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India is the world’s second largest producer of food next to China, and has the potential of being the biggest with the food and agricultural sector. The food processing industry is one of the largest industries in India-it is ranked fifth in terms of production, consumption, export and expected growth. The food industry is on a high as Indians continue to have afeast. Fuelled by what can be termed as a perfect ingredient for any industry – large disposable incomes - the food sector has been witnessing a marked change in consumption patterns, especially in terms of food.Increasing incomes are always accompanied by a change in the food basket. The proportionate expenditure on cereals, pulses, edible oil, sugar, salt and spices declines as households climb the expenditure classes in urban India while the opposite happens in the case of milk and milk products, meat, egg and fish, fruits and beverages. For instance, the proportionate expenditure on staples (cereals, grams, pulses) declined from45 per cent to 44 per cent in rural India while the figure settled at 32 per cent of the totalexpenditure on food in urban India. A large part of this shift in consumption is driven by the processed food market, which accounts for 32 per cent of the total food market. It accounts for US$ 29.4 billion, in a total estimated market of US$ 91.66 billion. The Confederation of Indian Industry (CII) has estimated that the food processing sector has the potential of attracting US$ 33 billion of investment in 10 years and generate employment of 9 million person-days. The Government has formulated and implemented several Plan Schemes to provide financial assistance for setting up and modernizing food processing units, creation of infrastructure, support for research and development and human resource development in addition to other promotional measures to encourage the growth of the processed food sector .Food processing is a large sector that covers activities such as agriculture, horticulture ,plantation, animal husbandry and fisheries. It also includes other industries that use agriculture inputs for manufacturing of edible products. One dominant segment in Food Processing as per Government of India indication is as follows :-
• Grain processing
Grain processing accounts for more than 70% of the sector’s output in terms of volume and 50% in terms of value. Though the organized sector seems comparatively small, it is growing at a much faster pace. There are 812 roller flour mills in our country producing approximate 25 million tones, of milled cereal products worth Rs. 1200 crores. Flour Mills can be installed with minimum capacity of 30 TPD of raw material crushing capacity per day to maximum 1000 TPD. The capacity suggested in this report is for mini flour mill i.e. 30 tones of raw material crushing capacity per day. As per CII mckinsey survey it is estimated that by 2005 the market for branded Atta has grown to Rs. 15000 crore and is expected to cross 25000 crore by 2015.
B) Cheap labour availibility of skilled and unskilled labour C) Good demand coming up from big industries like BISK FARM & CHOUDHARY GROUP . Whole wheat flour is used in making Chapaties. Wheat flour or Maida is a basic raw material for making Bread. Puries. D)Bulk quantity of Wheat alloted by state goverment for Job work for distribution through PDS( Rationing E)Big oppurtunity to export to Bangladesh and Bhutan F)Since liberalization. Parotha and other roasted cereal based products. The products sold under brand names are very few. The concept for branded cereal flour products is now increasing as the concern for hygene and quality is increasing day by day due to rising disposable income at the hands of the average Indian and 1/6th of worlds population living in India(120 billion) and also due to demand of special quality ATTA and MAIDA from the large Mnc like Macdonald. The current proposal to setup flour mill in Siliguri at Gandamore Dist Jalpaiguri has its own locational advantage which can be sumarised as follows:A) Abundant and easy availibility of raw material from FCI an growers of Eastern Bihar & northbengal. Britania.2) MARKET POTENTIAL. BRITANIA.Hundusan liver and Parle. Biscuits Cakes and other bakery products. Bran separated on milling is used as cattle feed. Nestle. there is no license requirement for setting up or capacity expansion of roller flour mills. The mills can obtain their wheat supply from any source G)There is no license requirement or price/distribution controls on manufacture of wheat products . Sooji / Rava is used in many sweetmeat products.
F)Upto 5 lakhs Rupees reimbursement on installation of Pollution Control Device and for obtaining ISI/BSI certification/ISO 9000 / ISO 1400 G)Unit/enterprise owned by women Will be entitled to get 10% extra subsidy with respect to A.D.3)GOVERMENT INCENTIVE/SUPPORT A) State Capital Investment subsidy @ 17% of the Fixed Capital Investment.1979 (Maida) IS : 1010 – 1968 (Sooji/Rawa) .B. 4)PROJECT PROFILE ON MINI FLOUR MILL PRODUCT : WHEAT FLOUR (Atta). BRAN PRODUCT CODE : 204109000 (Wheat Flour) 204111003 (Sooji /Rawa) 204108004 (Maida) 5)QUALITY STANDARD. IS : 1009 . SOOJI/RAWA WHEAT FLOUR (Maida).E and F as stated above. The BIS have also laid down Specification for the Products : IS :1155 – 1968 (Wheat Atta). : The Product may be manufactured as per AGMARK’ Specification. C)The Project will be entitled to waiver of electricity duty on the electricity consumed for the production / operation activity & reimbursement of electricity charges @30% for a period of 5 years from the date of commercial production/ operation D) Reimbursement of 80% expenditureincurred by it for paying its contribution towards Employees State Insurance (ESI) and Employees ProvidentFund (EPF) E) 50% Refund of Stamp Duty and Registration Fee incured on land and building for setting up the project.C. B) Interest subsidy to the extent of 25% of the annual interest liability on the term loan borrowed from a Commercial Bank/Financial Institution for 8 years.
it may vary from place to place depending upon the local circumstances: A) Selection of site. Commissioning & Trial Run. 4. The rates quoted in respect of Machinery/equipment raw materials are those prevailing at the time of preparation of report and are like to change the time of placing the order 7) IMPLEMENTATION SCHEDULE. Miller can change according to demand. However. The following extraction rates are presumed : Maida 50 % Sooji Atta Bran 12 % 20 % 18 % Extraction rates are only suggested. The rate of interest has been taken 14% on an average both for fixed investment and working capital.disbursement after the conversion of land is done E) Machinery Procurement. 5. etc. Already Selected B) SSI Registration = 7 days C) Project Report Preparation = Aready prepared D) Availability of Finance = Principally sanctioned . 8th months onward from date of conversion . Wheat quality & climatic conditions. Labour wages have been taken as per market rates. 3. Erection. It is presumed that the unit will run three shift per day and 300 working days per annum. 6. The approximate time required for various activities is given below.6) BASIS AND PRESUMPTIONS: 1. Different varieties of wheat may be blended for producing desired end product. 2.
Separator Vibrating screens remove bits of wood and straw and almost anything too big and too small to be wheat. Production Details & Process of Manufacture 2. The results from these tests determine how the wheat will be handled and stored. The wheat will then be stored at the mill in large bins. Before the wheat is even unloaded. samples are taken to ensure that it passes inspection. ship. Different qualities of wheat may be blended to achieve the desired end product. . or ferment. 1. eliminates foreign materials such as metal. Product control chemists begin their tests to classify the grain by milling and baking a small amount to determine end-use qualities. It can take as many as six steps. Power requirement of the unit is 500 kva. barge. and scours each kernel of wheat. sprout. Aspirator Air currents act as a kind of vacuum to remove dust and lighter impurities . De-Stoner 46 Using gravity. The right moisture. There are no pollution problems and it comes under green category The Process of Flour Milling Product Control Wheat arrives at the mill by truck. 3. Cleaning the Wheat The first milling steps involve equipment that separates wheat from seeds and other grains. Magnetic Separator The wheat first passes by a magnet that removes iron and steel particles. sticks.8) TECHNICAL ASPECTS. Storing wheat is an exact science. or rail car. stones and straw. the machine separates the heavy material from the light to remove stones that may be the same size as wheat kernels. heat and air must be maintained or the wheat may mildew.
are now in far better condition than when they arrived at the mill and are ready to be milled into flour. This is called tempering. The Miller's Skill . Conditioning the Wheat Tempering Now the wheat is ready to be conditioned for milling. Scourer The scourer removes outer husks. Grinding the Wheat The wheat kernels. Each size returns to corresponding rollers and the same process is repeated until the desired flour is obtained.soft.Disc Separator The wheat passes through a separator that identifies the size of the kernels even more closely. depending on the type of wheat . This makes the parts of the kernel separate more easily and cleanly." or corrugated rollers made from chilled cast iron. or coarse particles of endosperm. Blending of wheats may be done at this time to achieve the best flour for a specific end-use. Just one pass through the corrugated "first break" rolls begins the separation of bran. Currents of air pull all the loosened material away. The goal is to produce middlings. Tempered wheat is stored in bins from eight to 24 hours. crease dirt and any smaller impurities with an intense scouring action. medium or hard. moving at different speeds. or berries. From the entoleter. This modern milling process is a gradual reduction of the wheat kernels. Wheat kernels are measured or fed from the bins to the "rolls. Impact Scourer Centrifugal force breaks apart any unsound kernels and rejects them from the mill flow. more round. shorter. The rolls are paired and rotate inward against each other. large hoppers that will measure or feed wheat to the actual milling process. endosperm and germ. Moisture is added in precise amounts to toughen the bran and mellow the inner endosperm. It rejects anything longer. the wheat flows to grinding bins. more angular or in any way a different shape. The middlings are then graded and separated from the bran by sieves and purifiers.
or farina. The miller must select the exact milling surface. Sifters The broken particles of wheat are introduced into huge. there may be as many as 27 frames. almost like water. is usually a long-patent all-purpose or bread flour. rotating. through tubes. the grist is sent way upstairs to drop through sifters. with square openings that get smaller and smaller the farther down they go. all the parts of the wheat in the proper proportions yields whole wheat flour. Grinding too open allows good endosperm to be lost in the mill's feed system. a controlled flow of air lifts off bran particles while at the same time a bolting cloth separates and grades coarser fractions by size and quality. Purifiers in a purifier. Larger particles are shaken off from the top. Occasionally short patent flour is available in retail stores. Up to six different sizes of particles may come from a single sifter. based on the products they produce. Grinding too hard or close results in bran powder in the flour. Inside the sifter. are usually used to rework the coarse stocks from the sifters and reduce the wheat particles to granular "middlings" that are as free from bran as possible. Bakers buy a wide variety of flour types. The reduction rolls reduce the purified." the finished . The flour the consumer buys at the grocery store. including some flour with each sifting. each covered with either a nylon or stainless steel screen. or "scalped." or blending back together. each with successively finer corrugations and each followed by a sifter. Each break roll must be set to get as much pure endosperm as possible to the middlings rolls. This process produces a higher quality whole wheat flour than is achieved by grinding the whole wheat Bleaching the Flour Toward the end of the line in the millstream.The miller's skill is demonstrated by the ability to adjust all of the rolls to the proper settings that will produce the maximum amount of high-quality flour. Germ particles will be flattened by later passage through the smooth reduction rolls and can be easily separated. if the flour is to be "bleached. on the break rolls. consisting of close to 75 percent of the wheat. called "family flour" by the milling industry. box-like sifters where they are shaken through a series of bolting cloths or screens to separate the larger from the smaller particles. The remaining percentage of the wheat kernel is classified as millfeed .shorts. The process is repeated over and over again. granular middlings. Four or five additional "break" rolls. The "scaled" fractions are sent to other roll passages and particles of endosperm are graded by size and carried to separate purifiers. as well as the relation and the speed of the rollers to each other to match the type of wheat and its condition. until the maximum amount of flour is separated. There are various grades of flour produced in the milling process. sifters to purifiers to reducing rolls. or corrugation. "Reconstituting. The middlings rolls are set to produce as much flour as possible. to flour." leaving the finer flour to sift 47 to the bottom. From the rolls. The grist is moved via pneumatic systems that mix air with the particles so they flow. bran and germ.
CHALLENGES AND OPPORTUNITIES The future of the Indian farmer depends on the success of the food industry as India's prosperity is predominantly linked to the growth of incomes in the agrarian sector of the economy. In the bleaching process. The modern bleaching process simply duplicates this natural oxidation process. Increasing consumer awareness about health and hygiene has shifted the focus of the market to "safe" foods.Indian food processing industry has seen significant growth and changes over the past few years. Chlorine also affects baking quality by "maturing" or oxidizing the flour. This whitened the flour and improved its baking characteristics. The Indian food-processing sector is undergoing a veritable revolution . The Government of India’s focus towards food processing industry as a priority sector is expected to ensure policies to support investment in this sector and attract more FDI. driven by changing trends in markets. In the old days. having access to vast pool of natural resources and growing technical knowledge base. which is beneficial for cake and cookie baking. These trends. will shape the demand for value added products and thus for food processing industry in India. Even in the domestic market. such as changing demographics. The bleaching agents react and do not leave harmful residues or destroy nutrients.flour flows through a device. The market forces are compelling the Indian agriculture producers to increase the quality of their farm produce while continuing to maintain their cost competitiveness in order to be able to compete effectively in the global food market. but does so more quickly. growing population and rapid urbanization are expected to continue in the future and. The food processing sector in India is clearly an attractive sector for investment and offers significant growth potential to investors. which releases a bleaching-maturing agent in measured amounts.all the way from the plate to the plough . has strong comparative advantages over other nations in this industry. . consumer segments and regulations. This has exposed the sector both to the opportunities and challenges of the global food economy. rising per capita incomes and changing demographic profile of the population has ensured the growing demand for processed and convenience foods. therefore. It is an established fact that freshly milled flour makes a lesser quality baked product. India. 4. flour was stored for a few months to mature. flour is exposed to chlorine gas or benzoyl peroxide to whiten and brighten flour color. Increasing liberalization of the economy has tried to lift the protection that the food and agriculture sector once enjoyed in the country. or naturally oxidize.
Project Report SETTING UP OF ROLLER FLOUR MILL AT MOUZA JOGIVITA . BALARAMROAD. PARGANA AMBARI FALAKATA IN THE NAME OF SAKAMBARI FLOUR MILLS PVT LIMITED PREPARED BY MURARILAL AGARWAL ASSOCIATES CHARTERED ACCOUNTANTS M R ROAD SILIGURI 734005 . NEAR GANDAMORE.
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