Milk Processing

1. INTRODUCTION 1.1 The Indian dairy industry is contributing significantly to the country's economy, besides improving the health standard by increasing the nutrition value of the food. The value of output from Dairy Sector increased to Rs.5,00,510 million in 1994-95 from Rs.2,75,080 million in 1990 and is expected to reach the level of Rs. 8,50,000 million by the year 2000 A.D. 1.2 India occupies first position in the world having a total bovine population of 288 million compared to the world's total bovine population of 1420 million. As per 1992 livestock census, the country has about 62.90 million breedable cows and 42.46 million breedable buffaloes (Statewise and species/breedwise figures are given in Annexure I). The cross bred cattle are predominant in Kerala, Maharastra, Tamil Nadu , Punjab and Uttar Pradesh, While buffaloes are very common in Uttar Pradesh, Andhra Pradesh, Rajasthan, Madhya Pradesh, Maharastra, Gujarat, Punjab, Bihar, Karnataka , Haryana and Tamil Nadu 1.3 There has been a major improvement in milk production which increased from 17 million tones in 1951 to 70.1 million tonnes in 1997 and the growth was maximum between 1980 and 1990. Uttar Pradesh, Punjab, Madhya Pradesh, Rajasthan, Maharashtra, Gujarat, Andhra Pradesh, Haryana, Tamil Nadu and Bihar contributed to the extent of 85 percent of the total milk production in the country. Today, India is the second largest producer of milk in the world after the United States of America. The present per capita availability of milk is 205 gms as against the ICMR recommendation of 250 gms. The statewise milk production during 1992-93 and targets for 1996-97 along with the per capita availability of milk are given in Annexure I. 1.4 Recognizing the importance of the sector, the notable programmes taken up are key village schemes, intensive cattle development projects, crossbreeding projects through bilateral assistance, operation flood programme and technology mission by establishing National Dairy Development Board (NDDB). 1.5 In 1970 under the aegis of NDDB, "Operational Flood" programme was launched to modernize the dairy sector and flood the 4 metro cities with milk from dairy cooperatives. By the end of 1996-97, 74,383 village milk producers cooperatives were organised in 264 districts with an average rural milk procurement of 12.26 million liters per day. 1.6 Another step was taken in 1989, to augment rural income by launching Technology Mission on Dairy Development (TMDD), which aims at applying modern technology to improve productivity, reduce costs of operation and thus ensure grater availability of milk and dairy products. 1.7 With the liberalization of the Indian economy in 1991, the dairy sector too was delicenced. However, on June 9, 1992 GOI issued a Milk and Milk Products Order (MMPO), according to which, a dairy handling more than 10000 liters of milk per day is required to get itself registered. The registering authority shall be an officer of the State Government or Union Territory in respect of units handling upto 75000 liters/day, or 3750 MT of milk solids per annum, where the entire milkshed of the unit lies within a State / Union Territory. In case of those units, which are handling more than 75000 liters of milk per day or 3750 MT of milk solids per annum, the registering authority is Department of Animal Husbandry and Dairying ,Ministry of Agriculture, Govt. of India. 2. MILK PROCUREMENT AND PROCESSING The organized dairy sector (both cooperatives and private) is presently handling only 10-12 percent of total milk production in the country. The target and achievements of milk production, procurement and processing in cooperative sector by the end of VIII Five year plan are given in Annexure II. Thus it indicates, there is a wide scope for processing of milk and manufacture of milk products for domestic consumption as well as export. 3. EXPORT PERFORMANCE Dairy products form one of the fastest growing segments in the livestock product export. The major products exported are malted milk foods, ghee and cheese (to some extent) to the countries like Bangladesh, UAE, Nepal, Sri Lanka, Bahrain and Oman. The export performance during the years 1980-81 to 1995-96 are given in Annexure III. 4. EXPORT POTENTIAL AND MARKETS Bangladesh, United Arab Emirates, Nepal, Sri Lanka and Oman are the potential countries for export of malted milk products, butter and ghee. The export of milk and milk products to currently existing markets would increase to Rs.285 million and to new markets to Rs. 155 million. Thus the exports is likely to touch Rs.440 million (APEDA estimates) by the turn of the century. The GATT agreement further gave a boost to the dairy industry, as India has a comparative cost advantage in regard to milk production. NABARD has been actively involved in credit disbursement in number of schemes in dairy sector. It also encourages development of new products through its research and development funds

7. TYPE OF PROJECTS The type of milk processing projects that are normally considered for financial assistance are: i) Milk Chilling plants: It involves collection of milk from the villages. future expansion. etc.besides guiding various entrepreneurs in new areas of business and technology. About two acres of land is required for a milk processing plant handling about 10000 liters of milk per day (8 hours). iii). The surplus fat is converted into ghee or table butter or sold as cream to bakeries. Market Milk Plants: It involves procurement of milk from the villages. cheese. low milk production and scatteredness of production base. social infrastructure. butter. POTENTIAL AREAS: The scope for financing milk processing activities exists in the entire country. However.. electricity and effluent mains. etc. ii) For manufacturing various milk products to make it available for the domestic market as well as for export markets. it is limited in East and North Eastern parts of the country because of under utilization of existing processing capacities. parking of transport vehicles and for empty cans. partnership firms. 6. OBJECTIVES OF THE PROJECT The financial assistance is extended for processing of milk with the following objectives.1 Land and Location: i) Ample space is required for buildings. i) To enhance the keeping quality of milk and also to avoid economic losses to farmers.2 Site Development:i) Preferably the entire site should be fenced with barbed wire or compound wall is constructed with gates at suitable places. ii) Internal roads should be of tar/bricks/WBM depending upon the soil conditions. standard. ghee. packing of milk of various brands (whole. ii) The location of a plant should be close to the milk producing area in case of products manufacturing unit and if liquid milk is the main product it should be close to the consumer. iv) The subsoil of the site should be firm with proper drainage. homogenization. rainfall and the number of . chilling. services. chilling the milk to 3-4 degree Celsius and transporting to the main dairy for further processing and manufacture of products. 5. ii). such as water. BENEFICIARIES The beneficiaries may be individuals. 8. Composite Milk Processing Plants : The project involves the collection of milk and processing into market milk and products like milk powder. iii) The location of site should have proximity to road/rail facilities. pasteurization. toned and double toned milk) and supplying them to the consumers. 9. corporate bodies and cooperative societies/unions. companies. PROJECT DETAILS 9. 9. However the built up area to total area should be around 1:3 ratio.

quality control. percentage of animals in milk. L&T. average milk yield.7. The total requirement of compressed air and the capacity of the compressors is required to be furnished. The availability of other inputs such as packing materials.4 Plant and Machinery: The sectionwise equipment required. name of the firm. The layout plans for a plant of 10000 liters per day is given in Figure 1 . country and term of agreement is required to be mentioned. The power requirement depends upon the load to be connected and the necessary approval from SEB should be obtained for connection. garages. packing and storage of milk products should be as per the BIS. processing. ii) Water: A milk processing plant requires the water in the ratio of 2:1 (2 liters of water for 1 liter of milk processed) for cleaning of equipment. . v) Compressed Air: It will be required for various pneumatic operations flow control operations as well as for cleaning purposes. The method of procurement. the quantity of milk handled and the equipment chosen for services and product manufacturing. The essential sections of a milk processing plant are given in Annexure IV.etc will determine the size of the plant. cold storage and drinking purposes (source of water supply. iii) Steam: The steam requirement (kg/hr) depends upon the processes involved and the source of steam may be met by coal/oil/gas fired / electric boiler. security post etc. quantity available and suitability for the purpose has to be mentioned). marketed surplus . office. their specifications. The extent of milk shed area. standby generators may be considered for connecting the essential sections.2 Utilities:i) Power: Normally a three phase electricity supply is required for milk processing plants. area of building is required for handling 10000 liters of milk. the size of the well is required to be designed and depends on the quality of water.. Ltd.7. quantity and costs for 10.000 litres capacity plant are given in Statement 3. Nichrome Pvt. quarters. products manufactured. 9. 9. Accordingly .vehicles moving every day.. About 4000 sq.5 Technical Collaboration:Normally the technical collaboration may be for supply of machinery. iv) Fuel: LDO/coal/gas requirement and the availability to be ascertained. milch animal population . The machinery should be as per the BIS. etc. Depending upon the position of power supply. the water softening plant may be considered.1 Raw Material: The principal raw material is milk. 9. disinfectants and consumable should be ascertained.7 Infrastructural Facilities for Raw Material and Utilities 9. 9. The flow diagram for a 10. 9. Samarpan Fabricators .3 Layout and Buildings:The civil works comprises of factory building. The factory building for the milk reception. technical know-how for manufacture or marketing of products. 9. The total covered area depends on the processes involved.000 litre per day milk processing plant is furnished in the Annexure V for guidance. If any such collaboration arrangement is there.ft. HMT. transportation of milk and input supply to the farmers is required to be highlighted. Most of the dairy machinery are manufactured in the country by ALFA-LAVAL. Goma Engineering Ltd.6 Manufacturing Process:The operations involved in the manufacturing process should be given in the form of a flow diagram.

2. milk products and miscellaneous items. the availability of manpower should be looked into and the total requirement of manpower depends on the operations involved and the quantity of milk handled. office. 9. The items of income includes sale of liquid milk. Detailed market survey report is required to be submitted. viii) Communication: Proper communication facilities is essential. internal roads. The final effluent should meet the requirements of Pollution Control Board and is necessary to get clearance from them. while the expenditure includes the cost of raw material. The company projections for the next 3-5 years and the basis for projection may have to be furnished. 64. Rs. civil works (Plant building. fixed assets. quarters. Salient features of 10000 litre model milk processing plant is given in Statement 1.9 Environmental Aspects and Pollution Control: There are no hazardous effluents generated from a milk processing plant. .43 lakhs on account of misc. The details of project cost are furnished in statement 3. The product wise quantities and countries where it is to be exported need to be mentioned.52 lakhs on civil structures.Capital cost of a model dairy processing plant with capacity to process 10000 litres per day works out to Rs. 9. type of arrangements for distribution and sales. The project cost comprises of Rs. The detailed assessment of working capital and extent capitalised as margin money on working capital are presented in statement 2. the economics of the project has to be worked out for the project period or till the repayment of bank loan.4. preliminary and preoperative expenses. However. construction of effluent treatment plant is necessary in case of multiproduct large size plants for treating the effluents before discharging for proper disposal.8 Manpower: While selecting the site. margin money for working capital. For a plant handling 10000 liters of milk per day the manpower required is given in Annexure VI 9. commission and additional incentive to be given. The major competitors and their present share is to be ascertained. gap in supply and expected demand for various products. 11.37 lakhs of margin money for working capital. ECONOMICS OF THE PROJECT Based on the various techno-economic parameters.581 lakhs. The number of vehicles required.50 on vehicles. Rs. vii) Other Services: Although a maintenance workshop is an integral part of milk processing for carrying out repairs and maintenance of equipment. development of land. fencing. need to be furnished.38 lakhs on plant and machinery .10 Schedule of Implementation The activity wise schedule of implementation is to be given in the project.14.57 lakhs of contingency and Rs. Rs. composition in terms of fat and SNF and costing should be indicated. source of supply.116.22. rental charges etc.vi) Vehicles : The vehicles required for procurement and distribution of milk depends on the quantity of milk to be handled. 4.11 Products The major products and by products proposed to be manufactured along with quantities. etc.12 Marketing and Selling Arrangements The market for the product (domestic and export). Rs.81 lakhs on land and land development . 3. Depending upon the need. the requirement of vehicles may be considered in the project cost. CAPITAL COST OF PROJECT: Broadly the capital cost includes the cost of land. 10. 9.13 Business Prospects: It involves the present demand-supply for various products. etc. godowns. 9. deposits & preliminary and preoperative expenses. Rs. plant and machinery. the proposed net work and the advertisement plans should be furnished. 9. transportation and commission.).

profit before tax was estimated and income tax was considered @35% as per the existing rates . 15.145 laches . NPW is Rs.1 Margin Money: The promoters/company should normally meet 25% of the project cost out of their own resources. LENDING TERMS AND OTHER REQUIREMENTS: 14. FINANCIAL ANALYSIS: The cash flow statement covering the Benefit Cost Ratio (BCR).12 : 1 2 acres 10000 liters/day Toned milk. repairs and maintenance. 14.75 lakhs and IRR is more than 50%. 14. fuel packing distribution. 14. For arriving at the tax liabilities. 116. The details of the cash flow analysis (without considering income tax) is given in statement 8.power. 29. Therefore. Gee Domestic Rs. advertisement and other overheads. Normally the BCR should be greater than 1. FINANCIAL ASSISTANCE The projects on milk processing including manufacturing of milk products would be considered for refinance support by National Bank. it may be upto 8 years with first one/two years as the grace period. 13. The income as well as expenditure for each year has to be worked out and then it should be subjected to cash flow analysis. insurance.12:1. NPW should be positive and IRR/FRR should be greater than 15%. The depreciation schedules on straight line method and written down value are worked out (statement 7). Net Present Worth (NPW) and Internal/financial rate of return (IRR/FRR) has to be worked out for the project. Standard milk.5 Refinance Assistance: NABARD provides refinance assistance as per the existing pattern from time to time. On post tax income the FRR of the project is worked out as shown in statement 9. 14. For the model diary processing plant of 10000 litres per day. all participating banks may consider financing this activity subject to their technical feasibility. 12. However. financial viability and bankability .3 Security: As stipulated by the RBI. Cream. 14. 87. CHECK LIST: A check list of various points to be considered for feasibility of the project is appended. the BCR is 1.4 Repayment Period: Depends upon the gross surplus generated. The entire bank loan can be repayable in six years including one year grace period during which only interest will be recovered (statement 10). The methodology for estimating the income and expenditure is given in statement 5 and 6 respectively. Statement 1 Project at a glance for 10000 litres model milk processing plant 1 2 3 4 5 6 7 8 Land requirement Milk handling capacity Products to be manufactured Market Cost of the project Bank loan Margin money (Down payment) Financial viability ( at 15% D F ) BC R 1. wages and salary. 134. For the model project under consideration.436 laches Rs.581 laches Rs. the relevant technoeconomic parameters are furnished in statement 4. NABARD could consider providing margin money assistance in suitable cases.2 Interest Rate: Interest rate will be determined by RBI/NABARD from time to time.

460 5.250 0. Note : 1. Rs.56 165/RM LS LS 0.450 0.540 6. Particulars No.026 3.564 7. Particulars Unit cost (Rs.702 1.) I 70% 1 2 3 4 5 Stock in progress Packing material Chemicals & detergents Stores.960 0.259 9.168 0.479 2.75 15000 each 0.368 11.134.289 1.370 7. (statement 5).19.080 0.280 0.399 II 80% 0.0.30 iii) Gates iv) Land leveling and roads vi) Water Supply (borewell. Specification Quantity Unit Cost (Rs) Total Cost (Rs.326 0.763 8.798 7.400 6.822 9.17.624 0.70 0.220 0.00 10.420 4.189 0.408 III onwards 90% 0.670 13.452 17.504 0.840 0. It is assumed that payment to the producers are made once in a week.577 6.75 lakhs > 50% >50% 6 years with one year grace period Statement 2 CALCULATION OF MARGIN MONEY ON WORKING CAPITAL (Rs.00 1 1 10 30 7 0.0.00 40.394 0. pump) . Statement 3 CAPITAL COST OF THE PROJECT Sr.No.377 1.110 0. tank.914 13.052 2.686 5.950 4.569 0.523 15.80 0. Interest on working capital during first year is considered for 6 months only. In lakhs) 6 1 i) ii) 2 Land (including registration charges) Development charges 3 -brick wall Steel WBM -- 4 2 acres 424 RM 2 --- 5 A) LAND AND SITE DEVELOPMENT 78000/acre 1.07 -1 30 30 30 0.50 1.301 3.405 Period days Years ** Outlay on stores and spares is considered @ Rs.147 0. second year and third year onwards respectively on assuming 40% of power and fuel charges and repairs and maintenance. Rs. in lakhs) Sr.0.NPW IRR FRR ( Considering income tax liability) 9 Repayment Rs.40 0.00 40. 2. spaces and fuel** Finished goods Toned Milk Standard Milk Saleable Cream Saleable Ghee 6 Receivables Total ( 1 to 6) Less sundry creditors (days) Total working capital required Margin money @ 25% of working capital Bank Cash credit Interest on working capital @ 16% 7 9.546 0.15 per litre during first year.

20 2.50 0.00 0.60 LS 600 LS LS LS LS 0.000 75.12 1.76.000 3.14 1.18.10 iii) Condenser tank iv) Superviser quarters v) Workers quarters Total C) PLANT AND MACHINERY i) ii) Can conveying and washing system Weigh scale 450 sq.28 3.45 vi) Milk cans vii) Crate conveying system & trolleys viii) Lab equipment ix) Effluent treatment plant x) Water softener Total E) VEHICLES i) ii) Jeep Mahindra Scooter Bajaj Total F) DEPOSITS i) ii) State electricity board Telephone Total PRELIMINARY & PREOPERATIVE EXPENSES i) ii) Incorporation of company Project preparation 1 1 3.000 LS LS LS LS 30.ft. 250/sq.5KVA ------2 1 1 1 1 1 2 1 1 1 1 1 1 -1 set 4 --LS 1.76 0.08 14.000 99.20 12.000 25.76 3. 600 sq.ft 1000 sq.82 6.57 1. --300/sq.35 0.ft. FIXED ASSETS i) ii) Furniture Computer iii) Fire fighting equipment iv) Collection centre equipment v) Work table 3000/centre 0.25 0.52 -500 kg 1000 lts -3000-5000lph 2000-5000 lph 5000 lph 10. 200/sq.97 5. iii) Dump tank and accessories iv) Detergent tank v) Milk chiller vi) Cream Separator vii) Milk pasteuriser viii) Storage tanks ix) S S tanks x) Packaging machine & accessories xi) Ghee boiler xii) Ghee storage tank xiii) Boiler & accessories xiv) D.21 3. butyr.38 -Pentium -Centrifuge.81 9.000 LS LS LS LS 3.13.00 15.ft.60 0.50 --- --- LS LS 0.50 64.19.500 1.25 .ft.00 2.52 2.ft.75 0.20 -40 lts (plastic) ---------500 ----LS LS LS 0.ft.000 LS LS 1. 180/sq.59 0.50 0.25.36 0.00 0.ft.00 2.50 3.38 0.500 3.46 3.Total B) CIVIL WORKS i) Dairy plant building RCC ACC ii) E T Tanks --ACC ACC 3000 sq.000 lts 300 lts 2500 pph 500 kg 1000 lts 300 kg/h 62.02 1.20 0.25 3.G.31 0.23 2. set xv) Refrigeration equipment xvi) Electrical panels & cables xvii) Pumps xviii) S S pipes & fittings xix) Erection & commissioning Total D) MISC.25 0.7 7.25 0.000 59. LS LS 4.99 5.

00 40.No 1. Product mix i) Ii) Iii) Iv) v) Toned milk (3% fat) Standard milk (4.00 Written down value method 10 25 33 I II III onwards 2.40 0.60 5000 2500 460 115 169 9.00 40.5% fat) Cream (50% fat) Saleable cream (25% of iii approx. /litre Rs. 5.20 0.00 110. Chemicals & detergents 11. Repairs and maintenance 13.07 9. 6.33 0.38 4.3 1. Over heads (incl./ yr Rs.07 9. /litre Rs.iii) Market survey iv) Establishment ( Salary & wages ) v) Travelling vi) Consultancy vii) Administrative expenses viii) Interest during construction Total H) CONTINGENCY ( @ 5% of cost of buildings.00 10.50 9.57 I) MARGIN MONEY FOR WORKING CAPITAL ( 25% of first year's requirement .49 0.20 0.40 0.05 0.00 110.20 7.37 116. /litre Rs.40 0.00 Straight line method 3 10 10 80 8000 365 29.07 4.) Ghee Toned milk Standard milk Cream Ghee 17.85 7.37 0.42 0.58 10. /litre Rs.00 10.00 110.73 0./kg % Litres Unit litres /day 10000 70 7000 182 lakh litres/yr.00 90 9000 365 32. /litre Rs.05 0. 7. /litre Rs. Depreciation (%) Civil Structures Plant and Machinery Misc.20 0.00 10.30 4.20 0. /litre Rs.74 7. Salaries and wages 12. /litre Rs.20 0. 8. Selling prices . 4. 9.00 40.05 0.49 0.12 0. 3.40 0.73 0.2 ) J) GRAND TOTAL ( A+B+C+D+E+F+G+H ) Statement 4 TECHNO ECONOMIC PARAMETERS YEARS S.statement . Milk distribution cost 15.40 0.60 4375 2200 390 100 142 9. Fixed assets Statement 5 16.40 0. /litre Rs. Of insurance) 14. 2. plant & machinery and misc.12 0.12 0. Particulars Installed capacity Capacity utilisation No.00 2. 12. /litre Rs. fixed assets ) 0.60 5600 2800 555 135 206 9. /litre Lakhs Rs.20 0.00 1. /litre litres /day litres /day litres /day litres /day Kg/day Rs. of Working days Raw material – Milk Cost price of milk Commission on milk collection Transportation charges Power and fuel Packing material Rs.

3. 5.733 0.054 0. .065 litres/day litres/day litres/day litres/day kg/day 4375 2200 390 100 142 5000 2500 460 115 169 5600 2800 555 135 206 Unit I litres/day 7000 Years II 8000 III onwards 9000 5 Income per year (1st year for 6 months i. Lakhs Rs.144 388.570 6.No Particulars Unit I YEARS II III onwards 1.07.637 1.276 2.264 32.140 2. Lakhs Rs.00/ litre) Ghee ( Rs.046 0.0. Lakhs Rs.096 0.INCOME PROJECTIONS S.05.litre Rs.00 / litre ) Cream ( Rs.080 5.411 340.227 1.40.0. ) Ghee Income per day Toned milk (Rs.492 1.351 5. 10.200 216. lakhs 12. 7.milk Commission on milk collection Transportation charges Power and fuel (As per statement No.280 0.0.520 284.e.680 2.0. 5% fat ) Cream ( 50% fat ) Saleable cream ( 25% of iii approx.300 9.250 0. 10.579 Statement 6 EXPENDITURE PROJECTIONS S. 9.00 / litre ) Standard milk ( Rs.00/kg) Total income/day Rs.841 13. 110.litre -Rs. 2. 182 days) Rs.litre Rs. 4) Packing material Chemicals & detergents Salaries and wages(as per statement4) Repairs & maintenance Overheads Milk distribution cost (As per statement 4) Total operational cost Lakh litres/day Rs.litre Rs.643 3.20/litre Rs.220 0.litre Rs. Lakhs 0. 11.090 6.529 7.20.186 0.504 17.460 3.942 19. 6.892 4. Milk processing per year Raw material .740 94.548 5. Lakhs Rs.040 0.840 5.156 0.044 9.297 Statement 7 DEPRECIATION SCHEDULES OF CIVIL WORKS.548 2.644 125.0. FIXED ASSETS Note : The figures corresponding to each year represent end year values for the preceding year.932 0.06.7. In lakhs 147.850 243.40/litre Rs.804 11.810 0.253 29.710 317.500 0.394 0.0.No Particulars 1 2 i) ii) iii) iv) v) 3 i) ii) iii) iv) 4 Milk procured Yield per day Toned milk ( 3% fat ) Standard milk (4.9.492 1.40.450 0. 8.570 10. 4.840 10. PLANT & MACHINERY AND MISC.

Net profit 8.465 147.411 340.076 IRR is more than 50%.144 388.512 57.654 670.283 71.812 10.880 71.583 0. In lakhs) Sr.130 1.297 317.75 5 6 D F at 50% N P W at 50% D F 0.579 71.265 340.215 1.215 16.536 114.253 239.588 . On straight line method Civil works Plant and machinery Misc.903 51.046 26.212 125.054 0.176 2.283 1.695 -11.283 71.297 22.283 Particulars I II III IV V VI -11.158 55.609 0.452 5.297 388.579 388.072 186.330 34.No.331 18.579 VI BCR = 1. Residual value of a) Civil Structures b) Plant & machinery & misc.564 147.869 1.Statement 8 CASH FLOW ANALYSIS WITHOUT CONSIDERING THE INCOME TAX LIABILITY (Rs.661 52.072 9.921 22. No.528 61.379 20.264 284. Statement 9 CASH FLOW ANALYSIS ON CONSIDERING THE INCOME TAX LIABILITY (Rs.369 0.444 24.501 0. $ The capital cost considered excludes the capitalised margin money on working capital.150 0.148 49.857 3.951 52.253 284. Tax at 35% 7.569 12.906 -31. Amortisation of preliminary and preoperative expenses 5.250 7.046 17.297 317.904 257.579 317.12:1 NPW = + 134.997 46.797 114.411 284.667 -61.869 208.144 55.791 1.059 6.215 0.579 125.096 12. Profit before tax 6.297 317.095 128.307 1.362 0.579 388. fixed assets iv.144 317.215 1.810 0.100 ---340.093 1.449 16.820 0.432 137.411 -92.548 30. in lakhs) Years Sr.726 547.431 54.564 4.263 0.283 71.711 0.986 0.060 0. 1 Income (Statement 5) 2 Operational cost (Statement 6) 3 Gross operating profit 4 Less i) Interest on term loan @ 16% ii) Interest working capital @ 16% iii Depr.296 317.215 1.687 11. Net income available (7+4) 1.564 2.625 44.552 0.880 0.579 388.312 431. Benefits i.564 1. Particulars I II Years III to V 1. fixed assets ---Total benefits 3 4 Net benefits (3-(1+2)) D F at 15% a) P W of costs @ 15% DF b) P W of benefit @ 15% D F 147.133 37.158 46.215 0.000 9.559 1.135 21.297 388.148 ---388.326 1.394 40.296 317.054 9.756 214.953 5. Costs i) Capital cost $ ii) Recurring cost Total cost 2.088 10.264 317.

963 27.903 51.812 10.246 30. + residual value in last year) 10.250 7.130 8 22.690 0.534 Total repay ment (4+5+6) 7 10.951 52.564 1.429 Net income Balance left with com pany (8-7) 9 11.985 0.550 16.296 0.198 0.597 32. Repayment period : 6 years including 1 year grace period.148 49. 3. Name of the state No.869 2.108 9. $ During the first year the average loan utilisation is considered at 75% of the total amount. MILK PRODUCTION AND PER CAPITA AVAILABILITY OF MILK Population – in thousands (1992 census) Production – in thousand tonnes Availability – in gms.667 0.077 64.816 17.719 22.132 0. 2. 4400 44 740 3390 39 4750 9.431 54.476 0.083 18.828 20.077 80. 5. 4221 22 698 3250 36 4459 8.087 8.154 28.588 277.444 0.062 47. Annexure I STATE WISE CATTLE AND BUFFALOES.226 0. 4. 2.246 30.735 Int.117 13. 2632 95 3067 5366 30 2116 6. Sr.429 13. 221 7 136 65 4 126 Indigenous 4.979 16.178 D S C R = 2.326 1.569 1.806 0.976 135. Cattle Cross bred 1 1.636 16.178 30.000 4 0.450 6. on Wor king capital 6 0.282 10. 6.429 13.9. Net benefit after tax (capital cost in 1st yr. Financial rate of return (%) Discount factor @ 45% Discounted financial returns Discount factor @ 50% Discounted financial returns F R R is more than 50% Statement 10 REPAYMENT SCHEDULE (Rs.312 2 Begining of year 3 End of year 80.968 7.015 16. 2411 88 2931 5301 26 1990 5.611 1 1 2 3 4 5 6 80.980 -54.000 16. 163 64 80 97 81 280 Total Buffaloes Milk production Per capita availability 1992-93 1996-97 1994-95 Target .903 51.312 5 9.242 46.312 0.062 47.816 16. 2.148 92. in lakhs) Year Loan outstanding Prin cipal -82.047:1 1. 3.951 52.328 0.025 11.940 23.077 64.148 -56.631 25.431 54.609 12. 4729 3 298 2586 20 3130 7.276 26.564 1.321 26.158 46. Interest on Term loan and Working loan is assumed @ 16% per annum. on Term Loan $ Int.156 0. Andhra Pradesh Arunachal Pradesh Assam Bihar Goa Gujarat 3.559 4.564 1.

7. 1.10 Annexure III YEARWISE EXPORT OF DAIRY PRODUCTS Year Quantity(tonnes) Value (Rs.1 205 170 74383 122. 4. Meghalaya 16 Mizoram 17 Nagaland 18 Orissa 19 Punjab 20 Rajasthan 21 Sikkim 22 Tamil Nadu 23 Tripura 24 Uttar Pradesh 25 West Bengal 26 Union Territories GRAND TOTAL Source : Directorate of Economics and Statistics and State Department of Animal Husbandry and Dairying. Haryana Himachal Pradesh Jammu & Kashmir 159 122 251 277 905 89 897 28 10 3 45 262 730 43 16 800 44 648 430 41 6359 543 602 774 3605 825 8590 4879 147 190 21 71 3965 449 4478 48 2493 255 6297 5256 62 56297 702 724 1025 3882 1730 8679 5776 175 200 24 116 4227 1179 4521 64 3293 299 6945 5686 103 62656 2220 468 417 2315 110 3501 3201 38 10 3 10 434 2808 4091 1 1552 7 10097 233 174 42456 4062 663 780 3004 2117 5048 4811 64 54 14 46 584 6215 5103 32 3695 38 11321 3250 364 63951 4062 700 900 3260 2370 5205 5200 62 57 18 44 650 7100 5350 34 3867 40 12463 3440 387 68581 630 332 257 173 192 195 156 89 77 51 92 48 795 296 200 174 35 209 123 80 191 10.4 11. of Milk sheds No of Dairy Co-operatives Average milk procurement(LLPD) Processing capacity(LLPD) Targets 65 192 191 150000 150 220 Achievements 70.57 . 2. Manipur 15.11 32.37 12. Madhya Pradesh 13. Maharashtra 14. in crore) 1980-81 1985-86 1990-91 1991-92 1992-93 1993-94 1994-95 1995-96 Annexure IV 1084 395 604 2643 3800 2031 8957 NA 1. No.60 265. Kerala 12. Annexure II DAIRY DEVELOPMENT TARGETS AND ACHIEVEMENTS FOR VIII FIVE YEAR PLAN Sr. 8.47 40.99 1.04 2. 3. 9. 5 6 Particulars Milk production (million tonnes) Per Capita availability (gm) No. Karnataka 11.24 8.

for milk storage tanks./month) 1.ESSENTIAL SECTIONS OF A MILK PROCESSING PLANT The milk processing plant shall have the following essential facilities. v) Packing area-for packing of liquid milk and other products.for providing veterinary service. maintenance and store area for spares. pasteuriser and other related machinery are installed. 2. 6. 8. ii) Processing Hall . supply of feed.consisting of can conveyor. 4.cream separator. Plant Manager Procurement officer Field supervisors Processing supervisors Mechanics Driver Watchman Administrative staff Laboratory staff Unskilled labour Total Other perks Total salary and wages Index to Figure 1 S. dump tank etc. 3.No 1 2 3 4 5 6 Particulars Roller conveyor Dump tank Milk pump Float balance tank Milk pump Simple filter Quantity 1 1 1 1 1 1 H. water treatment plant. 10. the required equipment needs to be installed. x) Quarters and office area-for all the essential staff.No. Annexure VI SALARIES AND WAGES Sr.P 2. generator set. Particulars Number Salary/Wages (Rs. vii) Quality Control Laboratory-for testing the quality of milk and milk products. fodder seeds. viii) Utilities area-for installing boiler.year) 90000 60000 72000 72000 48000 18000 54000 48000 48000 144000 678000 271200 949200 . ix) Waste water treatment plant area-for treating the dairy effluents before releasing to the fields. weighting balance. iv) Products manufacturing area-depends upon the type of products and the quantity of milk handled. 5. 9. 7. chiller. xii) Input supply area. can washer.6 Capacity/ Make 5 mts 1000 lts 5000 lph 100 lts 5000 lph 1 1 2 2 2 1 3 3 2 8 25 (40% of the salary 7500 5000 3000 3000 2000 1500 1500 2000 2000 1500 Total (Rs. vi) Cold storage-for keeping the milk and milk products before sending to market. i) Raw Milk Receiption Dock (RMRD) .5 2. homogenizer. iii) Storage area. xi) Vehicle parking area-both for the milk procurement and distribution vehicles. etc.

0 15. viii) Technology Indigenous/Imported.5 1.5 7. expertise etc.5 1. Name and address of foreign collaborator (If any).0 6.5 3.0 2. ix) Brief write up on the organisation and collaborators (Giving information on projects implemented.Certificate/ Memorandum and Articles of association (as applicable) v) Certification of incorporation/commence-ment of business vi) Bio-data of directors vii) Profit and loss account and balance sheet for the last three years.) x) Copy of agreement with foreign collaborator xi) Copy of import license for equipment/plant and machinery.5 2.0 5000 lph 5000 lph 100000 KCal/hr Beacon FK 750 Kirloskar 2500/hr Elgi Kirloskar 1000 lph 200 cans / hr 250 kg/hr 500 kg 5000 lts each Appendix Check list for Milk Processing Project A) ORGANISATIONAL i) Type of beneficiary : Individual/Co-op Society Partnership Firm/Company ii) Address .0 1.0 1.Plant site Office : iii) Objectives of the organisation iv) Copy of the by-laws/ Regn.7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 Pasteuriser Holding vessel Control panel Milk transfer pump Hot water generator Hot water pump Electrical panel Remote control panel IBT agitator Ice bank tank IBT coils Liquid separator Chilled water pump Frion Compressor Motor for compressor Frion recoveror Pouch filling machine Air compressor Air cooling unit Cream separator Can steaming block Can scrubber Can wash through Ghee boiler Ghee storage tank Ghee transfer pump Raw milk storage tank 1 1 1 1 1 set 1 1set 1 1 1 1 1 2 2 2 1 1 1 2 1 1 1 1 1 1 1 2 210 1.0 1. .0 1.0 2.

processing. : PART C : TECHNICAL i) Location(present constraints on procurement. packaging).xii) Copy of the RBI clearance regarding Foreign Exchange/Exports. security.rate of interest. repayment schedule. : ii) Present market demand/ supply and future projections . xiii) RBI Code Number : xiv) Import-export code No. : xv) Approvals / permissions required a)NA permission from competent authority b)Pollution Control Board : c)Factory inspector : d)Electricity board : e)Irrigation dept. : viii) Working capital requirement (Itemwise detailed estimates) : ix) Arrangement for the working capital loan : x) Subsidy component (if any) and name the details regarding the organisation giving subsidy. : iv) Public issue. if any : v) Bank loan (Indian Rupee) : Name and address of the bank branch (letter of consent to be enclosed). transportation.domestic and export. ii) Promoters contribution : iii) Foreign collaborators contribution/equity participation from any organisation. storing. : xiii) Lending terms . for water lifting etc : f)Ground water report from competent authority g)Registration of brand name : h)MMPO registration : PART B : FINANCIAL i) Financial outlay with phasing (itemwise detailed break up of the outlay). if applicable. : iii) Promoters : iv) Proposed plant capacity : . : xi) Marketig arrangement/buy back arrrangements(letter of consent) : xii) Arrangements for insurance of capital goods and the product. vi) Foreign exchange component loan : vii) Name of the bank providing foreign exchange and letter of consent.

and layout plan (Section wise). : f) Utilities . : ix) FDA regulations and Export of quality products. : e) Detailed list and cost of imported items of equipment and license for import. etc. environmental social Issues. fodder. : xii) Supply of inputs . : g) Detailed processing mechanism (process flow Chart) : h) Byproduct processing : i) Handling. vety. : xi) Steps to involve farmers participation in maintaining milch animals. etc.v) Availability of raw Material : vi) Site location . packaging. : d) Machinery . : vii) Project engineering : a) Site plan and map along with necessary approval : b) Land.water electricity. Feed.detailed drawings.specification and costs. essential quarters etc. Land Development fencing. quality control lab and equipment.suitability of site. : x) Implementation schedule and PERT Chart. : l) R & D. : . : c) Civil works . specifications quantities and costs. preservation and marketing of milk including countries to be exported. aid. fuel with detailed specifications . transport facilities. quotations.Al. : viii)Man power requirement Technical staff and training needs. processing. : j) Effluent treatment : k) Other amenities. fodder seed. drainage. : m) Office.

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