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EGG POWDER Introduction
The egg is the most nutritious natural product. Eggs are rich in protein, vitamins and minerals. During last three decades, the poultry industry in the country has made remarkable progress and grown into an organized and highly productive industry. Dried egg powder can be stored and transported at room temperatures. It is quite stable and has long shelf life. The manufacture of egg powder is an important segment of egg consumption. There is enough scope of an egg powder manufacturing plant, with a suitable capacity. Whole egg powder is consumed in hotels, hospitals, restaurants, and military establishment etc. It is also used in bakeries and cake mix manufacture. Dried albumen is used in cake mix manufacture, marinque powder manufacture and in candy making. 1.2 Objective
The primary objective of the model report is to facilitate the entrepreneurs in understanding the importance of setting up unit of egg powder. This model report will serve as guidance to the entrepreneurs on starting up such a new project and basic technical knowledge for setting up such a facility. 1.3 Raw Material Availability
The major raw material required is fresh eggs and the daily requirement is 20,000. Prior confirmed arrangements for this quantity are necessary. In the year 2003-04 the total egg production in the state of MP is 8962 lakh numbers. 1.4 Market Opportunities
Eggs are full of nutrients and minerals and are consumed in different forms since centuries. There was misconception that they are from non-vegetarian food category but now people at large have accepted them as a vegetarian item and their consumption is increasing year after year. Transportation of eggs is difficult as chances of breakage during transportation are higher and it is costly also. Egg powder is comparatively easier to transport and there is no question of any breakage during the transit. 1.5 1.5.1 Project description Applications
Egg powder is one of the most common products in poultry industry in the country. Attempts have been made to prepare egg pudding also but this product has not yet been accepted by the consumers, whereas demand for egg powder is increasing year after year.
Project Profiles - MP Agros 1 Global AgriSystem Pvt. Ltd. Your Partner in Agri-business
Shorter holding times at 65OC are acceptable if the incoming egg quality allows this.4 Manufacturing process Manufacture of dried egg powder starts with breaking of eggs and removing egg-shells. The yield of the egg powder is around 80%. after heating the product is held at 65OC for 6 minutes gives sufficient pasteurization of the product for most situations and errs on the side of safety.3 Capacity of the Project 240 MT per year of dry egg powder.MP Agros 2 Global AgriSystem Pvt. After the special filtration process the egg is fed to the storage tank where it is cooled down to 40C by means of the chilled water jackets. After breaking and separation of the egg and shell the whole egg is discharged into the filtration system of the process.2 Availability of know how and compliances CFTRI.5. Mysore. Slow speed agitation is provided with these storage vessels. The material which comes out of high pressure spray drier is not only in dried form but also in powder form which is then packed in poly-lined boxes.5. 1. Mysore. CFTRI. The shells are deposited into a centrifuge where the residual liquid egg and shell are separated. 1. the mixture is filtered and stored in storage tanks at about 4º C and then it is taken to tubular heater wherein it is dried at about 65º C for 8 to 10 minutes and it is filtered and passed to high pressure spray drier with the help of high pressure pump. From the storage tanks the egg is fed by a positive displacement pump to the tubular heater.1. Compliance under the PFA Act is necessary. A typical process flow chart would be as under: Breaking of Eggs and removal of shells Filtration Storage and Drying Packing The eggs are fed to a convectional egg breaking system. can offer the technical know-how. Your Partner in Agri-business . Project Profiles . has developed a process and the promoters may like to seek their help. The average yield is around 80%. This tubular heater is heated by hot water. Ltd. The egg temperature is raised to 65O C. After removal of shells.5.
00 4.86 6.00 2.50 3.90 1.00 50.00 5.00 5.000 300.50 5. 1.61 1.00 3.00 3.6 Project component and cost Major components of the projects and their costs are described in the table hereunder: 1.000 350. Due to flash drying the hot air rapidly reduces in temperature.000 500. The powder is then cooled and filled into a container.000 25.00 6. Your Partner in Agri-business .000 300.00 140 Particulars LAND & BUILDING Land Land Development Land Area Building Production Block Main Production Area Store cum packing room & Sales Counter Contingencies PLANT & MACHINERY Egg breaker Centrifuge Filter Storage Tank Feed Pump Tubular Heater Balance Tank Feed Pump High Pressure Pump High Pressure Spray Drier Cyclone with Exhaust and Fan Packaging Unit Electrification and Installation Contingencies MISCELLANEOUS FIXED ASSETS Furniture and Fixture Vehicles-Delivery LCV Weighing Scale Others Contingencies PRE-OPERATIVE EXPENSES Establishment Professional Charges Security Deposits TOTAL 100.00 500.000 100. From the high pressure pump the egg is fed to the atomizing nozzles via a high pressure line.000 1.000 200.00 74.The warm egg from the holding tube is fed to one of the two dryer balance tanks and then to the high pressure pump by a centrifugal feeding pump.000 50.000 100.000.000 300. The product is finally atomized into the hot inlet air.00 3.00 6.00 4.75 6.75 2. Ltd.50 5.25 0.7 Land and Building Unit SqM Qty 1.00 8.00 8.90 2.000 400.000 750.MP Agros 3 Global AgriSystem Pvt.000 800. The dry powder and drying air leave the chamber at the bottom of the cone and are transported to a cyclone where the power is separated from the air.00 7.000.000 75.00 25.000 Total 51. Placed in this venturei are the atomizing nozzole lances.50 2.000 SqM SqM 500 300 10% 4 2 2 4 2 1 4 2 2 1 1 1 15% LS No No LS 1 2 1 1 15% 1 1 1 Cost/unit 250.000 75.00 9.000 290.00 7.00 4. The spray dryer is cylindrical with a conical outlet for air and powder.00 15. thus giving minimum product damage.50 0.000 Project Profiles . The filtered drying air is heated by steam and then introduced to the drying chamber by a specially designed venturi.00 0.000 350.
Your Partner in Agri-business . 6.00 59. centrifuge.31 42.31 42.10 Miscellaneous Assets A provision of Rs.53 32.85 13.00% 40.53 1.The cost of the various components will depend on the location of the project. storage cum packing room and sales counter.13 Means of Finance EQUITY CAPITAL MOFPI SUBSIDY TERM LOAN FINANANCIAL INSTITUTIONS -Payable half yearly Installments TOTAL 25% 10 50. 74. 1.MP Agros 4 Global AgriSystem Pvt.20 147.9 Building The main production block will cost around Rs.72 Year 3 12.71 41.99 Project Profiles . 1. professional charges. Item wise assumptions are as under: 1.61 lakhs would take care of all the requirements. filter.68 2.53 Year 5 12. storage tanks. high pressure spray drier. The entire building will be divided into two zones – production.55 54.90 lakhs would take care of pre-production expenses like establishment. 6. balance tank.38 25.00 9. high pressure pump.14 4. Ltd.12 Working Capital Assessment ITEMS STOCK OF RAW MATERIAL & PACKING MATERIAL SUNDRY DEBTORS TOTAL MARGIN MPBF INTEREST ON WC Year 1 7. security deposits etc.55 54. feed pump.71 41.8 Plant and Machinery The main machineries are egg breaker.11 Preliminary & Pre-operative Expenses A provision of Rs.91 8.14 4. tubular heater.23 24.90 35. 1.00% 100% 51. 1. cyclone with exhaust and fan etc.00% 25.80 37.00% 5.85 13.75 lakhs. The total cost of plant and machinery is Rs. 44 lakhs.
89 Year 7 144.14 13.68 1.19 25.63 13.80 96.W/O INCREASE IN TERM LOAN INCREASE IN BANK BORROWINGS-WC TOTAL Year 1 4.87 Year 7 51. Your Partner in Agri-business .84 6.17 Key Indicators NET PRESENT VALUE at current Inflation (Rs.85) (2.79 0.00 112.10 41.89 14.43 29.70 41.29 19.86 86.30 24.55 Year 5 23.63 Year 5 144.64 30.60 77.59 1.16 Profitability statement PROFITABILITY STATEMENT Particulars INCOME EXPENDITURE VARIABLE FIXED GROSS PROFIT PROFIT BEFORE TAX RETAINED PROFIT Year 1 93.79 0.73 85.14 Cash flow statement PARTICULARS SOURCES OF FUNDS EQUITY CAPITAL SUBSIDY NET PROFIT (INTEREST ADDED BACK) DEPRECIATION PRELIMINARY EXP.80 61.80 134.06 Year 5 51.42 27. 1 2 1 6 4 10 1 1 26 Global AgriSystem Pvt.79 0.78 4.06 73.68 15.11 23.23 Year 3 24.01 1.14 227.50 Year 3 51.00) 41.23 9.29 16.MP Agros 5 NOs.80 33.68 32.00 113. Ltd.18 Man Power Requirement PARTICULARS SUPERVISORY STAFF Production Manager Machine Operators Accountant WORKERS Skilled Workers Semi-Skilled Labour Unskilled-Skilled Labour Salesman Clerk TOTAL Project Profiles .58 58.85) Year 3 144.89 1.99 34.14 184.00 111.29 84. in lakhs) INTERNAL RATE OF RETURN % AVERAGE DSCR BREAK EVEN POINT % PAY BACK PERIOD ( YEARS) 154.31 31.77 9.79 0.65 (0.71 15.66 28.11 39.68 163.66 9.42 2.27 14.68 40.1.99 34.99 24.80 9.57 Year 7 23.99 4.15 Projected balance sheet PARTICULARS LIABILITIES EQUITY CAPITAL RESERVES & SURPLUS TERM LOAN BANK BORROWINGS-WC TOTAL Year 1 51.73 53.14 195.02 (2.
2527644-5046500 The actual cost of projects may deviate on change of any of the assumptions. Your Partner in Agri-business . Works. 2 Bhubhaneshwar Housing Soc. Tel No. Tel No. 31. Pashan Rd.63% 1. Boriwali. 11 RNT Marg.34% 7. 25893700. Works Pvt Ltd.0% 2. FIXED ASSETS LAND & SITE DEVELOPMENT 10% 15% 40% 9% 25% 10 6 240 300 20 60% 90% 100% 25. Girgaum.00% 2. Project Profiles .. Worli.. Mumbai 400 098 FMC Technologiy. 208 Manas Bhavan.MP Agros 6 Global AgriSystem Pvt.19 Assumptions Project & Financing Contingencies on Building Contingencies on Equipment Term Loan Rate of Interest on Term Loan Subsidy Considered Subject to ceiling Expected time of Installation Moratorium CAPACITY Rated Capacity Per Annum 80% of Installed capacity Number of Operational Days DAYS Working Hours Per day Hrs CAPACITY UTILIZATION Year I Year II Year III SALES PRICE W S Price OTHER EXPENSE Commission Marketing Expenses POWER Connected Load HP DEPRICIATION AS PER COMPANY’S ACT BUILDING PLANT & MACHINERY MISC.1.5% 75 3.000 10. Ltd. Flavourire Foods and Services Pvt. Hong Kong Ltd.. FIXED ASSETS LAND & SITE DEVELOPMENT MAINTENANCE BUILDING PLANT & MACHINERY MISC. Pune 411008.19.00% 1. Ltd.00% Months Months TPA 1.07% 1. Indore 452008.34% 10.50% 1.1 Sources of technology Techno Equipments. Mumbai-400004 GR Engg. Parekh street. Mumbai 400 018 and Apurva Engg.