INPUTS FROM PLANT

MASALA AND SEASONING BLOCK

OBSERVATION REGARDING STORAGE OF RAW MATERIAL

MASALA AND SEASONING EXISTING PLANT
SR.  CONSUMPTION MT/ DAYS OF STORAGE 
NO. MATERIAL NAME STORAGE TYPE DAY NATURE AS PER CLIENT
1 White salt Silo 10 Dry 15
2 Black salt Silo 3 Dry 15
3 Black pepper Silo 1.5 Dry 15
4 Pudhina Powder Silo 2 Hygroscopic 15
5 Maize Starch Silo 2 Dry 15
6 Malto Dextrin Silo 5 Hygroscopic 15
7 Degi Mirch Powder Silo 3 Dry 15
8 Red Chilli powder Silo 5 Dry 15
9 Sugar powder Container 5 Hygroscopic 15
10 Coriander Powder Container 1.5 Dry 15
11 Cumin Powder Container 1.5 Dry 15
12 Ginger Powder Container 0.8 Dry 15
13 Onion Powder Container 2 Hygroscopic 15
14 Garlic powder Container 2 Hygroscopic 15
15 Tomato powder Container 1.5 Hygroscopic 15
16 Dextose Container 1.5 Hygroscopic 15
17 Citric Acid Container 1 Hygroscopic 15
18 Saunf Powder Mandos 0.08 Dry 15
19 Amchur Powder Mandos 3 Hygroscopic 15
20 Turmeric powder Mandos 0.15 Dry 15
21 Green Chilli powder Mandos 0.1 Dry 15
22 Green coriander powder Mandos 0.1 Dry 15
23 I+G Mandos 0.1 Hygroscopic 15
24 2002 Mandos 0.1 Hygroscopic 15
25 Hing Powder Mandos 0.1 Hygroscopic 15
26 Whey powder Mandos 0.1 Hygroscopic 15

PREMIX INGREDIENTS
SR.  CONSUMPTION MT/ DAYS OF STORAGE 
NO. MATERIAL NAME STORAGE TYPE DAY NATURE AS PER CLIENT
27 Aloo Bhujia Block Container 2 Sticky
28 Garam Masala Container 2.5 Dry
29 Bholaram Chatni Container 2 Dry
Khatta Meetha
30  Chat Masala Container 0.5 Dry
31 Taka Tak block Container 2.5 Highly Hygroscopic
32 Punjabi Tadka block Container 2.5 Highly Hygroscopic

As per current scenario of production plan
Seasoning Production- 50 MT to 55MT per day
80% powder
20% Grinding (i.e. whole Ingredients and Premix)
So required Grinding production is 12 MT per day to produce 55 MT per day

Current plant 800 kg/h. Line cap in one shift @ 10 T, Currently making - Sugar 500 kg/h, Coriander 300 kg/h, Chili 500 kg/h.
Axtel New line 1.5 TPH.

Final Capacity:

Seasoning:

Today current capacity is 45 TPD. This is to be taken to 85 tons / shift. (12 hours).

30 Tons (Sec 68) + 15 Tons (Sec 63).

Retail Masala:

800 kg/h line

10 TPD (12 hours) installed capacity

Current average production is 3 to 5 TPD.

Fumigation areas – 30 T, 48 hours cycle time.

Temperature Control Required.

MACHINE DETAILS OF EXISTING PLANT

S NO. MACHINE NAME MANEFACTURER CAPACITY

1 Grinder 1 Universal 500 kg/hr
2 Grinder 2 Rubby 500 kg/hr
3 Grinder 3 Rubby 500 kg/hr
4 Grinder 4 Kaps engineers 500 kg/hr
5 Grinder 5 Chilly Plant 500 kg/hr
6 Blender 1 Amixn 1200 ltr
7 Blender 2 Amixn 1200 Ltr
8 Blender 3 Amixn 1500 ltr
9 Shifter 1,2 &3 Galaxy sivtek 2 MT/Hr
10 Silos AZO 6 Ton

Issues found in Existing Plant

1. Metal detector is required before the mixer which is not available in current plant
2. Variation in batches after mixer
3. Weighing Balance for IBC
4. Lux level need to improve
5. HVAC requirement in production block
6. Mixer with the Load cell
7. Temperature control for storage area
8. Proper storage area for Raw Material
9. Some grease found on the strip curtain due the movement of Stacker
10. Better dust collection system
11. Proper racking system for material storage
FLOW CHARTS

MASALA FLOW CHART

RM
UNLOADING/SAMPLING

RM
STORAGE

RM WHOLE
POWDER RM

MAUNAL CONTAINER /
AZO SILO FILLING

GRINDERS

POWDER
PREMIX INGREDIENTS

SMALL BAGS
 PRODUCT LINE 1

PRODUCT LINE -1

WEIGHING
HOPPER

BUFFER

RECIEVER

AS PER REQUIREMENT
MICRO INGREDIENTS MIXER - 1
LIQUIDS

IBC / BIG BAG

SIFTER
(2 MT/hr)

SMALL BAGS /
PACKING
 PRODUCT LINE 2

PRODUCT LINE -2

WEIGHING
HOPPER

BUFFER

RECIEVER

AS PER REQUIREMENT
MICRO INGREDIENTS MIXER - 2
LIQUIDS

IBC / BIG BAG

SIFTER
(2 MT/hr)

SMALL BAGS /
PACKING
 PRODUCT LINE 3

PRODUCT LINE -3

WEIGHING
HOPPER

BUFFER

RECIEVER

AS PER REQUIREMENT
MICRO INGREDIENTS MIXER - 3
LIQUIDS

IBC / BIG BAG

SIFTER
(2 MT/hr)

SMALL BAGS /
PACKING
 GRINDING SYSTEMS
UNIVERSAL MILL
500 KG/hr

GRINDING - 1

SILO / CONTAINER / BAG FILLING

RUBBY
500 KG/hr

GRINDING - 2

PREMIX / POWDER

RUBBY
500 KG/hr

GRINDING - 3

PREMIX / POWDER

SUGAR KAPS
500 KG/hr

GRINDING - 4

SMALL BAG FILLING

CHILLY
PLANT

GRINDING - 5

SILO / CONTAINER / BAG FILLING

AXTEL
GRINDING - 6 (1 MT/hr)
(UNDER PROGRESS)
MOONG DAL BLOCK
FLOW CHARTS

RM STORAGE

MANUAL AUTO
HOPPING CYCLONE HOPPER

DE STONER

SILO STORAGE

BUFFER
TANK

WASHING (2-2.5 HRS)

SOAKING
(6 HRS)

BUCKET
ELEVATOR

FRYER
(184 °C)

COOKING
SYSTEM

SPECTRUM

MIXING
SYSTEM

PACKAGING
SYSTEM

CONVERYOR FOR FG
EXISTING PLANT OBSERVATIONS
1. In washing, time takes around 2-2.5 hrs. Total nos. of tank is 10. Capacity of tank is 800 kg.
2. Perforation tank (soaking tank) time takes around 6-7 hrs. Total no. of tank is 40 nos.
3. For washing, RO water used.
4. Frying temperature is around 184 °C. with the capacity of 3 Ton.
5. Oil consumption is 1500 liters.
6. Frequency of oil changed is everyday
7. The initial temperature of product is around 35-40 °C. and the final temperature is 185 °C.
8. Silo storage tank capacity is 30 Ton. Total no. of silos are 2 nos.
9. Buffer tank capacity is 1600 kg. The total nos. of tank is 2 nos.
10. Cooling system is used to cool material is done by a natural process.
11. Packaging machine is 24 nos. The speed of packaging machine for 18 gram is 48 PPM and for the 200 gram is 60 PPM
12. Frying time is 54 seconds.
13. Water consumption 4000 liters. 800 kg tank is filled with 800 kg of Moong dal which is filled with 4000 ltrs of water (Ration
1:5)
14. The percentage of oil consumption is 18%. For e.g. To fry 100 kg of Moong dal then 18 liters of oil will be consumed
15. Load of heat exchanger is 1500 kw
16. Mixing temperature is around 50-55 °C
17. Moisture content in Raw material is 11%
18. Moisture content after soaking is 55-58%
BIKANERI BHUJIYA BLOCK
FLOW CHARTS

RM STORAGE

GRINDER

MIXING

BEASN SILOS

BHATTIS

MIXING SYSTEM

PACKAGING

CONVEYOR TO FGS
Hand Bhujia
18 inch
1 day / kahdi – 200 to 225 kg Output.
Currently 124 Kadhi – 35 TPD output
15 tons Continuous fryer
Total 50 TPD

Projection 50 X 4 = 200 MT/day

Every 100 Kadhi – 1 to 1.5 Tons fryer required.
Dankoli – 2 fryer

Disscusion with Gurvendra Sir (Plant In charge)

Old building data:

220-250 tons in 12 hours

Aloo Bhujia – 125 tons/day – 3 fryer – 2 lines (12h) + 1 line (24 h) operation.
375 tons / 12 hours.
Mixing and packing = 12 hours.

Ratio of Bikaneri Bhujia:

5% Dankoli
35 % Machine fried Bhujia
60% 0 Hand Bhujia

85-90 packing machines required for Bhujia

New Bhujia Plant

Existing – 50 TPD (12 hours)

124 Kadhi – 225 – 35 Tons + 15 ton fryer.

Projection X 4 = 400 tons =

124 * 4 @ 500 Kadhai required.

Change size – 400 Kadhai.

Getting 386 Kadhai.

Total Kadhai required 400 Kadhai.

Fryer required = 4
Capacity – 1 to 1.5 TPH fryer

Dankoli – 2 no – 500 kg/h

Ration
200 T

Dankoli = 5% - 10 Tons (2 no’s fryers – as it gives 400 kg /h output)

Hand Bhujia – 60% 0f 200 – 120 tons (120/225 kg = 533 Kadhai) Taken as 400.
Fryer Bhujia = 35% of 200 – 70 tons (4 fryer) = 17.5 ton / fryer – 17.5/12 – 1.45 tons / fryer
EXISTING PLANT OBSERVATIONS
1. Temperature of Bhatti is around 160-165 °C. Total no. of bhatti at ground floor is 46 and at first floor is 80 nos.
2. In every 1 hour oil of bhatti is changed
3. Grinder capacity is 1000 kg/hr
4. Capacity of bhatti is 300 kg/hr
5. 400 gm packaging machine with the capacity of 1200 packets per hr. Total no. of machine is 2 nos.
6. 100gm -200gm packaging machine with the capacity of 30 PPM. Total no. of machine is 10 nos.
7. Oil consumption is 15-16 liters per bhatti. In 15-16 liter of oil used for 17 kg besan.
8. Oil inlet temperatue is 35-40 °C. Oil outlet temperature is 170 °C.
9. 10 liter of water consume in 12 kg of besan
10. Heat consumption 170 kcal/hr
11. Heat exchanger load is 170 kw
12. Temperature of product during frying is 170 °C and after cooling temperature is 45 °C
13. Fryer capacity is 500 kg. Frying time is 72 seconds. Feeding quantity in fryer is 16 kg. Output that fryer gives is 789 kg/hr.
The critical limit is 125 °C. So frying must not be done less than 125 °C
14. Final frying temperature is 160-170 °C
15. Oil consumption in fryer 500 liters which change every day. 1-2 liter of oil top-up in every 5 mins.
16. 40% fry bhujia, 60% Hand Bhujia and 20% Dankoli
17. Moisture content in Raw material is 11%
18. Moisture content

Material Moisture Content (%)

Beasn 9
Channa Dal 10
Fryer Bhujiya 1.6 - 1.8
Bhatti Bhujiya 1.8 - 2.0
Mixing 1.8 - 2.0
OIL TANKS

1. Oil tanks

Tanks No.s Length (M) Width (M) Height (M)

60 KL Tank 5 11 6
22 KL Tank 1 6 4
5 KL Tank 1 5 1.5

Total Capacity : 327 KL

Total No. Of Tanks : 7 No.s
2. All operation of oil tank is done through the SCADA system.
3. Consumption of oil is 140 ton per day.
4. Type of oil stored are as follows: Cotton seed oil, Rice bran oil, Palm oil, Corn oil and Groundnut oil.
5. Pressure of oil during the transfer is 6 Kg.

BOILER

1. Nos. of boiler 3
a) TP 6 - 1 no. : 600000 kcal/hr
b) TP 10 -2 nos : 1000000 kcal/hr
2. Heat consumption for bhujia and moong dal is 170 kcal/hr
3. Circulation pump 3 nos. 22 kw -2 nos. and 11 kw 1 no.
4. Fuel used in boiler is diesel and gas
a) Diesel consumption is 110 liters per hour on full load
b) Gas consumption is 110 kg per hour on full load
5. Pressure of gas at burner is 110 mbar (millibar)
6. PNG gas is used through pipe line
7. Connection load is 16 kw and 11kw
8. Maximum temperature is 280 °C
9. Inlet temperature tripping point is 275 °C
10. Outlet temperature tripping point is 300 °C
11. Stack temperature tripping point is 300 °C
12. Oil in boiler is 12000 liter
13. Frequency of change of oil is not defined.

WATER TREATMENT (In Present C3)

1. Plant capacity 30 KL + 10 KL Total

2. MGF tank around 40 KL (Multi Grade Filter)
3. ACF tank around 40 KL (Activated Carbon Filter)
4. Pressure in MGF and ACF tank is around 2-2.5 Kg
5. Dosing pump 2 nos. with the capacity of 6 LPH
6. Cartridge filter in RO Membrane line with 5 micron and size 2.5x40 mm
7. High pressure pump 2 nos. 30 kw. Make Grundfos
8. RO membrane capacity 1 KL. Total nos. of membrane is 30.
9. Antiscalant dosing tank 300 ltrs. Dosing quantity in 100 ltr of water 1.5 liter of antiscalant use. Newtech company chemical
is used
10. Descaling pump 3 KW 1 nos.
11. CIP tank with the capacity of 500 ltrs. 1 nos. Dosing quantity in 500 ltrs of water 50 ltrs of chemical is used. Newtech
chemical is used 1033 and 1034.
12. In RO membrane the pressure is 10 KG
13. 40% is reject water. Reject water goes to ETP.
14. PH is maintained b/w 6 to 7
15. Raw water TDS is 1500 PPM and from RO it is maintain b/w 200 to 250 PPM
16. Raw water pump is 4 KW.
17. RO load around 40 KW
18. No Softner System present.
ETP

C3 ETP Scheme