Wednesday, 30 November 2011

Start a Pasta Products Manufacturing

    
(233) Start a Pasta Products Manufacturing 


     

Pasta Products
Production Capacity
:
150 tpa
Uploaded on:February 2009
1.0 Product and its Applications
One of the popular pasta products is noodles made from tapioca flour and maida. These are thread like products, 0.22 to 0.40 mm in diameter. This product is becoming very popular due to increasing consumption of fast foods.
2.0 Market Potential
The demand for pasta food is over increasing due to growing trends towards fast foods particularly among younger generation, increase in the purchasing power of the people, convenience of preparation, scope for a number of recipes to suit individual's palate.
3.0 Basis and Presumption
a) The unit will work for 300 days per annum on single shift basis.
b) The unit can achieve its full capacity utilization during the 3rd year of operation.
c) The wages for skilled workers are taken as per prevailing rates in this type of industry.
d) Interest rate for total capital investment is calculated @ 12% per annum.
e) The entrepreneur is expected to raise 20-25% of the capital as margin money.
f) The unit would construct its own building.
g) Costs of machinery and equipment are based on average prices of machinery manufacturers.
Implementation Schedule
Project implementation will take a period of 8 months. Break-up of the activities and relative time for each activity is shown below:
Scheme preparation and approval:01 month
SSI provisional registration:1-2 months
Sanction of financial supports etc:2-5 months
Installation of machinery and power connection:6-8 months
Trial run and production:01 month
5.0 Technical Aspects
5.1 Location
The plant can be located at any suitable place keeping in view the marketing convenience, availability of power, water and skilled manpower.
5.2 Process of Manufacture
The noodle is manufactured in different sizes, hollow as well as solid and cooked in different methods. Some are made for cooking and others are for frying. The manufacturing method for frying quality noodles is as follows: The average moisture content of dry mixes is 10-11%. The three ingredients, viz. maida, starch and sodium bicarbonate are dry blended in a vertical mixer along with edible colour. Dough is made from the above blend by using boiled water wherein a part of the starch is gelatinized. The ingredients are mixed in dough mixer for about 12 to 15 minutes. The kneaded dough is transferred to a noodle making machine herein extruded material of desired shape and length is obtained by using an appropriate die and suitably adjusting the distance between the dye surface and cutting blade. The moisture content of the product at this stage is about 33%. The cut noodles from the cutting machine fall on wooden trays. The product undergoes surface drying and becomes hard enough to be handled without sticking or being crushed. The moisture content of the pre-dried product at this stage is about 30%. The pre dried product is finally semi-dried. The moisture content of the product is around 17%. The product is exposed to steam for 15 minutes and subsequently dried to 10% moisture level.
6.0 Pollution Control
There is no major pollution problem associated with this industry except for disposal of waste which should be managed appropriately The entrepreneurs are advised to take "No Objection Certificate" from the State Pollution Control Board.
7.0 Energy Conservation
The fuel for the steam generation in the boiler is coal or LDO depending upon the type of boiler. Proper care should be taken while utilising the fuel for the steam production There should be n
8.0 Production Capacity
Quantity150 tpa
Installed capacity700 kg/day
Optimum capacity utilization70%
Working days300/annum
Manpower12
Utilities
Motive Power25 kW
Water10 kL/day
Coal/LD oil125 kg/day
9.0 Financial Aspects
9.1 Fixed Capital
9.1.1 Land & Building
ParticularsAmount (Rs. lakh)
Land 60 m 202.50
Built up area 150 m 211.00
Total cost of land and building13.50
9.1.2 Machinery and Equipment
DescriptionAmount (Rs. lakh)
Vertical powder mixer cap 500 kg, Dough mixer, noodle making extruder, Wooden trays , boiler, weighing scales, buckets, handling equipment:05.50
Erection & electrification of machinery & equipment @10% cost:00.55
Office furniture & fixtures:01.75
Total:07.80
9.1.3 Pre-operative Expenses Amount (Rs. lakh)
Consultancy fee, project report, deposits with electricity department etc02.00
9.1.4 Total Fixed Capital Amount (Rs. lakh)
(9.1.1+9.1.2+9.1.3)23.30
9.2 Recurring expenses per annum
9.2.1 Personnel
DesignationNo.Salary Per monthAmount (Rs. lakh)
Factory Manager1120001.44
Supervisory staff280001.92
Office Assistant260001.44
Technician250001.20
Skilled workers130000.36
Unskilled workers425001.20
7.56
Perquisites @15 %1.14
Total128.70
9.2.2 Raw Material including packaging materials
ParticularsQty (t)Rate/t (Rs.)Amount (Rs. lakh)
Maida1301600020.80
Starch201400002.80
Salt, chemicalsLS-01.50
Packaging materialLS-05.20
MiscellaneousLS-01.70
Total32.00
9.2.3 Utilities
ParticularsAmount (Rs. lakh)
Power0.90
Water0.10
Total1.00
9.2.4 Other Contingent Expenses
ParticularsAmount(Rs. lakh)
Repairs and maintenance @10%0.61
Consumables & spares, others0.55
Transport & travel0.30
Publicity, postage, telephone1.36
Insurance @1%0.18
Total3.00
9.2.5 Total Recurring Expenditure Amount (Rs. lakh)
(9.2.1 + 9.2.2 + 9.2.3 + 9.2.4)44.70
9.3 Working Capital Amount (Rs. lakh)
Recurring expenses for 3 months11.20
9.4 Total Capital Investment Amount (Rs. lakh)
Fixed capital (Refer 9.1.4)23.30
Working capital (Refer 9.3)11.20
Total34.50
10.0 Financial Analysis
10.1 Cost of Production (per annum) Amount (Rs. lakh)

Recurring expenses (Refer 9.2.5)44.70
Depreciation on building @ 5%00.55
Depreciation on machinery @10%00.60
Depreciation on furniture @ 20%00.35
Interest on Capital Investment @ 12%04.15
Total50.35
10.2 Sale Proceeds (Turnover) per year
ItemQty (t)Rate/t (Rs.)Amount (Rs.lakh)
Noodles1504500067.50
10.3 Net Profit per year
=
Sales - Cost of production
=
67.50– 50.35
=
Rs. 17.15 lakh
10.4 Net Profit Ratio
=
Net profit x 100
-------------------------
Sales
=
17.15 x 100
-------------------
67.50
=
25.4 %
10.5 Rate of Return on Investment
=
Net profit x 100
-----------------------------
Capital Investment
=
17.15 x 100
-------------------------
34.50
=
49.7 %
10.6 Annual Fixed Cost Amount (Rs. Lakh)
All depreciation01.50
Interest04.15
40% of salary, wages, utility, contingency05.08
Insurance00.18
Total10.91
10.7 Break even Point
=
Annual Fixed Cost x 100
-----------------------------------
Annual Fixed Cost + Profit
=
10.91 x 100
--------------------
10.91+ 17.15
=
1091
----------------
28.06
=
38.9 %
11.0 Addresses of Machinery and Equipment Suppliers
1. M/s Marvel Machines Pvt Ltd.
140, Anna Salai, Saidpet
Chennai - 600015
Email: marvel12@vsnl.com
2. M/s Gee Gee Foods & Packaging Co. (P) Ltd.
B -188/2, Savitri Nagar,
Malviya Nagar
New Delhi -110017
Email: swantour@satyam.net.in
3. M/s Azad Engineering Company
C-83, B.S. Road, Indl Area,
Ghazibad -201009
Email: azadeng@satyam.net.in/azadenggco@hotmail.com
4. M/s M. Son Industries
D -33, Sector 2,
Noida -201301
Email: mson@nda.vsnl.net.in
5. M/s Sanjivan Industries
A -13, Karimsheth Indl. Estate,
Wagdevi Nagar, Near Valishali Nagar
Dahisar (E), Mumbai -400068
Email: sanjivanind@roltanet.com
6. M/s Pharamalab India Pvt. Ltd.
Star Metal Compound,
LBS Marg, Vikroli (W)
Mumbai -400083
Email: mkt@pharmalab.com
7. M/s. Mona Machinery Mfg. Co.
Chandralok, 111 SD Road,
Secunderabad (A.P.)
8. M/s. Khan Engg.
Works, 5-5-274 Nampally,
Near Gandhi Bhavan, Patel Nagar
Hyderabad
9. PPM International
70, Rama Road,
New Delhi –110 015
10. M/s. Mahalaxmi Engg. Works,
Craftman, Gylid, Mallepally,
Hyderabad
11. M/s. Debdoot India,
67-B, Biddan St.,
Kolkata – 700006
.Jyothi Industries.
12. Shanti Engineering Works
Figure of 8 Road
Coonoor – 643 101
13..M/s Hightek Engineers
702, GIDC, Phase II, Gundiav,
Valsad -396035 (Gujarat)
Email: info@hightekengineers.com
14. M/s Bombay Industrial Engineers
13, Crystal Apartments,
Gulmohar Cross Road,
12.0 Other Special Features
A careful selection of product mix is necessary based on the local market demand and availability of raw materials. The facilities can also be utilised to manufacture other pasta products with local recipes for fuller utilisation of capacity.
Contact for more information: 
Information Manager
TIMEIS Project
E-mail: timeis@ficci.com

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