourdoughbreadhas a slightly sour flavour and a denser texture than regular

bread.Sourdoughdescribestheraisingagentusedtomakethistypeofbread.A

starter,madefromamixtureofflourandwater,servesasamediumforgrowing

either commercial yeast that is added to themixture or theever‐present wild

yeast that is captured by the mixture from the air we breathe. (Yoghurt is

alsosometimesaddedtoprovideyeast.)Thismixtureisallowedtosourthrough

a fermentation processthat produces a gas and an acid. It is then used as a

starter to leaven other breads; the gas

produced by the fermentation is trapped in the elastic gluten structure of the

dough, causing it to rise,while the acid imparts the final product with a

tartflavour.

Damper

Traditionally baked in the Australian bush, damper is a chemically leavened

white,roundbread.

Lavashbread

Athin,flatbreadmadefromwhitewheatflour,yeast,saltandwaterwhichis

oven‐bakedonaheatedmetalplate.

Bagel

AJewishbreadwherethedough(withyeast)isshapedintoaringandthrown

intoboilingwaterbeforebaking.Thisgivesthecrustachewytexture.Itmaybe

coatedwithpoppyorsesameseedsandcanbeflavoured,e.g.raisinandcinnamon.

MiddleEasternflat,pocketorpitabread

Flat, oval or round wheat bread made from flour, water, yeast and salt. The

"pocket" insomebreadsismadebyrestingtheflattenedpiecesofdoughunder

dry conditions so that both sidesbecomeslightly drier than the centre.During

baking at high temperature, the steam produced inside the

dough is trapped by the baked, drier outside layers. The pocket can also be

stuffed with variousfillings. The Turkish version of pita bread is pide.

Naan

Made in India, Pakistan andAfghanistan, naan is awheat‐flour bread leavened

withastarterofthesourdoughkindandcookedinaclayTandooroven.Theclay

and the smoke in the tandoor combineto produce a characteristic flavor. The

bread is flattish and has a crisp crust.

Chapatti(chapatti)

Sometimes called roti, chapatti is served throughout India, Pakistan and also

Iran.Theyaremadefromfinelymilledwholewheatflour,calledatta.Thedough

isrolledintothinroundswhicharecookedinanironpanoronagriddle.They

aremadeeverydayinNorthIndiawheretheyareusedasaplatetoholdother

food, curved to scoop up food or used for dipping in soupsorsauces.

Parathaorparata

AnIndianflakybreadpreparedbysmearingtheunleaveneddoughwithgheeor

oilandthenfoldingthedough.Thisprocedureisrepeatedthreetimes.Thedough

is then rolled out and fried in oil or dry cooked on a griddle.

Chinesesteamedbread

Eaten inmostcountriesofeastAsia,Chinesesteamedbreadsareshaped likea

ballandhaveeithernofilling,asweetbeanpasteorameatfilling.Laobingisa

Chinese‐styleflatbreadwhichisbakedinapanuntilbothsidesaregoldenbrown.

Chinesebunsanddumplings

Buns and dumplings are common in north and South‐East Asia. Manju, the

generic term for steamedJapanese buns, are either lightly baked or steamed

bunspreparedbysteamingafermenteddoughwithapork,curryorsweetbean

paste filling. InnorthernChina,mantou is a steamed leavenedbreadwithout a

filling, eaten as a staple in place of rice. Yit bien ormoon cake is a baked bun

filled with nutsand seeds popular amongst Chinesepopulations.

Mantou or mantu describes the food category of dumplings in Asia. They

resemble ravioli and arestuffed with meat and/or vegetables and beans.

Gluten‐freebread

Gluten‐freebreadisusuallybasedoncornflourtowhichflourfromgluten‐free

grains(suchasriceandmaize),potatoorpulsesisadded.Gluten‐freebreadhasa

denser,morecrumblytexturethantraditionalbread,sincethepresenceofgluten

isessentialforthetypicalstructureandtexture

BreadManufacturing

Breadmanufacturingprofessionisasoldasstartingofhumancivilization.Itisoldest professionwhen every house having its own bakery. Now withmechanizationandwithnewtechnologybreadsaremanufacturedinmassscales.Worldoverwecan find thousandsofbakeriespreparingVarietyofbreads .Welabelbreadwithvariousnameslikebread,loaf,roti,kaboosetc

BREADMANUFACTURINGPROCESS‐STAGES

Preparationofingredients ·Doughmixing ·Bulkfermentation,spongetime ·Dividing(scaling) ·Rounding ·Moulding ·Panning ·Baking ·Cooling ·Slicingandpackaging

BREADMAKINGPROCESSFLOWINAUTOMATEDBREADPLANT

MIXING

Mixingstartswithsiftingflourwithhelpofvibratorysifter.Flouristhen

collectedinbowlandthenweighed.Allingredientarethenaddedinbowl

.Ingerientsareflour,sugar,fat,salt,yeast,gmspowder,sodiumstearoyl

lactilate,smpsolution,bio‐bake,Improvers,ammoniumchloride,ascorbicacid,

cystiene,pot.bromate,calciumpropianateandaceticacid.These

areaddedinstdproportionasperrequirement.

Afteradditionofallingredientsbowlismovedtospiralmixerwhereisdone

Waterisaddedindifferentquantities.Mixingtimedependsonqualityofflourin

generalmixingtimecanvaryfrom6‐12min.undermixingandovermixingcan

havedirectimpactondoughconsistency.Doughqualitycanbecheckedwith

stretchingthedough.doughtemperatureismaintained

between80degf‐82degf.

FORMING

Oncompletionofmixingdoughbowlisliftedthroughtiltinghoistandfromthe

hoistbowlistiltedsoasdoughgoesintohopperofDividerHopper.

DIVIDER

Doughiscutintotwoequaldoughpiece.Itsamechanicaldevicewhichusesa

commoncranktocut,pushanddropdoughpiecethroughdividertoconveyor

.Volumeofthedoughpiececanbeadjustedatdivider.Dividerisdefinedasno

ofdoughpiecepermin.

HANDERUP

Fromdividerthedoughpiecemovestohanderupwhichismechanicaldevice

conicalinshapeonwhichdoughpiecetakescurvilinearpath.Ithasgotblower

attachedtoitwhichcontinuouslyprovidesaironthepath.Basicfunctionof

handerupistogivedoughpiecesphericalshapeandremovemoisturefrom

surfacefromdoughpiece.

INTERPROOVER

Doughpieces are then transferred to buckets of interposer .Heredoughpiece

areallowedtotravel for5‐6min .Thishelps inrelaxationofdoughas itwould

havestressduetomechanicalactiononitatdivider.

MOULDER

Ithasthreesetofroller.Thedoughpieceisallowedtopassthroughtheserollers

.Nowdoughpieceareslightlyflattened.

PRESSUREBOARD

Doughpieceareturnedandfedintopressureboardwhereittakescylindrical

shape.Airispassedthroughtheboard.

FINALPROOVER

These dough pieces are then carried to platform where these lobes

are twistedandkept inmoulds ,two lobesare twisted inonemouldboxasper

wt requiredlike400gms or800gms loaves .Mouldboxaregreasedprior to

lobes being put into. Final proover has arrangement for steamwhich spreads

uniformly in entirechamber. Temperatures at final proofer is maintained

between 36‐38deg c. Humidity and temperature are maintained so as to get

maximumofyeastactivity.Precautionsaretakentoseeifthereisoverorunder

developmentofdough.Speedcanbevariedatfinalproofer.

Doughshouldrise3/4thofthemould.volofmouldis1320ccfor400gmand

2700ccfor800gmloaves.Traveloftraysislongitudinalinswingtraytype

plantwhereasincontrarytypeitisvertical.

Provingtime=75min

Dependingupondesignwecandefinecapacityoffinalprooferas

cap/cycle:noofloaves.noofracksxnoofmouldsboxperrackxnoofmouldin

eachbox.

BreadManufacturingProcess‐FlowChart

Machines&EquipmentusedinBreadManufacturingMIXERS.

FLOURSIFTER

DOUGHELEVATORHANDERUP

OVENS

BURNERS

DIVIDER

MOULDER

INTERPROOFER&FINALPROOFER

PRESSUREBOARDDEPANNER

SLICER

MOULDS&PANS

PRINTERSANDCODERS

PACKINGMACHINE

AUTOMATEDBREADPLANTLAYOUT

Breadplantslayoutconsistsofmixers,doughelevators,divider,handerup,interprover,moulding,finalprover,oven,de‐panerandcoolingtunnel.Pointstokeepinmindwhileplanningforbreadplantlayout.

Mixerwithdoughelevatorsorgravitytipping. Finalproverloadingmanualorautomatic. Oventobeeithertunneltypeorswingtrayasperrequirement. OvenLoadingtobemanualorautomatic. Coolingtunneltohaveatleast2‐3hourscoolingtime. Ventilationofthebakinghall.

RoleofIngredients.

VariousIngredientsareusedinBreadandBiscuitmanufacturing.EachIngredientshasspecificroletoplayduringmanufacturingprocess.SugarPrimaryroleofsugarinbreadandbiscuitisprovidesweetness(taste)totheproduct.Colortotheproductduetocarmalisation.Colorofthecrustinbreadloavesisduetothesugar.Basicroleofsugaristoactivatetheyeasttoproducecarbondioxideandalocholduringbreadmanufacturing.Note:Whenpreparingformixingyeastisseparatelybeingputintoammoniumchlorideandsugarsolution.HydrogenatedVegetableOil‐(HVO)

MainfunctionofHVOistoretainthemoistureinsidethedough.Givesmoothnesstothebite.SaltItprovidestastetotheproduct.Saltactascontrollingagentagainstwildyeastactivity.Thuscontrolledyeastactivitycanprovidebettertextureornetwork.GMS(GlycerolMonostearate)‐

Itsactasemulsifierwhichbindstogethertheoilandwatermoleculesandithelpsbreadtoholdmoisture.SSL(SodiumStearoyllactilate)‐

ItisalsoknownasSmoother.Itisacompoundwhichretainssoftnessinbreadanddelaysstalingofbread.

SMP(SkimmedMilkPowder)‐

Solution‐MainfunctionofSkimmedmilkpowderistogiveflavourtotheproductandsweetenstheproduct.AmmoniumChloride‐

AmmoniumchlorideprovidesNitrogenwhichusedtoactivateyeastinpresenceofwaterandsugar.

Yeast‐

It is an unicellular living organism .Its growth is max at higher humidity and

temperature45degc .Yeastactionon food releases carbondioxidewhichgets

entrappedin dough and gives puffiness to the product after baking .Yeast are

usedforsourdoughproductsorSpongedoughproducts.Spongearepreparedin

cracker production yeast isadded during mixing are then kept for 18‐20 hrs

beforeproduction.

Commercialyeastareoftwotypes‐CompressedyeastandDryyeastCompressedyeast‐ThesecanbefurtherclassifiedasBreweriesyeast‐Itactsonmalttogivealcoholandcarbondioxide.Distillersyeast‐Itactsonmolassestogivealcoholandcarbondioxide.

Baker'syeast‐Itactsonsugartoproducecarbondioxideandalcohol.Carbondioxideisthemainbyproduct.

OtherfeaturesofcompressedyeastItsavailableincakeform.Itscheaperthandryyeast.Moisturecontentis80%Lifeofcompressedyeastis5days.Cellusageis90‐95%.

DryYeast.ItscostlierthanCompressedyeast.Itsisavailableinpowderform.Moistureisaround5%.Lifeofdryyeastismorethanoneyear.Cellusagearound60%.

ImplementationSchedule

Activity NoofMonths

1.Arrangementofland,Registration, 2

approvalofloanandotherformalities

2 Sitedevelopment,fencingandcivil 1

construction.

3 Machineryprocurement 2

4 Erectionandcommissioning 1

5 Trial‐cum‐commercialproduction 1

FinancialAspects.

CostofProject

S.NO. PARTICULARS AMOUNT1 Land1000sqmts@550 5.502 Landdevelopmentandfencing 2.503 Mainfactorybuilding600mts@Rs3000sq

mtrotherconstruction18.00

4 Costofmoulds/otherfixtures 0.706 Costofofficeequipmentandfurniture 1.505 MarginforWorkingCapital 10.406 Preoperativeexp 2.50 Total 41.10

MeansofFinance

S.NO. PARTICULARS AMOUNT1 OwnContribution 13.562 TermLoan 22.003 UnsecuredLoan 5.54 Total 41.10

ProductionCapacity(PerAnnum)

S.NO. PARTICULARS Production/yearinmeter

Weight/meter) Quantity(Tonnes)

1 Bread 30lacsloavesof400gm 30lacsloavesof400gm

TOTALCAPITALINVESTMENT

Rs.

1 TotalFixedCapital 47.622 WorkingCapitalfor3

Months 41.58

Total 89.20

FixedCapital.

Landandbuilding Amount(InRs.lacs)

Landandbuilding 26.00(Workshop,Officeandstore)(permonth) Otherfurniture&Fixture 2.20MachineryandEquipment

Description Qty.nos.

Price/unit Amount(InRslacs.)

Autofloursifterwithcapacitytosift2bagsper5minutecompletewith0.373kwmotorandotheraccessories

1 0.4

Watermeasuringtank(S.S.)capacity100literswithallaccessories

1 0.15

100kgcapacitydoublearmedtypedoughkneaderwith1.5kwmotor

1 1.2

M.S.extratub 2 0.12Singlepocketslowspeeddoughdividingcompletewith1kwmotor

1 0.8

Firstproveroundertabletypewith0.46kwmotor

1 0.3

Conicalumbrellatyperoundercompletewith1.12kwmotorandsuitablereducinggearbox

1 0.6

Breaddoughstraightthroughmolderwith1.5kwgearedmotorandswitches

1 0.6

Tunneltypefinalproveroverallsize6’x6’longdoublewalledcompletewithrecirculationfan1HPandwith1HPautomaticarrangementofmechanicalpushingtrolleysthroughthetunnel

1 2

ProofingRacksAsetof8No.forfinalproofing 1 1

Oilfiretravellingtypeofovenhavingcapacityof1000loaveschargehaving1HPmaindrivemotor,3HPrecirculationfananother1HPdrivenexhaustfancompletewithmediumpressureburner

1 3.75

Hotloavescollectiontable6’diameterturntablehavingsunmicadopdrivenby1HPmotor

1 0.3

Slitconveyerforpanreturnedfromoventomouldingareadrivenby1HPmotor

1 0.8

Slicingmachineoutput500‐600loavesperhourwith0.746KWmotor

3 0.75

Wrappersealingmachine8simmerstate5heaters1.5KWload

3 0.18

Breadcoolingracks 8 0.6

Breadmouldsetof3panswithlid 0.45

Refrigeratedcabinetforstoringcompressedyeastupto200kgcapacityfittedwith1HP3phasemotor

0.25

CoalFiredbabyboilerofcapacity200kgsteam/hrcompletewithallfittings

1 0.4

6’cottoncanvasconveyerdrivenby0.37KWmotor

2 0.3

TestingEquipment LS 0.5

Pollutioncontrolequipment Nil

Energyconservationfacilities/equipment Nil

1Costofpowerconnection 0.5

2Electrificationandinstallationcharges@10%ofthecostofmachinesandequipments

1.27

CostofMoulds/otherfixtures 0.7

Costofofficeequipmentsandfurnitureetc. 1.5

TotalFixedCapital 47.62

TotalWorkingCapital. Rsinlacs

SalaryandWages (i) 1.81RawMaterial (ii) 10.53Utilities (iii) 0.61

OtherContingentExpenses (iv) 0.91Total 13.86

WorkingCapitalfor3months 41.58

Staff&LabourExpenses.

Designation No. Salary(Rs.) Total(In.Rs.) Manager 1 18,000.00 18,000.00Supervisorcumchemist 1 15,000.00 15,000.00Mechanicalsupervisor 1 12,000.00 12,000.00AccountantSenior 1 10,000.00 10,000.00Salescumpurchaseclerk 2 10,000.00 20,000.00SkilledWorker 4 9,500.00 38,000.00UnskilledWorker 8 8,500.00 68,000.00Peoncumwatchman 1 7,500.00 7,500.00

Total 18 181,000.00TotalMonthlySalary(Inlacs) 1.81

RawMaterialExpenses

Particulrs Rate(Rs) Quantity(Tonnes) Total(In.Rs.) Flour 8.5 92 7.82Sugar 14.5 2.76 0.40Salt 4 1.4 0.06DryYeast 150 0.7 1.05Chemicalandadditives 0 LS 0.40Packagingmaterials 0 LS 0.80TotalExpensesinamonth (Inlacs) 10.53

CalculationofPowerExpense.

COSTOFPOWER

(I)CostofpowerfromUPPCL 53,620.00(@7/‐perUnit) Add:Water 0.01

Add:Lubricants 0.07

TotalAnnualPowerExpense(InLacs) 0.54

OtherContingentExpenses

Particulars Amount(In.Rs)RepairandMaintenance 5000.00PostageandStationery 1500.00TelephoneCharges 8500.00

TransporatationandFreight 15000.00Insurance 30000.00

SalesExpenses 20000.00OtherMaufacturingExpenses 3500.00MiscellaneousExpenses 7800.00

Total 91300.00

Totalinlacs 0.913

CostofProduction.

Particulars In.Rs.TotalRecurringExpenditure 165.42

DepreciationonBuilding@10% 1.80DepreciationonPlantandMachinery@15% 2.58

DepreciationonOtherToolsandFixtures@15% 0.11DepreciationofFurniture/Fixture&OfficeEquipment

@10% 0.15

FinanceCost 8.24TOTALCOSTOFPRODUCTION(InLacs) 178.30

Turnover(PerAnnum)

Particulars Production(meter) Qty(Nos.) UnitRate(inRs)

In.Rs.

30lacsloavesof400gms 6.50

TOTALTURNOVER OrSayinlacs 195.00

Profit[ii‐i]16.70

Percentageprofitonsales 8.56%

Ratios

RateofReturnonTotalCapitalInvestment= NetOperatingProfit/Invested

Capital

= 19% ReturnonAssets = Sales/AveragetotalAssets = 0.35 ReturnonEquity = Sales/Stockholder'sEquity = 1.23 DebttoEquityRatio = TotalTermLiabilities/TotalShareholder'sEquity= 1.62 InterestCoverageRatio = EarningsbeforeInterest&Tax/InterestExpense= 3.03

AddressesofMachineryandEquipmentSuppliers

Mis.BakerandCo.(P)Ltd.OomrigalBuilding,Opp.CrawfordMarket,Mumbai‐400008

NagpalBrothers(Regd.)C127,Phase‐II,MayapuriIndustrialArea,NewDelhi‐II0064Ph.25400407,25402631

Mis.MangalEngg.WorksLahoriGate,Patiala.(Punjab)

Mis.J.Se.DassandBros.33/8,AnathNathDevLane,Kolkata‐700037

Mis.EverFreshProductRamBagh,Indore(M.P.)

Mis.NewEngg.IndustriesFirozpurRoad,Ludhiana.

Mis.BijoyEngineersMiniIndustries,Arimpur,Trichur‐680611(Kerala)

BakerEnterprise23,BehraEngg.LaneNearPeeragarhi.NewDelhi‐110041

FloraEngg.Corp.28‐A,Phoolbag,Rampura,NewDelhi‐I10035Phone:25415335,25411920.