project report of dmr marketing limited

Project Report of Ms/ DMR Marketing Private Limited

Chapter Particulars Page No.

1 Introduction

1.1 M/s Mamta Food Products 5

2 Location & Operation 6

2.1 Location of the Company 6

3 Prospective Clients & Suppliers List 7

3.1 Prospective Clients 7

3.2 Prospective Suppliers 7

4 Partners Background & Profile 8

4.1 Background of Partners 8

5 Products & Services of the Company 9

5.1 Chakki Fresh Atta 9

5.2 Chana Besan 9

5.3 Chana Dal 9

6 Manufacturing Process 10

6.1 Wheat Flour 11

6.2 Gram Besan 13

7 Infrastructure 15

8 Industrial Scenario 17

9 Production/ Cultivation Scenario 20

10 Market Study 22

11 SWOT Analysis 29

12 Quality Control 30

13 Key Players 32

14 Brief of the Proposed Proposal 34

14.1 Total Credit Exposure to the firm 34

14.2 Means of Finance for Term Loan 34

14.3 Details of proposed plant & machinery & Utilities, Electrical & Civil

Construction

35

14.4 Assessment Of Working Capital 39

14.5 List of Security Offered 40

14.6 Financial Data 41

14.7 Cash Flow 42

2 Project Report of Ms/ DMR Marketing Private Limited

14.8 Profitability Projections 47

14.9 Projected Balance Sheet 49

14.10 Calculation of DSCR 50

14.11 Calculation of ISCR 50

14.12 Draw-Down Plans 51

14.13 Project Implementation Schedule 51

14.14 Repayment Schedule 51


VISION:

To be a well acceptable Taste in the market.

MISSION:

To provide hygienic food in the present most polluted & stressful life. Serve the Indian people by providing highly nutritious food products. To manufacture the highest quality of flour products and to provide services with exceptional

value to our customers.


Chapter-I

1.1 M/s MAMTA FOOD PRODUCTS:

Mamta Food Products is a registered partnership firm established in May 2011 to serve the Indian people through manufacturing & marketing of the high quality, nutritious food products mainly Wheat Flour & Gram Besan. The products will be manufactured at their proposed unit located at near Taloja Industrial Estate, Close to Navi Mumbai.

Looking to the increase in population in India the demand for basic necessity of life which is staple food is increasing rapidly. So, by keeping this in mind the products (such as Wheat flour which is used in making Chapattis, Purées, Parantha and other roasted cereal based products. Gram Besan which is used in cooking food like in making curries, pakoda etc. & some sweet dishes) which we are proposing to manufacture in our flour mill will be free from any artificiality and therefore it would be helpful in mental as well as physical growth of the family members. For manufacturing Wheat Flour & Gram Besan we will use fully automatic chakki atta plant & besan plant under the hygienic conditions, in order to meet the set quality standards.

During this whole process the By-Products which will be obtained from it such as bran from wheat flour & chuni from chana besan will be used by the dairy industry as feed for the livestock. These products will be properly packed into rugs and bags, ensuring their safety during transportation, loading and unloading. These products will be hygienic in nature and at the same time, offer high nutritional value and longer shelf life. Further, these will be safely secured in our warehouse so that these can be saved from worms & environmental changes. In addition, with the help of these precautions, our products will be good in taste and completely pure because we believe in service to the customer so that they enjoy the satisfaction of savoring the best food products, a true value for money.


Chapter-II

2.1 LOCATION OF THE COMPANY Administrative Office:

Plot No- 7/9 Opposite Jindal Drugs Ltd., Taloja MIDC Area, Taluka Panvel, Dist. Raigad, Navi Mumbai-410208, Maharashtra. Tel. :- +91-9768130940 EMAIL : [email protected].

Locational Advantages:-

Plot which was selected to construct this dream project is situated just across the existing industrial belt of Taloja MIDC.

Manpower required to run the facility will be easily available within close proximity of Taloja MIDC area.

Advance means of transport & communication will be easily available at site.

An uninterrupted round a clock electric & water- supply will be easily available at a location.

Due to close vicinity to JNPT & upcoming International Airport there will be an ample storage & warehousing facility at good commercial rates.

The logistic facility to bought raw-material to the factory & finished products to the various locations will be easily available at Taloja MIDC area.

Since it will be located in such an area where promoters can appoint marketing professionals & agencies who were having more than 15-20 years of experience in marketing of the food products at relatively much cheaper rate.


CHAPTER-III

3.1 PROSPECTIVE CLIENTS:-

Sr.No. Names Addresses1. Mukesh Traders Plot No-256, Pimpri- Chinchwad Link Road,

Near Pimpri Main Over Bridge, Pune-4110172. Maratha Palace Plot No-10/11, Kodoli, Vilaspur, Banglore

Highway, Satara.3. Mayura Enterprises E-15/1, MIDC Area, Murbad, Dist. Thane

4. Hariyana Trading Co. 481, Market Yard, Pune-4110375. Amrita Foods Gala No-10-11, Yashshri Apartment, Bapat

Vadyasmor, Panvel..

6. Laxmi Traders Plot No-506/507, Marketyard, Gultekdi, Pune-411037

3.2 PROSPECTIVE SUPPLIERS:-

Sr.No. Names Addresses1. Manish Trading Company 51, New Anaj Mandi, Sanyogitaganj, Indore

(M.P.)2. P. Laxmichand & Co. M-7, A.P.M.C. Market II, Phase II, Turbhe,

Navi Mumbai-4007033. National Engineering Corporation 2, Saibaba Shopping Centre, Keshavrao

Kadam Marg, Mumbai-400008

CHAPTER-IV7 Project Report of Ms/ DMR Marketing Private Limited

4.1 BACKGROUND OF PARTNERS:

The Partners of the firm are as under 1. Mr. Rajendra Shivajirao Kadam2. Mrs. Vandana Kishore Khole

Mr. Rajendra Shivajirao Kadam, 44 years who is having immense experience in the same line of business since his childhood as he was working in his own flour mill at his native place. He has done Masters in Human Resource Development from K. J. Somaiya Institute of Management Studies & Research, Mumbai University.

He was working in the Austrian Multinational Infrastructure & Construction Company as “HR & Administration Manager”. He has also worked as a “Senior Manager” in Nicholas Piramal India Limited in the Administration & Industrial Relation department at Research Center, Goregaon. He has worked in many other companies related to HR, Administration & Audit field.

Achievements:- Honored by the management, for saving lives of employees, by providing timely medical assistance, at

Nicholas Piramal India Limited.

Received Appreciation Certificate & Trophy with Cash Prize, in the year 2004, for handling all Liaison work and co-ordination with all major state and central government agencies, while at Nicholas Piramal India Limited.

Personal Detail : Name : Rajendra Shivajirao Kadam

Designation : PartnerQualification : MBADate of Birth : 27/12/1966Residential address : Flat No-18/602, Siddhachal Co-operative Housing Society,

Phase-III, Vasant Vihar, Thane (W)-400610

Mrs. Vandana Kishore Khole, 26 years who is a young, energetic, experienced & adequately qualified in B.A (Eco.) person. She is fond of administrating organizational activities & licensing with governmental, non-governmental authority & is equally aspirant in exercising her talent in the ensuring projects.

PERSONAL DETAILS:

Name : Vandana Kishore KholeDesignation : PartnerQualification : B.A.(Eco.)

Date of Birth : 22/12/1984 Residential address : A-1/4, 1st Floor, Shree Samrudhi CHS opposite Kokan Mercantile

Bank, Dudhnak Kalyan(w)

C HAPTER-V


5.1 Chakki Fresh Atta

Chakki Fresh Atta is the finish product of wheat will be procured from various local market/ mandis from the state of MP (Indore), Gujarat, Rajasthan & Punjab which are available in good quality & the same will be delivered to the manufacturing site through commercial vehicles like trucks & containers.

It is made from finest quality golden wheat grains, meticulously destoned and clean, untouched by hand in a completely hygienic environment. Real chakki atta is a good source of dietary fibre, minerals and vitamins. Therefore consuming whole wheat atta reduces chances of chronic diseases. Hygienically packed in the most modern plant.

5.2 Chana - Besan

The source of supply of Gram (Chana) will be basically imported from Australia or Ghana. The same can be procured from local markets from the state of Gujarat, Harayana, Maharashtra & part of MP from various locations. The quality of imported chana is far better than the quality available at local market. Due to location advantage of our manufacturing site import of chana from Australia & other countries will be more feasible because we can utilize JNPT as well as Mumbai port trust facility for sale. They are just 30-50 km away from our manufacturing locations.

Fine quality Besan will be manufactured by using cool grinding technology. This technology helps in retaining all the essential nutrients of the gram, and maintaining optimum quality and its freshness. Hygienically processed, using best quality grams, these will be available in customized packaging to meet the needs of our clients. Highly nutritious and tasteful, our range will be used to make a plethora of appetite pleasing dishes including dhokla, gathia papri and dahi kadhi etc.

5.3 Chana - D al: During manufacturing process the shell of gram will be removed in cleaning

process by using Perforated Cylindrical Metal Sheet & gets chana dal Indian cooking pulse. It is a major source of proteins & is extremely nutritious and healthy. It will be packed in a variety of pack sizes for ease of storing & usage.

CHAPTER-VI


The Manufacturing Process of Wheat Flour & Gram Besan is described below through flow diagram which helps in understanding of how the whole process will work & how the final product will be obtained.

The Wheat Flour will be manufactured in Chakki Atta Plant & Gram Besan will be manufactured in Besan Plant where automatic machines will be used.

The whole process will be performed by keeping quality control standards in mind.

The final product will be sold in the market.


6.1) Wheat Flour : -

FLOW-DIAGRAM

Wheat (in Bags)

Unloading [Hopper]

Cleaning [Reel M/c]

Cleaning [V. S.-I]

Storage [Silo]

Cleaning

De-stoning

Scouring-I

Dampening

Storage

Scouring-II

Aspiration

Magnetic Separation

Storage [Bin]

Clean wheat

Grinding [Rollers]

Plansifter

Purifier

Packing

Project Report of Ms/ DMR Marketing Private Limited

Bran Wheat Flour

Brief Description of Above Process:-A) Cleaning Section:

Wheat will be thoroughly cleaned to remove all impurities including the dust adhered to the surface of the wheat grains. To remove the impurities a few set of cleaning stages are going to employed, such as pre-cleaning, cleaning first stage, second stage etc. Small pieces of sticks, stones, sand, straw etc., will be removed by scouring. The scourer removes outer husks, crease dirt and any smaller impurities with an intense scouring action. It will also b e passed through magnetic separator for the separation of iron particles. Aspiration system will be used as a cleaning means as air currents act as a vacuum to remove dust and lighter impurities. Destoner will be used to remove heavier particles like stone. After completion of cleaning, wheat will be conditioned by dampening. The conditioned wheat will be stored in a silo for 24 hours and then it will send to a milling section.

B) Milling Section:Milling of wheat will be carried out predominantly by roller flour mills. The roller milling system comprises of break rolls and reduction rolls. The break rolls and reduction rolls will be differentiated through the variation in their surface conditions. The surface of the reduction roll will be smooth where as surface of the break roll will be corrugated. In the break rolls, the bran is cracked and the kernel is opened. After each break, the mixture of free bran, free endosperm, free germ and endosperm still adhering to the bran will be passed through the next break roll while the middle sized endosperm called middling are sent to the reduction rolls and are used for grinding of free millings into proper flour size. After each reduction of endosperm (middlings) the flour will be shifted away from the bigger size middlings and the remaining middlings are passed again through reduction rolls.

The broken particles of wheat will be introduced into box-like sifter machines, where they are shaken through a series of bolting cloths or screens to separate the larger from the smaller particles. Inside the sifter, there are a number of frames, each covered with either a nylon or stainless steel screen, with square shape openings, reducing in size in subsequent stages of screening. Up to six different sizes of particles may come from a single sifter, including some flour with each sifting. Larger particles are shaken off from the top, or “scalped”, leaving the finer flour to sift to the bottom. The “scaled” fractions are sent to other roll mills and particles of endosperm are graded by size and carried to separate purifiers.

In a purifier, 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. Four or five additional “break” rolls, each with successively finer corrugations and each followed by a 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. Germ particles are flattened by later passage through the smooth reduction rolls and can be easily separated. The reduction rolls reduce the purified, granular middlings (called farina) to flour.

C) Wheat Roasting (Processing)The raw wheat bags are cut open & fed to bucket elevator (B/E). The B/E lifts the material & delivers to a rotary type-cleaning screen. The cleaned wheat will be stored in a separate room. This cleaned wheat will be retrieved as per requirement and fed to the roaster through a bucket elevator chute arrangement. The roaster is a cylindrical steel vessel with tapering ends on both sides and it is enclosed inside a refractory brick lined enclosure. The roaster is indirectly heated by an oil-fired burner. The wheat along with some quantity of sand is kept rotating inside the roaster and wheat gets roasted by the time it reaches the other end. The roasted wheat is discharged from the roaster and is lifted by a bucket elevator and sent to separate storage room. The combustion gas from the roaster enclosure is separately collected and discharged to atmosphere through a stack. After this process flour will be obtained & bran as a by-product.

12 Project Report of Ms/ Mamta Food Products

6.2) Gram Besan:- FLOW-DIAGRAM

Chana (in Bags)

Unloading

Cleaning

Scratching

Cleaning

Conveyor

Storing for24 hour

Drying

Storing for24 – 48 hours

Conveyor

Storage 6-8 hours

Scratching

Cleaning

Round

Splitting

Grinding/Pulverizing

Centrifuge (3 in parallel)

PPaacckkinging && DispatDispatchch


Gram Flour Chuni

Chana Dal

Brief Description of Above Process:-

A) Cleaning ProcessThe cleaning process starts from unloading of raw material (whole gram) from gunny bags to the plant site unloading area. The gram will be elevated continuously with the help of bucket elevator (B/E) and fed to a cleaning screen. The cleaning screen comprises of perforated cylindrical metal sheet with holes of various sizes. The impurities such as dirt, dust, mitti, plant waste remains, shells of gram etc. are cleaned either by screening through the screen or by blowing away the impurities with the help of axial fans & get lentil ( chana dal). Some units also use destoners to remove stones from the chana dal. They are then passed through a set of rubber rollers (called reel machine) to scour adhered dust etc. and to break the tips of chana dal (called Nakku) which is again passed through a Second or Th i rd set of rotary screens for screening the impurities. The clean pulses are then sent for conditioning.

B) Conditioning ProcessThe conditioning process involves application of water followed by soaking for desired hours under sun-drying The soaking time is about 6 hrs or more. After proper conditioning, the pulses will sent for milling.

C) Milling ProcessThe milling process mainly involves application of abrasive force in various types of rollers to remove (separate) the outer shell of Gram, which will be followed by shearing of chana dal in two halves in grinders/chakkis. This pulse is easy to dehusk. Dehusking after cleaning and grading is done in roller machines. After milling process besan will be obtained & chuni as a by-product.

CHAPTER-VII

FOUR COMPARTMENT DRUM SIEVE :- It will be used to clean or grade the raw-materials at the various stages in the process. It adopts vertical suction channel and magnetic device to efficiently remove the large impurities, light impurities and magnetic impurities. It will be used for the first cleaning stage in the flour plant.

ROLL ( MODEL 1433) :- This machine will be used for marking the outer surface of the raw material helps in better absorption of water in pulse hence aiding the dehusking & splitting. It is normally made for the capacity from 1 MT / hr to 3 MT/ hr. depending upon the material and the use by allowing required power ranging from 10 HP to 25 HP

DESTONER:- This machine will be used to clean the raw materials by separating the stone, pebble, clod from wheat & gram. It works by weight where sizes are similar of materials those are to be separated from the other materials in stream. Normally in grain milling industry stones, glass and metal pieces are removed and separated so it is named de-stoner.

GRAVITY SEPARATOR:- This machine will be used as a combination of air flow nod principles of vibration to separate lighter, defective grain particles from the raw material depending on their specific gravity.

VERTICAL 18” CHAKKI :- This machine will be used for splitting the wheat & chana dal when it is attached to a pneumatic conveying system for offloading the output. Fresh air passing through the grinder always keeps the inside grinding system cooler. It is greatly being used in making whole wheat Flour( Chakki Atta).

ELEVATOR:- This machine is a kind of vertical conveyor used to transport the raw material from one machine to another. In grain milling industry, elevators will be used in cleaning section for vertical conveying because it consumes less power than a pneumatic conveying system.

WARUM :- This machine is a kind of horizontal conveyor used to transport the raw material from one machine to another. The capacity and required power depend upon diameter and RPM of screw.

BLOW FAN:- In this machine the raw material passes through a high pressure air stream which cleans any particle impurity present in the raw material which is lighter in weight than it. Normally HP Fan are used from 550 mm wg to 1050 mm wg in grain milling industry in milling section. Air volume varies from range of 1500 cmh to 12000 cmh in general cases.

MICRO PULVERIZER :- This machine will be used for pulverizing chana to besan. It consists of a rotor assembly fitted with hammers (beaters) & is generally operated at high speeds. The grinding action in all the pulverizes is due to the impact between rapidly moving hammers (beaters) & the particle itself. The energy of the moving hammers is dissipated into the particles being ground by virtue of their inertia, thus causing the particle size reduction.

Centrifugal flour filter unit:- This machine will be used for the filtration of the flour. It helps remove coarse particles from the flour. Fed materials into the filter, the spiral wing occurs a cyclone pressure inside the sieving screen to bring materials into cylinder. The spiral wing makes materials occur centrifugal force and let materials pass through the sieving screen quickly. The wing won’t contact the screen during working and it will break softer materials. In order to separate the fine and coarse powder, materials can’t pass through the screen will push forward into the coarse powder outlet.

17

Grains Fruits& Meat & Dairy Marine Consumer Vegetables Poultry Products Food

Food Processing Segments

fffffffood Processing ood Processing

USD

BnCHAPTER-VIII

India is the world’s second largest producer of food next to China and has the potential of being the biggest with the food & agricultural sector. The food processing industry is one of the largest industries in India- it is ranked fifth in terms of production, consumption, export & expected growth. India's Food Processing Industry is estimated to be around USD 67 billion of the USD 180 billion Food Industry and creates more employment opportunities per unit investment than any other sectors.

Food Consumption in India will grow at a CAGR of 5.32 percent

250 229.7: 198 210.3

200 168.6 180.1 184.4 191.4

151.7 157.7 150

100

50

0 2005 2006 2007 2008 2009 2010 2011 2012 2013

Contribution in GDP:-

This industry contribution in GDP is about 15% & has a share of about 12% in total industrial production & it is expected to growing above 17% in 2015.ontribon in GDP

Ministry of Food Processing Industries (MOFPI):-

They has formulated a Vision 2015 action plan which includes trebling the size of the food processing industry, raising the level of processing of perishables from 6 per cent to 20 per cent, increasing value addition from 20 per cent to 35 per cent, and enhancing India’s share in global food trade from 1.5 per cent to 3 per cent.

Below diagram shows food processing segments in India:-

18

Employment Opportunities:-

The Confederation of Indian Industry (CII) has estimated that the food processing sectors has the potential of attracting US $33 billion of investment in 10 years & generates employment of 9 million persons per day. It is a large sector that covers activities such as agriculture, horticulture, plantation, animal husbandry & fisheries.

Food processing is the set of methods and techniques used to transform raw ingredients into food or to transform food into other forms for consumption by humans or animals either at home or by the food processing industry. 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. The food processing industry is made up of primary, secondary and tertiary food processors.

Primary FoodProcessors

Primary industries process raw foods (wheat into flour, for example)

Secondary FoodProcessors

Secondary industries use primary products to manufacture other foods(flour into bread).

Tertiary FoodProcessors

Tertiary industries produce prepared convenience foods such as frozen dinners or canned soup.

In India, Primary Food Processing is a major industry with lakhs of rice-mills/hullers, flour mills, pulse mills and oil-seed mills. Also, there are several thousands of bakeries, traditional food units and fruit & vegetable/spice processing units in unorganized sector.Wheat & Gram which is the most widely produced cereal in the world, most of which is destined for human consumption; thus, its contribution to energy intake is significant. The processing of whole wheat & Gram to flour is generally concentrated in a few large mills. Processing of grain includes milling of wheat and pulses. In 1999-00, there were Around 820 large flourmills in the country convert about 10.5 mn tones of wheat into wheat products. Also there are 10,000 pulse mills milling about 75% of pulse production of 14 mn tones in the country.Primary milling of grains is the considered to be the important activity in the grain-processing segment of the industry. However, primary milling adds little to shelf life, wastage control and value addition. Wheat is processed for flour, refined wheat flour, semolina and grits. Apart from the 820 large flourmills, there are over 3 lakh small units operating in this segment in the unorganized sector. Dal milling is the third largest in the grain processing industry, and has about 11,000 mechanized mills in the organized segment. Oilseed processing is another major segment, an activity largely concentrated in the cottage industry. According to estimates, there are approximately 2.5 lakh ghanis and kolus which are animal operated oil expellers, 50,000 mechanical oil expellers, 15,500 oil mills, 725 solvent extraction plants, 300 oil refineries and over 175 hydrogenated vegetable oil plants.

19

Food Processing Units in Organized Sector (numbers)

Source: Ministry of Food Processing Industries

Pulses occupy important place in the world food and nutrition economy. Pulses are an important constituent in the diet, and are primary sources of protein. They also provide substantial quantity of minerals and vitamins to the diet.

Wheat is the staple food of Northern India and is commonly used all over the country in the form of its by-products. Numerous type of qualities of wheat products and by-products of wheat like wheat flour, suji, maida & dalia etc. are produced by the wheat flour and processing mills. The wheat flour is used in domestic purposes for making chapatti. Wheat in combination of maida is used for making bread, biscuit etc.

20

CHAPTER-IX

1) Area Wise Share in Production of Gram/ Wheat

The Gram production in India increased from 6.33 Million Tons in 2006-07 to 8.25 Million Tons in 2010-11. Similarly, wheat production in India increased manifold from 75.81 Million Tons in 2006-07 to 81.16 in 2010-11.The figures of average cultivation area, production and yield of Pulse, Wheat in the country over last few years are given below:-

Area, Production & Yie ld Of Gram/Wheat In India

Year Pulse(Gram) WheatArea (Million Hect.)

Prodn (Million Tonnes)

Yield (Kg/ Hec)

Area (Million Hect.)

Prodn (Million Tonnes)

Yield (Kg/ Hec.)

2006-07 7.49 6.33 845 27.99 75.81 27082007-08 7.54 5.75 762 28.04 78.57 28022008-09 7.89 7.06 895 27.75 80.68 2907

2009-10 8.21 7.35 895 28.52 80.71 28302010-11 8.48 8.25 915 28.87 81.16 2843

Source: Agricultural Statistics Ministry of Agriculture, Govt. of India

2) State W i s e Share In Production Of Gram /W h e at

In the country, major share in Pulse Production is by the state of U.P. (20.3%) & M.P. (19.5%) followed by Maharashtra (15.4%), Karnataka (9.1%) & Andhra Pradesh (8.1%). The northern states of Punjab, Himachal, J & K, Uttaranchal as well as North Eastern States & Kerala do not produce pulses in significant quantities.Maximum share in wheat production is by UP (36.3%) followed by Punjab (22.6%) and

Haryana (14%) and the rest 1/4th

share is by all other states. The figures of average cultivation area, production and yield of Pulse, Wheat in the country over last few years are given below:-

State W i s e Producti o n Of P u l s e/W h e at

State Pulse(Gram) WheatProduction (Million Tonnes)

% of total production

Production(MillionTonnes)

% of total Prod n.

Uttar Pradesh 2.17 20.34 24.94 36.27MadhyaPradesh

2.08 19.49 3.89 5.66

Maharashtra 1.64 15.37 0.95 1.38Karnataka 0.97 9.09 0.24 0.35AndhraPradesh

0.86 8.06 - -

Haryana 0.07 0.66 9.65 14.03Punjab - - 15.55 22.61Others 0.23 2.16 0.14 0.20

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3) INVENTORIZATION OF PULSE/WHEAT/RICE MILLS IN INDIA

In all the information is available for 27 states; for some states only partial information covering part of the state is available. Regarding pulse mills, based on the information available from 15 states, the number of pulse mills are 1220. As regards to the rice mills, based on information available from 16 states, the number of rice mills is 5780. For the Wheat flour/processing mills the information (though partial) has been received from 27 states, as per which there are 867 mills. (The above mentioned numbers are based on the partial information received from various states and subject to change.).The state-wise inventorisation of the pulse/wheat/rice mills in the country is given below:-

In v ente r i z ation Of Gram/Wh e at/Rice M i lls In Ind i a

StateNumber of Mills

GRAM WHEAT RICEAndhra Pradesh 51 58 257Assam NA 40 NABihar 0 58 16Chhattisgarh 125 0 373Punjab 1 48 8Delhi 76 18 0Goa NA 2 NAGujarat 24 13 20Haryana NA 47 3,065Himachal Pradesh NA 15 NAJammu & Kashmir NA 19 NAJharkhand 12 9 17Karnataka 104 60 668Kerala 1 32 103Madhya Pradesh 549 44 360Maharashtra NA 65 NAManipur NA 1 NAMeghalaya 6 81 96Nagaland NA 4 NAOrissa 1 22 214Pondicherry 14 99 61Rajasthan NA 10 NASikkim NA 3 NATamilnadu 247 62 516Tripura NA 2 NAUttar Pradesh 9 6 6West Bengal NA 49 NA

22

CHAPTER-X

1) Past Supply and Present Demand

The demand for wheat & Gram flour is met through both local production and imports. The apparent consumption of flour, comprising both domestic production and import is shown in below:-

APPARENT CONSUMPTION OF WHEAT & GRAM FLOUR IN (TONNES)

Year Domestic Production Import Total

2008 259131 51100 310231

2009 275791 51258 327049

2010 294163 41050 335213

2011 343846 20985 364831

2) Projected Demand

The demand for wheat & gram flour is mainly determined by the growth rate of population which is 1.33 billion at present and the per capita consumption of flour. Increased application of wheat & gram flour for industrially processing of food products such as pasta and macaroni would also have great bearing of future flour demand. In view of the likely change in these determining variables, an 8% annual growth in demand is considered to be reasonable rate to project future demand.

PROJECTED DEMAND FOR WHEAT & GRAM FLOUR IN (TONNES)

Year Projected Demand Existing Capacity Un Satisfied Demand

2012 386,017 194786 191,231

2013 408,898 194786 214,112

2014 433,610 194786 238,824

2015 460,299 194786 265,513

2016 489,123 194786 294,337

2017 520,253 194786 325,467

2018 553,873 194786 359,087

2019 590,183 194786 395,397

2020 579,397 194786 434,611

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3) Exporting of Products

Exporting of Milled Products:-

Indian milled products include the products like Wheat/Meslin Flour, Corn Flour, Rya Flour, Maize (corn) Flour, Rice Flour, Cereal Flour other than of Wheat (Meslin, Rye, Maize, Rice), Groats of Wheat, Meal of Wheat, Pellets of wheat etc.

India Export of Agro Food Products Product Group Report/Country Wise

2008-2009 2009-2010 2010-2011

Qty in Mt Value in Rs. Lacs

Country Qty Value Qty Value Qty Value

UNITED STATES 9,073.35 1,845.10 16,892.12 3,751.29 19,297.54 4,293.26

UNITED ARAB EMIRATES

5,218.48 1,103.47 6,865.59 1,791.38 9,550.45 2,468.37

NEPAL 322.39 46.28 196.90 28.95 8,147.47 1,668.15

AUSTRALIA 1,424.56 278.92 5,628.38 1,256.85 5,602.13 1,235.46

UNITED KINGDOM

3,448.55 905.21 5,469.60 1,212.77 5,557.26 946.03

SINGAPORE 712.45 122.03 2,057.17 463.04 2,823.88 660.27

OMAN 697.52 178.63 1,158.06 292.99 3,000.94 615.29

SAUDI ARABIA 1,778.65 319.92 2,268.30 496.88 2,064.01 460.19

CANADA 1,869.65 374.59 1,889.57 383.68 2,086.42 445.47

VIETNAM SOCIAL REPUBLIC

245.00 23.75 0.49 0.04 2,588.00 400.92

QATAR 1,444.65 310.02 1,585.36 449.16 1,085.95 335.09

KUWAIT 1,050.29 294.48 918.54 278.32 1,232.95 305.54

SRI LANKA 191.32 27.04 1,156.85 147.81 1,466.46 284.92

MALAYSIA 600.27 116.68 510.69 113.75 1,093.63 253.18

NEW ZEALAND 594.09 106.11 1,172.95 250.82 1,122.00 234.67

THAILAND 1.50 0.32 163.72 36.71 1,250.22 212.69

HONG KONG 244.55 41.41 514.29 85.91 818.02 160.55

BAHRAIN 675.26 123.38 661.83 142.06 519.05 122.77

SOMALIA 0.00 0.00 0.00 0.00 550.00 97.33

BRUNEI 14.21 1.10 197.89 47.90 310.76 81.20

NIGERIA 0.00 0.00 192.64 30.28 408.44 80.11

SOUTH AFRICA 135.19 18.11 289.56 53.72 291.16 64.80

MALDIVES 8,176.21 1,379.95 1,898.98 364.82 214.71 55.15

GERMANY 41.57 6.34 224.89 45.82 243.37 53.74

JAPAN 33.58 12.36 188.48 36.05 190.80 52.31

UNSPECIFIED 22.00 3.39 190.28 35.03 197.57 47.55

24

NETHERLAND 17.57 9.61 142.91 23.42 181.17 43.49

NORWAY 153.24 23.99 199.18 34.35 153.76 35.82

MADAGASCAR 0.33 0.04 0.00 0.00 164.00 31.74

PHILIPPINES 35.72 11.95 59.84 11.40 164.00 30.63

ANGOLA 0.00 0.00 0.00 0.00 260.70 28.72

YEMEN REPUBLC 3.31 0.87 131.70 27.02 89.48 23.22

MAURITIUS 41.31 9.04 58.44 10.44 103.81 22.86

SPAIN 0.00 0.00 22.00 6.08 80.51 21.80

SWEDEN 72.62 11.41 73.11 15.77 78.21 15.54

SEYCHELLES 22.33 3.77 138.56 28.83 54.87 14.78

KENYA 27.35 3.53 1,152.78 153.02 103.83 14.10

GHANA 0.30 0.05 43.37 3.90 61.83 13.16

EGYPT ARAB REPUBLIC

83.14 12.77 370.08 67.35 105.77 12.92

PAKISTAN 0.00 0.00 117.60 13.31 107.80 12.33

IRELAND 123.28 26.44 127.74 22.70 96.39 11.81

KOREA REPUBLIC 907.00 109.80 17.52 5.26 44.12 11.42

SWITZERLAND 284.47 66.78 163.41 37.18 75.18 10.70

UGANDA 31.75 5.16 23.20 3.64 47.83 9.88

LEBANON 0.00 0.00 0.84 0.51 47.73 8.70

TONGA 0.00 0.00 89.58 14.05 42.00 8.04

ITALY 13.77 1.73 0.10 0.02 17.43 7.73

FINLAND 0.00 0.00 0.00 0.00 35.75 7.65

INDONESIA 0.00 0.00 24.00 6.13 26.00 7.25

MACAO 11.42 2.81 33.00 6.45 38.85 6.83

LIBERIA 1.00 0.12 16.66 0.87 33.89 6.67

BELGIUM 46.10 4.71 117.20 27.36 29.99 6.55

AFGHANISTAN 0.00 0.00 0.00 0.00 31.00 6.40

ISRAEL 221.00 35.92 0.00 0.00 15.64 6.32

JORDAN 0.00 0.00 147.68 23.03 60.26 6.08

NETHERLANDANTIL

19.92 1.94 19.57 2.05 25.31 5.57

MOZAMBIQUE 0.00 0.00 3,872.74 716.93 25.70 5.48

BOTSWANA 31.82 4.36 40.69 8.82 22.35 5.45

TOGO 2.25 0.42 4.08 0.81 30.07 4.91

TANZANIA REPUBLIC

0.03 0.00 8.37 2.26 45.27 4.71

DENMARK 0.00 0.00 44.37 11.83 34.45 4.53

POLAND 0.00 0.00 4.95 1.12 19.42 4.31

CHINA P RP 3.15 0.76 44.31 11.02 17.20 3.80

GAMBIA 0.10 0.02 15.97 1.98 25.21 3.54

GREECE 27.08 4.10 28.45 3.49 15.52 3.07

TAIWAN 4.00 0.96 0.00 0.00 18.76 2.81

25

BENIN 0.00 0.00 37.41 5.57 5.70 1.67

BRAZIL 0.00 0.00 24.50 4.88 3.00 0.99

GUINEA 0.00 0.00 0.00 0.00 1.91 0.65

COTE D IVOIRE 4.00 0.48 1.10 0.28 3.47 0.51

LITHUANIA 0.00 0.00 0.00 0.00 1.92 0.49

MALAWI 0.00 0.00 332.08 62.16 1.50 0.45

SIERRA LEONE 0.00 0.00 0.00 0.00 1.70 0.39

GUYANA 0.00 0.00 0.00 0.00 2.52 0.37

SUDAN 0.00 0.00 59.23 12.36 0.27 0.36

FRANCE 10.51 1.81 44.34 10.31 1.60 0.30

SWAZILAND 0.00 0.00 0.00 0.00 1.60 0.25

SLOVAK REPUBLIC

0.00 0.00 0.00 0.00 1.30 0.22

ZAMBIA 0.00 0.00 2.62 0.48 0.55 0.22

CHILE 0.00 0.00 2.46 0.64 1.05 0.18

REUNION 0.00 0.00 3.22 0.36 0.62 0.15

ST. KITTS NEVIS 0.00 0.00 0.00 0.00 0.42 0.14

TRINIDAD 0.00 0.00 0.03 0.01 0.28 0.13

CYPRUS 0.00 0.00 0.00 0.00 0.17 0.07

IRAN 3.50 1.69 0.00 0.00 0.00 0.00

IRAQ 0.00 0.00 18.00 4.65 0.00 0.00

JAMAICA 0.00 0.00 2.00 0.36 0.00 0.00

MEXICO 0.00 0.00 0.24 0.11 0.00 0.00

CONGO P REPUBLIC

1.25 1.56 3.50 1.06 0.00 0.00

LUXEMBOURG 0.02 0.00 0.00 0.00 0.00 0.00

PORTUGAL 0.00 0.00 0.00 0.00 0.00 0.00

SENEGAL 0.00 0.00 4.00 0.28 0.00 0.00

UZBEKISTAN 0.04 0.01 0.00 0.00 0.00 0.00

COMOROS 0.02 0.00 0.00 0.00 0.00 0.00

SYRIA 24.19 7.25 0.00 0.00 0.00 0.00

BELARUS 0.00 0.00 0.00 0.00 0.10 0.00

KOREA D P REPUBLIC

320.00 45.93 0.00 0.00 0.00 0.00

KAZAKHSTAN 0.05 0.01 6.05 0.93 0.00 0.00

BHUTAN 0.00 0.00 45.00 6.48 0.00 0.00

RUSSIA 9.28 0.51 0.00 0.00 0.00 0.00

ALGERIA 0.00 0.00 44.00 7.86 0.00 0.00

AUSTRIA 0.00 0.00 7.10 0.96 0.00 0.00

BANGLADESH 480.00 82.89 0.00 0.00 0.00 0.00

PARAGUAY 0.00 0.00 0.12 0.02 0.00 0.00

Total 41,053.51 8,133.79 60,284.13 13,218.19 74,373.93 16,133.87

Source: DGCIS Annual Export

26 Exporting of Pulses:-

India Export of Agro Food Products Product Group Report/Country Wise

2008-2009 2009-2010 2010-2011

Qty in Mt Value in Rs. Lacs

Country Qty Value Qty Value Qty Value

PAKISTAN 31,918.60 10,947.73 25,829.00 9,235.12 73,488.22 27,169.95

ALGERIA 16,102.00 6,640.01 11,563.00 4,929.71 24,466.00 11,103.59

TURKEY 10,125.50 4,247.61 10,463.73 4,405.23 22,688.52 10,002.99

SRI LANKA 10,149.32 4,395.32 13,025.95 5,890.50 17,487.21 8,048.22

UNITED ARAB EMIRATES

17,780.29 7,361.78 8,790.41 3,624.07 14,825.20 6,553.75

TUNISIA 7,233.00 3,200.36 3,360.00 1,464.16 8,066.60 3,459.16

SAUDI ARABIA 8,275.49 3,208.23 4,465.32 1,877.78 7,677.55 3,244.21

EGYPT ARAB REPUBLIC

8,512.00 3,368.18 5,307.56 1,984.84 7,298.56 2,942.75

PORTUGAL 3,612.00 1,330.33 1,728.00 710.36 4,196.65 1,756.15

KUWAIT 2,492.51 1,046.81 2,482.27 1,071.89 3,910.58 1,656.19

JORDAN 1,835.00 704.07 1,648.14 730.37 2,813.89 1,302.41

IRAQ 696.00 317.32 579.00 271.04 2,695.45 1,175.43

SPAIN 600.00 252.75 588.00 230.83 2,548.49 1,139.77

MALAYSIA 1,753.33 735.54 1,526.77 659.42 1,819.24 830.63

IRAN 336.00 167.98 480.00 200.27 1,462.00 657.32

FRANCE 751.50 324.73 1,033.79 418.29 1,184.25 502.49

OMAN 872.93 361.94 719.49 306.80 1,104.88 461.57

BAHRAIN 1,160.91 456.67 699.97 296.96 851.90 352.03

ITALY 366.83 129.60 384.00 144.93 636.84 292.53

UNITED STATES 2,192.61 1,041.44 934.38 497.20 645.64 272.65

LEBANON 1,853.00 705.43 985.00 405.77 647.38 269.78

UNITED KINGDOM 798.90 372.98 252.88 111.40 540.16 248.81

SINGAPORE 748.72 257.52 282.55 109.46 649.79 244.47

TRINIDAD 554.00 241.65 404.00 180.16 543.44 236.89

ISRAEL 27.79 5.72 30.38 13.53 348.00 141.70

UNSPECIFIED 240.00 118.77 311.61 129.69 405.00 140.06

PHILIPPINES 288.11 125.85 72.00 31.10 239.20 112.93

SOUTH AFRICA 26.56 6.74 150.61 64.14 188.94 95.72

QATAR 349.96 120.65 242.12 101.22 217.57 91.03

YEMEN REPUBLC 516.00 167.95 335.00 146.60 207.92 80.49

GEORGIA 0.00 0.00 0.00 0.00 156.10 79.11

LIBYA 2,623.00 1,056.32 497.00 203.84 291.00 77.79

THAILAND 171.25 70.93 42.40 20.19 151.63 62.26

GERMANY 67.16 27.97 10.31 1.15 134.00 61.83

NEPAL 315.42 106.21 175.90 48.01 132.64 61.57

27

BELGIUM 350.24 143.83 121.75 48.48 97.72 44.51

AUSTRALIA 45.77 13.59 48.08 22.02 95.95 42.87

CANADA 206.02 84.90 165.43 74.56 106.66 39.80

CHINA P RP 51.49 18.61 2.00 1.12 67.00 31.79

GUYANA 0.00 0.00 0.00 0.00 72.00 31.03

JAPAN 61.24 16.15 57.17 24.46 86.56 24.79

KOREA REPUBLIC 34.02 15.26 24.00 8.33 48.00 16.03

TAIWAN 96.00 40.66 0.00 0.00 31.80 15.16

HONG KONG 85.21 35.71 68.92 29.75 67.28 13.15

BRAZIL 0.00 0.00 0.00 0.00 14.00 11.63

CROATIA 0.00 0.00 0.00 0.00 41.75 11.04

MALDIVES 26.87 10.89 48.23 24.85 63.86 10.91

GREECE 106.00 48.14 20.00 10.14 24.00 10.49

SURINAME 0.00 0.00 0.00 0.00 24.57 9.17

BRUNEI 68.49 30.78 5.55 3.29 15.71 8.66

FIJI ISLANDS 22.84 10.34 9.00 3.50 34.29 8.35

MAURITIUS 42.00 15.11 12.10 5.38 16.00 7.47

INDONESIA 0.00 0.00 0.00 0.00 14.00 6.61

NEW ZEALAND 59.83 22.14 4.25 2.71 31.64 6.61

FINLAND 0.00 0.00 0.00 0.00 35.27 5.54

VIETNAM SOCIAL REPUBLIC

0.00 0.00 0.39 0.27 38.22 4.21

NORWAY 3.45 2.26 0.00 0.00 12.28 3.76

MACAO 0.00 0.00 0.00 0.00 13.69 2.96

MALTA 0.00 0.00 0.00 0.00 8.80 2.65

POLAND 0.00 0.00 0.50 0.28 5.00 2.50

SWITZERLAND 7.15 4.19 8.99 2.14 11.11 2.24

KENYA 11.48 3.12 10.15 2.20 3.81 2.03

UGANDA 0.00 0.00 0.10 0.05 3.51 1.53

SEYCHELLES 0.00 0.00 1.83 1.22 4.89 1.03

TANZANIA REPUBLIC

0.00 0.00 4.56 1.95 1.80 0.79

NIGERIA 20.57 6.95 4.00 0.80 2.46 0.75

NETHERLAND 12.83 3.58 5.51 1.15 0.87 0.66

CYPRUS 22.00 9.66 43.00 17.24 0.90 0.36

ZAMBIA 0.00 0.00 0.58 0.21 1.00 0.29

BENIN 18.53 4.84 21.88 6.57 2.00 0.25

BOTSWANA 2.60 0.99 6.88 0.90 0.50 0.23

TOGO 0.00 0.00 0.00 0.00 0.30 0.15

GAMBIA 0.80 0.20 0.06 0.06 0.40 0.14

NETHERLANDANTIL

0.03 0.01 0.19 0.08 0.21 0.12

SUDAN 0.00 0.00 0.00 0.00 0.46 0.11

28

GHANA 0.00 0.00 0.00 0.00 0.10 0.06

DENMARK 0.00 0.00 4.50 2.81 0.08 0.04

MALAWI 0.10 0.03 0.00 0.00 0.07 0.04

REUNION 0.00 0.00 0.31 0.12 0.00 0.00

IRELAND 0.00 0.00 1.07 0.38 0.00 0.00

BANGLADESH 0.00 0.00 9.48 9.64 0.01 0.00

SYRIA 120.00 45.25 0.00 0.00 0.00 0.00

PAPUA N GNA 0.10 0.38 0.00 0.00 0.00 0.00

GUINEA 1.06 0.60 0.00 0.00 0.00 0.00

SWEDEN 0.11 0.02 0.00 0.00 0.00 0.00

RUSSIA 0.48 0.12 0.00 0.00 0.00 0.00

BHUTAN 0.00 0.00 15.00 7.83 0.00 0.00

CONGO P REPUBLIC 0.00 0.00 0.05 0.03 0.00 0.00

SENEGAL 4.70 0.98 0.00 0.00 0.00 0.00

MOZAMBIQUE 2.00 0.40 0.34 0.24 0.00 0.00

LIBERIA 50.40 19.70 0.70 0.25 0.00 0.00

ZIMBABWE 0.00 0.00 3.90 1.49 0.00 0.00

Total 1,36,880.10 54,232.48 1,00,130.99 40,832.53 2,05,820.97 85,310.74

Source: DGCIS Annual Export

Export of By-Product:-

India is currently self-sufficient in livestock feeds and does not depend on imports. Instead, the country exports large quantities of solvent extracted meals, which are a major source of foreign exchange earning. By-products are very nutritious and palatable to cattle, and these products form the bulk of cattle feed. They include wheat bran, rice bran and oil-extracted rice bran, tapioca, guar meal, safflower meal, maize gluten and molasses. A special mention should be made of Indian cattle feed's unique use of hulls or shells, popularly known as chunis in the local language. These shells come from pulses: horse gram, black gram, mung bean and pigeon pea.

4) Export Promotion:- Food processing industry is one of the growing areas identified for exports. Free Trade Zones (FTZ)

and Export Processing Zones (EPZ) have been set up with all infrastructures. Also, setting up of 100% Export oriented units (EOU) is encouraged in other areas. They may import free of duty all types of goods, including capital foods.

Capital goods, including spares up to 20% of the CIF value of the Capital goods may be imported at a concessional rate of Customs duty subject to certain export obligations under the EPCG scheme, Export Promotion Capital Goods. Export linked duty free imports are also allowed.

Units in EPZ/FTZ and 100% Export oriented units can retain 50% of foreign exchange receipts in foreign currency accounts.

AVAILABILITY & MARKETING OF MAMTA FOOD PRODUCTS:-

1) Availability of Raw-Material

29Wheat:- The wheat is available in an around Indore in MP as well as at Devas & DharDist. Mandi & also the wheat in good quality can be purchased from various locations in the state of Gujarat, Raj & Punjab. The wheat as a raw-material will be procured from various local market/ mandis from above mentioned locations. The same will be delivered to the manufacturing site through commercial vehicles like trucks & containers.

Chana :- The source of supply of chana will be imported from Australia or Ghana. The same can be procured from local markets from the state of Gujarat, Harayana, Maharashtra & part of MP from various locations. The quality of imported chana is far better than the quality available at local market. Due to location advantage of our manufacturing site import of chana from Australia & other countries is more feasible because we can utilize JNPT as well as Mumbai port trust facility for sale. They are just 30-50 km away from our manufacturing locations.

2) Marketing of Products:

o Chakki Fresh Aata :- The resource for marketing of a product will be very huge & it is multi locational. The prime market for our product will be APMC market at Vashi Navi-Mumbai where per day turnover is around 5000-6000 kg per day ( it means450 to 500 truck load per day) Apart from this at local level the market close to our plant will be Kalyan, Dombivili, Ulhas Nagar etc.

Our product will be consumed at various locations such as Pimpari Chinchade, Pune, Goa, Banglore & various Tier-II cities in South as well as Western Part of the countries. Due to expansion of IT sector at Banglore, Chennai & other locations of South India the local people has also started eating chapattis in the main course of their lunch & dinners. Earlier in South India people are consuming rice & occasionally on the day of festival they consumed the wheat products such as atta & maida.

For our product there will be a vast scope for export to various locations particularly in Middle-East countries, South Africa part of Western African Countries etc. Our product can be export to Wartone Countries like Afghanistan, Iran etc. where local traders paid in advance to buy the product.

o Bran :- This is the by-product of wheat flour which is merely 7-8% of the main product. The bran mostly purchased by the manufacturer of Cattle Feed products such as Godrej & other local manufacturer in the country. They will pay reasonably good rate in procuring.

o Besan: - The consumption of besan & its related products is very huge in India. Out of our daily food stock average Indian spend near about 10-15% on besan or the product manufacture from besan. The daily requirement at APMC & others market is near about 600-700 MT per day & same will be fulfilled by local manufacturer.

o Chuni:- This can be consumed by local manufacturer who have huge capital to manufacture cattle feed products to our livestock’s.

CHAPTER-XI

Strengths

Abundant availability of raw material Priority sector status for agro-processing given by the central Government Vast network of manufacturing facilities all over the country Vast domestic market

Weaknesses

30 Low availability of adequate infrastructural facilities Lack of adequate quality control and testing methods as per international standards Inefficient supply chain due to a large number of intermediaries High requirement of working capital. Inadequately developed linkages between R&D labs and industry. Seasonality of raw material

Opportunities

Large crop and material base offering a vast potential for agro processing activities Setting of SEZ/AEZ and food parks for providing added incentive to develop greenfield projects Rising income levels and changing consumption patterns Favourable demographic profile and changing lifestyles Integration of development in contemporary technologies such as electronics, material science, bio-technology

etc. offer vast scope for rapid improvement and progress Opening of global markets

Threats

Affordability and cultural preferences of fresh food High inventory carrying cost High taxation High packaging cost

CHAPTER-XII

In India following Quality control standards are made for food processing industries in order to maintain & control malnutrition in the country, so that people could get quality food not only in India but also in abroad.

1)BUREAU OF INDIAN STANDARDS :-

FOOD SAFETY MANAGEMENT SYSTEMS CERTIFICATION SCHEME

International Organization for Standardization (ISO) has published ISO 22000:2005 - Food Safety Management Systems – Requirements for any Organization in the Food Chain, with a view to provide framework for internationally harmonized requirements for systematically managing safety in food supply chains. Consequent to publication of ISO 22000 on BIS has adopted this International Standard as IS/ISO 22000:2005. This standard integrates the principles of Hazard Analysis and Critical Control Point (HACCP) system developed by Codex Alimentarius Commission and combines the HACCP plan with Prerequisite Programmes (PRPs) and is fully compatible with Quality Management Systems (QMS) as per ISO 9001: 2000. BIS has launched Food Safety Management Systems (FSMS) Certification IS/ISO 22000:2005 scheme which envisages grant of FSMS Certification license to organizations according to IS/ISO 22000.

2) AGMARK :-

Agricultural Produce (Grading and Marketing) Act, 1937 (Agmark):

The Directorate of Marketing and Inspection enforces the Agricultural Produce (Grading and Marketing) Act, 1937. Under this Act Grade standards are prescribed for agricultural and allied commodities.

3)HAZARD ANALYSIS CRITICAL CONTROL POINT (HACCP)

Hazard Analysis and Critical Control Point (HACCP) is a process control system designed to identify and prevent microbial and other hazards in food production. It includes steps designed to prevent problems before they occur and to correct deviations as soon as they are detected. Such preventive control system with documentation and verification are widely recognized by scientific authorities and international organizations as the most effective approach available for producing safe food.

HACCP involves a system approach to identification of hazard, assessment of chances of occurrence of hazards during each phase, raw material procurement, manufacturing, distribution, usage of food products, and in defining the measures for hazard control. In doing so, the many drawbacks prevalent in the inspection approach are provided and HACCP overcomes shortcomings of reliance only on microbial testing.

HACCP enables the producers, processors, distributors, exporters, etc, of food products to utilize technical resources efficiently and in a cost effective manner in assuring food


safety. Food inspection too would be more systematic and therefore hassle-free. It would no doubt involve deployment of some additional finances initially but this would be more than compensated in the long run through consistently better quality and hence better prices and returns.

BIS offers two Certification schemes to the food industry.

i) HACCP Stand-alone Certification against IS 15000:1998ii) HACCP based Quality System CertificationIt provides for two Certification through one audit Certification of Quality System against IS/ISO 9000 and Certification of HACCP against IS 15000:1998

4)ISO-9000 (International Organization for Standardization):

Implementation of the ISO standards enables export enterprises in developing countries to offer products or services that meet well-defined needs, satisfy consumer expectations, comply with applicable standards and specifications, as well as conform to requirements in regard to health & safety, protection of the environment and conservation of energy and materials: all these at lower costs and higher levels of efficiency.

5)Application of ISO 9000 in the Fruit & Vegetable Processing Industry:

ISO 9000 series of standards are generic standards and are applicable equally both to manufacturing as well as to service industries. Under individual circumstances these need to be tailored to meet the requirements specific to each industry. The fruit and vegetable processing industry has its own special features such as variable quality of raw material due to its agricultural origin, limited shelf life of both raw materials and final product, importance of packing and storage to maintain the products safe for human consumption, need to maintain proper hygienic conditions during manufacture, storage and distribution as these products are often liable to microbial contamination and toxin development, importance of safety as these products tend to get contaminated with metallic impurities and pesticides. In addition, food additives are added to enhance appeal and shelf life and if these are not added judiciously or controlled, these may prove to be harmful. These special features need to be given due consideration while orienting ISO 9000 to this industry. The main stages in the fruits and vegetable processing industry and related elements of ISO 9001 as applicable are given below.


CHAPTER-XIII

KEY PLAYERS

WHEAT FLOURCompanies Description

Annapurna Fortified Atta Launched nationally in 1998, Annapurna Atta was aimed at helping the homemaker to provide wholesome tasty nutrition to her family. After its successful launch, in a pursuit to stay ahead and cater to the changing mindsets of the Indian consumer, Annapurna Atta was fortified with extra iron and vitamins, which are essential for children during their formative years. It was awarded the prestigious 'Awaaz Consumer Award' for the most preferred brand of atta for two successive years in 2006 and 2007.

Godrej Pillsbury Godrej Pillsbury's Pillsbury Chakki Fresh atta has come up with a `Pillsbury Nutri-Soft Chakki Fresh atta' - which the company claims is enriched with vitamins and iron.

Pillsbury Nutri-Soft has been launched in the South. Available in pack sizes of 1 kg and 5 kg, Pillsbury Nutri-Soft Chakki Fresh atta is priced at Rs 21 and Rs 102, respectively. The Pillsbury brand commands a slight premium to competing brand Annapurna Fortified atta which is priced at Rs 90 for 5 kg.

Aro Fresh Chakki Fresh Atta It is a cleaned and refined atta which is free of any kind of worms which forms due to old stock of the atta. The packing of this atta is also done very neatly. The main point to be noted about this product is that the cost of the Aro fresh chakki atta is very low compared to any other branded attas that are kept of sale. And even the quality of the chapathi that prepared using this atta is very good and very soft.

Aashirvaad Aatta From the stable of India’s most trusted Atta brand comes a new and improved variety – Aashirvaad Atta with Multigrains. This all-new variant is designed to provide nourishment for people of all ages and is an integrated mix of six different grains – wheat, soya, channa, oat, maize & psyllium husk – which gives a better and healthier option for the consumers. Aashirvaad Atta with Multigrains is an excellent source of vitamins which is vital in strengthening immunity and ;extra protein content to improve body strength. The extra fibre makes your food easier to digest; low content of saturated fat keeps your heart smiling all through the day and above all, still retaining the same great taste!!

GRAM FLOUR


http://www.reviewstream.com/reviews/?p=21865




Rajdhani

The chana, used to manufacture Chana Dal and then Besan, is procured from the best of places in the world. Strict quality control standards are laid down for procurement of chana for which the responsibility rests on the shoulders of experienced personnel.As a result, clean chana dal is obtained with a gold-like sparkle, which is then grounded using the pulverizers. The chana dal not sent for grinding is further graded according to color to eliminate the green grains. Sortex, the most high tech machine man has ever made is used to make the dal actually pure. This Chana dal is then packed in an attractive consumer pack using automatic FFS machines.

Sanghvi Group The products manufactured by us include all the types and range of food products that are produced as a result of mining of gram which are collected from various parts of India for providing the best quality of products ensuring their purity and edibility. The product range which is delivered by us has undergone rigorous and continuous process to make them what our customers demand for.

Marudhar Foods Pvt. Ltd. Established in 1980, the Company is among top five manufacturing facility in Rajasthan. Headed by Mr. Sunil Jain and Sanjay Jain the Company is into manufacturing of Gram dall, Gram flour and Peas flour. In 2007 the Company went into expansion mode and at present the Company has a production capacity to produce more than 8,000 tonnes of grams dall and more than 20,000 tonnes and 10,000 tonnes of gram flour and peas flour respectively. The Company 's policy is to find the low competitive potential markets in order to operate with full efficiency. The Company believes in building long lasting relationship with its clients by outperforming in its product performance and delivering world class services.


CHAPTER-XIV

14.1 TOTAL CREDIT EXPOSURE TO THE FIRM (Amount in Lacs)

Sr. No. Particulars Existing Proposed Enhancement with Bank Of India

Total with proposed bank

A. FUND BASE LIMIT

1 Cash Credit 0.00 +70.00 70.00

2 Term Loan 0.00 +565.00 565.00

Total (A) 0.00 +635.00 635.00

B. NON FUND BASE LIMIT

3 Letter Of Credit 0.00 0.00 0.00Total (B) 0.00 0.00 0.00

Total (A+B) 0.00 +635.00 635.00

14.2 MEANS OF FINANCE FOR TERM LOAN(Amount In lacs)

Cost Of Project Means Of Finance

Land 182.00 Promoter’s Contribution 192.46

Factory Building 125.75 Proposed Bank Term Loan 565.00

Plant & Machinery & Utilities 188.00

Electrical / Power set-up 60.00

Delivery Vehicles 12.00

Total 567.75

Continengencies - 5% 28.39

Interest Expenses 55.63

Pre Operative Exp 69.93

Working Capital Margin 35.76

TOTAL 757.46 TOTAL 757.46


14.3 DETAILS OF PLANT & MACHINERY & UTILITIES, ELECTRICAL SET-UP, CIVIL CONSTRUCTION

(a) DETAILS OF WHEAT CLEANING SECTION & CHAKKI ATTA PLANT

S. No.

Particulars Qty. Rate Amount Taxes Duties

Total

1 Elevator 20 Feet Long 6 1600/Feet 192000.00 24000.00 216000.00

2Motor, Drive Pulleys, V-Belts & Motor Mounting System

6 8000/Elevator 48000.00 6000.00 54000.00

3 Warum 32 feet Long 3 1200/Feet 115200.00 14400.00 129600.004 Warum 16 Feet Long 3 1200/Feet 57600.00 7200.00 64800.00

5Motor, Drive Pulleys, V-Belts & Motor Mounting System

6 8000/Warum 48000.00 6000.00 54000.00

6 SILO 4 110000 440000.00 55000.00 495000.007 SILO 10 65000 650000.00 81250.00 731250.008 4 Compartment Drum Sieve 1 135000 135000.00 16875.00 151875.009 1 Compartment Drum Sieve 1 35000 35000.00 4375.00 39375.0010 Blow Fan 2 35000 70000.00 8750.00 78750.0012 Roll ( Model 1433) 1 100000 100000.00 12500.00 112500.0013 Destoner Model B 1 110000 110000.00 13750.00 123750.0014 Gravity Separator 1 160000 160000.00 20000.00 180000.0015 Pinmill 2 150000 300000.00 37500.00 337500.0016 Horizontal Chakki 12 110000 1320000.00 165000.00 1485000.0017 Centrifugal Flour Filter 3 225000 675000.00 84375.00 759375.00

185 H.P. Pneumatic Dust Proofing System

1 175000 175000.00 21875.00 196875.00

1910 H.P. Pneumatic Flour Conveying System

3 220000 660000.00 82500.00 742500.00

205 H.P. Pnemuatic Bran Conveying System

1 120000 120000.00 15000.00 135000.00

21 Installation Cost 270000 270000.00 33750.00 303750.00 Total Rs. 5680800.00 710100.00 6390900.00


(b) DETAILS OF FULLY AUTOMATIC CHANA DAL WITH BESAN PLANT

S. No.


Total

1 4 Compartment Drum Sieve 2 135000 270,000.00 33750.00 303750.002 3 Compartment Drum Sieve 1 105000 105,000.00 13125.00 118125.003 2 Compartment Drum Sieve 1 60000 60,000.00 7500.00 67500.004 Roll ( Model 1433) 2 105000 210,000.00 26250.00 236250.005 Destoner 1 110000 110,000.00 13750.00 123750.006 Gravity Separator 1 160000 160,000.00 20000.00 180000.007 Vertical 18" Chakki 4 50000 200,000.00 25000.00 225000.00

8 Blow Fan 8 30000 240,000.00 30000.00 270000.009 Elevator 20 Feet Long 17 1600/Feet 544,000.00 68000.00 612000.0010 Motor, Drive Pulleys, V-Belts &

Motor Mounting System17 8000/Elevator 136,000.00 17000.00 153000.00

11 Warum 15 feet Long 8 1200/Feet 144,200.00 18025.00 162225.0012 Motor, Drive Pulleys, V-Belts &

Motor Mounting System8 8000/Warum 64,000.00 8000.00 72000.00

13 SILO 2 110000 220,000.00 27500.00 247500.0014 SILO 6 60000 360,000.00 45000.00 405000.0015 SILO 2 30000 60,000.00 7500.00 67500.0016 Taiko Pulverizer 1 700000 700,000.00 87500.00 787500.0017 Micro Pulverizer 1 200000 200,000.00 25000.00 225000.0018 Centrifugal Besan Filter 3 300000 900,000.00 112500.00 1012500.0019 10 H.P. Pneumatic Besan

Conveying System1 160000 160,000.00 20000.00 180000.00

20 7.50 H.P. Pneumatic Besan Conveying System

1 160000 160,000.00 20000.00 180000.00

21 10 H.P. Pneumatic Conveying System for Chuni

1 280000 280,000.00 35000.00 315000.00

22 2 H.P. Pneumatic Dust Proofing System

1 60000 60,000.00 7500.00 67500.00

23 Platform for Dal Section

1 300000 300,000.00 37500.00 337500.00

24 Platform for Besan Section

1 200000 200,000.00 25000.00 225000.00

25 Installation Cost 292000 292000.00 36500.00 328500.00Total Rs. 5,843,200.00 766,900.00 6,902,100.00


c) DETAILS OF ELECTRICAL NETWORK AND GENERATOR

S. No.


Total

1Supply of 22 KV Indoor Type Isolator Panel Pune Switch gear

1 Nos 220000.00 220000.00 2

20,000.00

2 Supply of 22 KV GOD, DO, set 1 Set 50000.00 50,000.00

50,000.00

3 Supply of 22LA set with fabrication 2 Set 15000.00 30,000.00

30,000.00

4Supply of HT Substation earthing with 25 * 3 mm GI strip, cast iron hinged cover, GI nut bolts, salt & charcoal etc. for the substation.

1 set 60000.00 60,000.00

60,000.00

5Supply of 630 KVA, 22/0.433 KV D Distribution Transformer (T/F)

1 Nos 700000.00 700,000.00 7

00,000.00

6Supply of 'HUPEN' make 22 KV H.T. Outdoor type metering KIOSK

1 Nos 250000.00 250,000.00 2

50,000.00

7Supply of 22KV, 3C* 95 sq.mm. Al. Arm. HT XPLE cable.( Make: Polycab) Round Arm

1200 Rmt

1100.00 1,320,000.0

0

1,320,000.00

8Supply of 22KV, 3C* 95 sq.mm. Al. Arm. HT XPLE cable End Termination:-

a) Indoor Type 6 Nos 9000.00 54,000.00

54,000.00

b) Outdoor Type 2 Nos 12000.00 24,000.00

24,000.00

9 Supply of G.I. nut & bolts of various sizes 100 Kg 150.00 15,000.00

15,000.00

10Supply of 800 Amp ACB Panel with 800 Amp bus bar. Phase Inductor, Volt Meter etc.

1 Nos 105000.00 105,000.00 1

05,000.00

11Supply of 1C * 400 Sq. mm All L.T. XLPE Armored Cable.

180 Rmt

410.00 73,800.00

73,800.00

12 Supply of G.I. Channels 1 L/S 50000.00 50,000.00

50,000.00

13 Supply of 6" GI PIPE 2 Mtr Length300 Nos

600.00 180,000.00 1

80,000.00

14Labour charges for Erection of 630 KV DP Streator, Pole Erection, Cable Laying etc.

Job L/S 200000.00 200,000.00 2

00,000.00

15Liasoning charges for sanction of load with M.S.E.D Co. Ltd. & PWD Electrical Inspector

Job 350000.00 350,000.00 3

50,000.00

16 Internal Electrical Work 2,347,153.

13 2,347,153.13

Total Rs. 6,028,953.13 6,028,953.13

16.1 INTERNAL ELECTRICAL EQUIPMENTS & CONNECTIONS


Sr. No. Particulars Qty Rate Amount

Taxes Duties

Total Amount

1 APFC Panel 1 No 305000.00 305000.00 38125.00 343125.00

2Labour Charges for Cable Laying & Motor Connections 1 No 250000.00 250000.00 31250.00 281250.00

3Siemens Switchgear, VEPL Products, Learand Products, Polvcab Cables 1 No 1238057.53 1238057.53 118220.60 1356278.13

4Electric wires, cables & equipments for internal domestic work job 1 Nos 366500.00 366500.00 ------ 366500.00

Total 2347153.13

d). UTILITY

S. No.


Total

1M.S. C Section Channel, M.S. I Beams, M.S. Angels, M.S. Corrugated Sheets for Platform

1 No 4000000.00 4,000,000.00 4,000,000.00

2Utilities described in d.1 to d.3 point

1,394,534.20

Total Rs. 4,000,000.00 - 5,394,534.20

d.1) WEIGHING SCALE

S. No.


Total

1 Plat Size 7M * 3M Four Loadcell Systems 20 Tons * 10 KG

396000.00 396000.00 49,500.00 445,500.00

2 Electronic Scale 10/20 KG

25200.00 25200.00 3,150.00 28,350.00

3 Electronic Scale 500 KG 14500.00 14500.00 1,812.50 16,312.504 Electronic Scale 1 Ton 67500.00 67500.00 8,437.50 75,937.50

Total Rs. 503,200.00 62,900.00 566,100.00

d.2) TROLLY

S. No.


Total

1 Hand Pallet Trolly JP2500 4 Nos 16500.00 66000.00 2,059.20 68,059.202 Semi Automatic Stacker 1 Nos 198000.00 198000.00 24,750.00 222,750.00

Total Rs. 264,000.00 26,809.20 290,809.20

d.3) Packing & Sealing Machines

S. No.


Total

1 Band Sealer Machine NP-1200 2 97000.00 194000.00 12,125.00 206,125.002 Band Sealer Machine NP-1500 2 156000.00 312000.00 19,500.00 331,500.00

Total Rs. 506,000.00 31,625.00 537,625.00

E) Civil Construction


Sr. No. Particulars Area(Sq. Ft) Rate Total

Amount

1

Construction of Chakki Fresh Atta & Besan/ Chana Dal Plant, With RCC foundations and Brick wall up to 12'0''and P.E.B., Roofing System & Slide Cladding Complete

650 15000.00 9750000.00

2Construction of Ground & Mezzanine structure in PEB for Storage Purpose 550 1500.00 825000.00

3 Construction of Compound Wall ( West Bound) 1000000.004 Construction of Internal Road 1000000.00

Total 12575000.00

14.4 ASSESSMENT OF WORKING CAPITAL (Amount In lacs)

Sr. No.

WORKING CAPITAL ASSESSMENTEstimate Projection Projection Projection2011-12 2012-13 2013-14 2014-15

1 Total Current Assets 71.59 264.64 421.06 472.342 Other CL (other than bank borrowing) 33.85 104.52 269.39 279.553 WCG 37.74 160.12 151.67 192.794 Minimum stipulated NWC (25% of WCG /

25% of total CA as the case may be)17.90 66.16 105.26 118.08

5 Actual / projected NWC 37.74 90.12 81.67 122.796 Item 3 minus Item 4 19.84 93.96 46.40 74.707 Item 3 minus Item 5 0.00 70.00 70.00 70.008 MPBF (Item 6 or 7 whichever is lower) 0.00 70.00 46.40 70.00


14.5 LIST OF SECURITY OFFERED

(Amount in Lacs)Sr. No. & Security Type

Particulars of Security Amount Proposed Bank Share

1. PrimaryHypothecation of Entire Current Assets & Book Debts of the company

Inventory Book Debts Plant & Machinery & All The Utilities Electrical Power-Setup Equitable Mortgage of proposed factory

Land & Building situated at Survey No. 7, Hissa No-9 admeasuring about One Acre situated at Koina Village, Taluka - Panvel, Dist. Raigad

123.1618.87

188.0060.00

307.75

100%

2.Collateral Security

Equitable Mortgage of Shop No.-1, Building Name “Mamta Residency” admeasuring about 103.67 sq. fts. on Ground Floor, Sector .No.-10, Plot No-100, Mouza- Taloja Panchanand Nod, Taluka- Panvel, Dist. Raigad

7.26 100%

Equitable Mortgage of Flat No-105, Building Name “Mamta Residency” admeasuring about 350.31 sq. fts. on Ground Floor, Sector .No.-10, Plot No-100, Mouza- Taloja Panchanand Nod, Taluka- Panvel, Dist. Raigad

17.17 100%


15.24 100%


24.59 100%

Equitable Mortgage of Flat No-502, Building Name “Mamta Residency” admeasuring about 501.77 sq. fts. on Ground Floor, Sector .No.-10, Plot No-100, Mouza- Taloja Panchanand Nod, Taluka- Panvel, Dist. Raigad,

24.59 100%


16.81 100%


16.81 100%

Total Security Value 820.25 100%


14.6 Financial Data:

(Amount in Lacs)

Estimate Projection Projection Projection Projection Projection Projection Projection Projection

2011-12 2012-13 2013-14 2014-15 2015-16 2016-17 2017-18 2018-19 2019-20

a) Paid up Capital : 117.92 192.47 192.47 192.47 192.47 192.47 192.47 192.47 192.47

- Equity 117.92 192.47 192.47 192.47 192.47 192.47 192.47 192.47 192.47

- Preference Share 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00

b) Tangible Net worth (Excl. rev. reserve & net of intangible assets)

108.71 231.52 259.41 346.12 492.41 686.92 940.88 1260.00 1636.75

c) Investment in cos.(of which associated companies/ subsidiaries)

0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00

d) Adjusted TNW 108.71 231.52 259.41 346.12 492.41 686.92 940.88 1260.00 1636.75

e) Quasi Capital

f) Capital Employed*(total funds employed)

438.92 678.77 612.46 604.97 657.06 757.37 940.88 1260.00 1636.75

g) Net Block 401.19 588.65 530.79 482.19 441.04 406.01 376.04 350.32 331.53

h) Net sales : Domestic 0.00 1377.54 3127.15 3533.97 3978.34 4289.00 4622.62 4980.83 5279.68

Exports 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00

Total 0.00 1377.54 3127.15 3533.97 3978.34 4289.00 4622.62 4980.83 5279.68

i) Other Income 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00

j) Depreciation 0.00 6.65 57.87 48.60 41.14 35.04 29.97 25.72 18.79

k) Gross Profit/Loss 0.00 144.45 268.88 231.50 296.91 347.44 415.06 490.28 557.01

l) Net profit/loss -9.21 48.26 97.82 86.71 146.29 194.51 253.96 319.11 376.75

m) Cash Accruals (l+k) -9.21 54.91 155.68 135.31 187.43 229.55 283.93 344.83 395.54

n) Net profit / Capital Employed (%)

-2.10% 7.11% 15.97% 14.33% 22.26% 25.68% 26.99% 25.33% 23.02%

o) Current Assets 71.59 264.64 421.06 472.34 527.89 565.94 705.29 779.67 975.22

p) Current Liabilities 33.85 174.52 339.39 349.55 311.87 214.58 140.45 70.00 70.00

RATIOS :

q) Current Ratio 2.11 1.52 1.24 1.35 1.69 2.64 5.02 11.14 13.93

r) Debt/Equity :

Total Term Liab./TNW 3.04 1.93 1.36 0.75 0.33 0.10 0.00 0.00 0.00

Total Outside Liab./ TNW

3.35 2.69 2.67 1.76 0.97 0.41 0.15 0.06 0.04

s) Profitability %: PAT/Net Sales

#DIV/0! 3.50% 3.13% 2.45% 3.68% 4.54% 5.49% 6.41% 7.14%

t) DSCR a) Company as a whole

-0.39 0.58 1.65 1.44 1.99 2.44 4.03 #DIV/0! #DIV/0!

b) For specific TL

u) Interest Coverage 0.00 2.10 3.77 3.92 6.35 10.06 18.62 56.47 #DIV/0!

v) Inventory + Receivables/ Sales

#DIV/0! 10.31% 12.99% 12.92% 12.86% 12.80% 12.74% 12.68% 12.62%

Debt quasi equity ratio 3.35 2.69 2.67 1.76 0.97 0.41 0.15 0.06 0.04


14.7 CASH FLOW

14.7.1 Wheat Commodity

(Amount in Lacs)

FINANCIAL YEAR ENDED 2011-12 2012-13 2013-14 2014-15 2015-16 2016-17 2017-18 2018-19 2019-20 TOTAL

RECEIPT

WHEAT COMMODITY

1. Flour

Qty (MT) 0.00 5796.00 12364.80 13137.60 13910.40 13910.40 13910.40 13910.40 13910.40

Closing Stock 0.00 111.16 237.13 251.95 266.77 266.77 266.77 266.77 266.77

Market Rate 16500.00 17490.00 18539.40 19651.76 20830.87 22080.72 23405.57 24809.90 26298.49

Amount 0.00 99427918.68 224839666.79 253225674.72 284208580.80 301261095.65 319336761.39 338496967.07 358806785.10 2179603450.19

2. Bran

Qty (MT) 0.00 441.00 940.80 999.60 1058.40 1058.40 1058.40 1058.40 1058.40

Closing Stock 0.00 8.46 18.04 19.17 20.30 20.30 20.30 20.30 20.30

Market Rate 9000.00 9540.00 10112.40 10719.14 11362.29 12044.03 12766.67 13532.67 14344.63

Amount 0.00 4126455.12 9331290.52 10509365.95 11795217.78 12502930.85 13253106.70 14048293.10 14891190.69 90457850.70

Total Reliazable Amount 0.00 103554373.81 234170957.30 263735040.66 296003798.58 313764026.50 332589868.09 352545260.17 373697975.78 2270061300.89TOTAL Stock Value ( value

has been taken in projections Under Closing Stock (Finished

Goods) 0.00 2024806.19 4578761.74 5156830.40 5787783.77 6135050.80 6503153.85 6893343.08 7306943.66

GROSS RECEIPT 0.00 103554373.81 234170957.30 263735040.66 296003798.58 313764026.50 332589868.09 352545260.17 373697975.78 2270061300.89

EXPENDITURE TOTAL Plant Capacity in MT per day 60.00 60.00 60.00 60.00 60.00 60.00 60.00 60.00 60.00 TOTAL CAPACITY UTILIZATION YOY 75.00% 75.00% 80.00% 85.00% 90.00% 90.00% 90.00% 90.00% 90.00% TOTAL CAPACITY UTILIZATION Per Day in MT 45.00 45.00 48.00 51.00 54.00 54.00 54.00 54.00 54.00

Working Day in a Year 0.00 140.00 280.00 280.00 280.00 280.00 280.00 280.00 280.00 Raw material of Wheat

Quantity (MT) 0.00 6300.00 13440.00 14280.00 15120.00 15120.00 15120.00 15120.00 15120.00


A.1 Raw Material Cost

Market Rate (Per MT) 12500.00 13125.00 13781.25 14470.31 15193.83 15953.52 16751.20 17588.76 18468.19

Amount (RMC) 0.00 82687500.00 185220000.00 206636062.50 229730681.25 241217215.31 253278076.08 265941979.88 279239078.88 1743950593.90

A.2 Processing Cost

Chakki Aata Plant

Running Cost

Rate/MT 1550.00 1627.50 1708.88 1794.32 1884.03 1978.24 2077.15 2181.01 2290.06

Amount 0.00 10253250.00 22967280.00 25622871.75 28486604.48 29910934.70 31406481.43 32976805.51 34625645.78 216249873.64

Products Out Come 1. Flour (92% of

RM)

Qty (MT) 0.00 5796.00 12364.80 13137.60 13910.40 13910.40 13910.40 13910.40 13910.40

Result Marketable Marketable Marketable Marketable Marketable Marketable Marketable Marketable Marketable 2. Bran (7% OF

RM)

Qty (MT) 0.00 441.00 940.80 999.60 1058.40 1058.40 1058.40 1058.40 1058.40

Result Marketable Marketable Marketable Marketable Marketable Marketable Marketable Marketable Marketable 3.Losses (1% OF

RM)

Qty (MT) 0.00 63.00 134.40 142.80 151.20 151.20 151.20 151.20 151.20

Result Loss Loss Loss Loss Loss Loss Loss Loss Loss

Total Quanity in Plant 0.00 6237.00 13305.60 14137.20 14968.80 14968.80 14968.80 14968.80 14968.80

TOTAL EXPENDITURE 0.00 92940750.00 208187280.00 232258934.25 258217285.73 271128150.01 284684557.51 298918785.39 313864724.66 1960200467.54

NET CASH GENERATION 0.00 10613623.81 25983677.30 31476106.41 37786512.86 42635876.49 47905310.57 53626474.78 59833251.12 309860833.35ACCUMULATED CASH GENERATION 10613623.81 36597301.11 68073407.53 105859920.38 148495796.87 196401107.44 250027582.23 309860833.35


14.7.2 Gram Commodity

(Amount in Lacs)

FINANCIAL YEAR ENDED 2011-12 2012-13 2013-14 2014-15 2015-16 2016-17 2017-18 2018-19 2019-20 TOTAL

RECEIPT

GRAM COMMODITY

1. Besan

Qty (MT) 0.00 470.40 1019.20 1097.60 1176.00 1254.40 1332.80 1411.20 1411.20

Closing Stock 0.00 9.02 19.55 21.05 22.55 24.06 25.56 27.06 27.06

Market Rate 50000.00 53000.00 56180.00 59550.80 63123.85 66911.28 70925.96 75181.51 79692.40

Amount 0.00 24453067.40 56160544.79 64109421.90 72809986.30 82323824.51 92717207.35 104061430.37 110305116.19 606940598.80

2. Channa Dal

Qty (MT) 0.00 201.60 436.80 470.40 504.00 537.60 571.20 604.80 604.80

Closing Stock 0.00 3.87 8.38 9.02 9.67 10.31 10.95 11.60 11.60

Market Rate 42000.00 44520.00 47191.20 50022.67 53024.03 56205.47 59577.80 63152.47 66941.62

Amount 0.00 8803104.26 20217796.12 23079391.88 26211595.07 29636576.82 33378194.65 37462114.93 39709841.83 218498615.57

3. Chuni

Qty (MT) 0.00 100.80 218.40 235.20 252.00 268.80 285.60 302.40 302.40

Closing Stock 0.00 1.93 4.19 4.51 4.83 5.16 5.48 5.80 5.80

Market Rate 9000.00 9540.00 10112.40 10719.14 11362.29 12044.03 12766.67 13532.67 14344.63

Amount 0.00 943189.74 2166192.44 2472791.99 2808385.19 3175347.52 3576235.14 4013798.03 4254625.91 23410565.95

Total Reliazable Amount 0.00 34199361.40 78544533.35 89661605.77 101829966.55 115135748.85 129671637.14 145537343.33 154269583.93 848849780.32TOTAL Stock Value ( value has been

taken in projections Under Closing Stock (Finished Goods) 0.00 668702.60 1535786.97 1753159.89 1991088.73 2251257.66 2535478.94 2845702.24 3016444.38

GROSS RECEIPT 0.00 34199361.40 78544533.35 89661605.77 101829966.55 115135748.85 129671637.14 145537343.33 154269583.93 848849780.32

EXPENDITURE

TOTAL Plant Capacity in MT 10.00 10.00 10.00 10.00 10.00 10.00 10.00 10.00 10.00 TOTAL CAPACITY UTILIZATION YOY 60.00% 60.00% 65.00% 70.00% 75.00% 80.00% 85.00% 90.00% 90.00% TOTAL CAPACITY UTILIZATION Per Day in MT 6.00 6.00 6.50 7.00 7.50 8.00 8.50 9.00 9.00

Working Day in a Year 0.00 140.00 280.00 280.00 280.00 280.00 280.00 280.00 280.00


Total Raw material of Gram (MT) 0.00 840.00 1820.00 1960.00 2100.00 2240.00 2380.00 2520.00 2520.00

A.1 Raw Material Cost

Market Rate (Per MT) 33000.00 34650.00 36382.50 38201.63 40111.71 42117.29 44223.16 46434.31 48756.03

Amount (RMC) 0.00 29106000.00 66216150.00 74875185.00 84234583.13 94342733.10 105251111.61 117014471.15 122865194.71 693905428.69

A.2 Processing Cost

Besan Plant

Running Cost

Rate/MT 2000.00 2100.00 2205.00 2315.25 2431.01 2552.56 2680.19 2814.20 2954.91

Amount 0.00 1764000.00 4013100.00 4537890.00 5105126.25 5717741.40 6378855.25 7091786.13 7446375.44

Products Out Come

1. Besan ( 56% of RM)

Qty (MT) 0.00 470.40 1019.20 1097.60 1176.00 1254.40 1332.80 1411.20 1411.20

Result Marketable Marketable Marketable Marketable Marketable Marketable Marketable Marketable Marketable

2. Channa Dal (24% of RM)

Qty (MT) 0.00 201.60 436.80 470.40 504.00 537.60 571.20 604.80 604.80


3. Chuni (12% of RM)

Qty (MT) 0.00 100.80 218.40 235.20 252.00 268.80 285.60 302.40 302.40


4 Loss ( 8.00% of RM)

Qty (MT) 0.00 67.20 145.60 156.80 168.00 179.20 190.40 201.60 201.60

Result Loss Loss Loss Loss Loss Loss Loss Loss Loss

Total Quantity in Plant 0.00 571.20 1237.60 1332.80 1428.00 1523.20 1618.40 1713.60 1713.60

TOTAL EXPENDITURE 0.00 30870000.00 70229250.00 79413075.00 89339709.38 100060474.50 111629966.86 124106257.28 130311570.14 735960303.16

NET CASH GENERATION 0.00 3329361.40 8315283.35 10248530.77 12490257.18 15075274.35 18041670.28 21431086.05 23958013.79 112889477.16

ACCUMULATED CASH GENERATION 3329361.40 11644644.76 21893175.53 34383432.70 49458707.05 67500377.32 88931463.38 112889477.16

14.7.3 COMBINED CASH FLOW


(Amount in Lacs)FINANCIAL YEAR ENDED 2011-12 2012-13 2013-14 2014-15 2015-16 2016-17 2017-18 2018-19 2019-20 TOTAL

RECEIPT NET INCOME FROM WHEAT COMMODITY (As per Wheat Sheet) 0.00 106.14 259.84 314.76 377.87 426.36 479.05 536.26 598.33 3098.61NET INCOME FROM GRAM COMMODITY (As per Gram Sheet) 0.00 33.29 83.15 102.49 124.90 150.75 180.42 214.31 239.58 1128.89PROMOTER CONTRIBUTION 117.92 74.55 192.47BANK'S LOAN 353.76 211.24 565.00GROSS RECEIPT 471.68 425.22 342.99 417.25 502.77 577.11 659.47 750.58 837.91 4984.97

EXPENDITURE LAND ACQUITISION 182.00 CIVIL WORK & FACTORY BUILDING 125.75 PLANT & MACHINERY & UTILITIES 94.00 94.00 ELECTRICAL/ POWER SET-UP 0.00 60.00CONTINENGENCIES 0.00 28.39 DELIVERY VEHICLES 0.00 12.00 PRE OPERATIVE EXP 69.93 0.00 REPAYMENT OF LOAN - INTEREST 9.21 64.53 64.78 52.53 40.28 28.04 15.79 3.81 0.00 278.96REPAYMENT OF LOAN - PRINCIPAL 0.00 23.55 94.20 94.20 94.20 94.20 94.20 70.45 0.00 565.00 TOTAL EXPENDITURE 480.89 282.47 158.98 146.73 134.48 122.24 109.99 74.26 0.00 1510.03 NET CASH GENERATION -9.21 142.75 184.01 270.52 368.28 454.87 549.48 676.32 837.91 3474.94 ACCUMULATED CASH GENERATION 133.54 317.56 588.08 956.36 1411.23 1960.71 2637.03 3474.94


14.8 Profitability Projections

(Amount in Lacs)

2011-12 2012-13 2013-14 2014-15 2015-16 2016-17 2017-18 2018-19 2019-20 TOTAL

Production during the year (Quantity)

% Utilization of installed capacity

Sales

1.a. By Wheat Commodity 0.00 1035.54 2341.71 2637.35 2960.04 3137.64 3325.90 3525.45 3736.98 22700.61

1.b By Gram Commodity 0.00 341.99 785.45 896.62 1018.30 1151.36 1296.72 1455.37 1542.70 8488.50

1. Gross Sales (1a+1b) 0.00 1377.54 3127.15 3533.97 3978.34 4289.00 4622.62 4980.83 5279.68 31189.11

2.Less Excise/VAT 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00

3.Net Sales 0.00 1377.54 3127.15 3533.97 3978.34 4289.00 4622.62 4980.83 5279.68 31189.11

Cost of Production

1.Raw material consumed 0.00 1117.94 2514.36 2815.11 3139.65 3355.60 3585.29 3829.56 4021.04 24378.56

1.a. To Wheat Commodity 0.00 826.88 1852.20 2066.36 2297.31 2412.17 2532.78 2659.42 2792.39 17439.51

1.b To Gram Commodity 0.00 291.06 662.16 748.75 842.35 943.43 1052.51 1170.14 1228.65 6939.05

2.Power & Fuel 0.00 43.39 97.33 108.71 120.99 127.79 134.97 142.54 149.67 925.41

3.Direct labour & wages 0.00 30.21 66.02 74.67 84.18 90.89 98.27 106.40 113.39 664.03

4.Consumable Stores 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00

5.Repairs & Maintenance 0.00 7.50 16.82 18.80 20.93 22.16 23.45 24.82 26.06 160.54

6.Other Manufacturing expenses

0.00 89.96 201.89 225.60 251.17 265.87 281.42 297.86 312.75 1926.52

7.Depreciation/ Development Rebate Reserve

0.00 6.65 57.87 48.60 41.14 35.04 29.97 25.72 18.79 263.77

Total Cost of Production 0.00 1295.65 2954.30 3291.49 3658.07 3897.35 4153.37 4426.90 4641.70 28318.84

8.Add opening - Raw Material 0.00 0.00 93.16 209.53 234.59 261.64 279.63 298.77 319.13 1696.46


9.Deduct closing - Raw Material

0.00 93.16 209.53 234.59 261.64 279.63 298.77 319.13 335.09 2031.55

10.Add opening - stock-in-process

0.00 0.00 3.06 6.89 7.71 8.60 9.19 9.82 10.49 55.77

11.Deduct closing - stock-in-process

0.00 3.06 6.89 7.71 8.60 9.19 9.82 10.49 11.02 66.79

12.Add opening finished goods Stock

0.00 0.00 26.94 61.15 69.10 77.79 83.86 90.39 97.39 506.61

13.Deduct closing stock - finished goods

0.00 26.94 61.15 69.10 77.79 83.86 90.39 97.39 103.23 609.84

Cost of Sales 0.00 1202.49 2837.93 3266.43 3631.03 3879.35 4134.23 4406.55 4625.75 27983.75

Gross Profit (B-D) 0.00 175.05 289.23 267.53 347.31 409.64 488.38 574.28 653.93 3205.36

Interest on

1. Term Loans 9.21 64.53 64.78 52.53 40.28 28.04 15.79 3.81 0.00 278.96

2. Working Capital 0.00 4.33 6.50 6.50 6.50 6.50 6.50 4.88 0.00 41.71

3. Other Loans if any 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00

Selling, General & Administrative Expenses

0.00 37.25 78.22 84.63 91.54 97.23 103.29 109.72 115.71 717.58

Profit before Taxation {E-(F+G)}

-9.21 68.94 139.74 123.87 208.99 277.87 362.80 455.88 538.22 2167.11

Provision for Taxes 20.68 41.92 37.16 62.70 83.36 108.84 136.76 161.47 652.89

Net Profit (H-I) -9.21 48.26 97.82 86.71 146.29 194.51 253.96 319.11 376.75 1514.21

Depreciation added back 0.00 6.65 57.87 48.60 41.14 35.04 29.97 25.72 18.79 263.77

Net Cash Accruals -9.21 54.91 155.68 135.31 187.43 229.55 283.93 344.83 395.54 1777.98

Repayment obligations

1. Towards Term Loan 0.00 23.55 94.20 94.20 94.20 94.20 94.20 70.45 0.00 565.00

2. Towards other Loan, if any. 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00

Total Repayment 0.00 23.55 94.20 94.20 94.20 94.20 94.20 70.45 0.00 565.00

Debt Service ratio (L:M) #DIV/0! 2.33 1.65 1.44 1.99 2.44 3.01 4.89 #DIV/0! #DIV/0!


14.9 Projected Balance Sheet

(Amount in Lacs)

2011-12 2012-13 2013-14 2014-15 2015-16 2016-17 2017-18 2018-19 2019-20 TOTAL

A. Liabilities

1. Equity Share Capital 117.92 192.47 192.47 192.47 192.47 192.47 192.47 192.47 192.47 1657.68

2.Reserve & Surplus -9.21 39.05 66.94 153.65 299.94 494.45 748.41 1067.53 1444.28 4305.05

3. Term loans 353.76 541.45 447.25 353.05 258.85 164.65 70.45 0.00 0.00 2189.46

4.Bank Borrowings for Working Capital

0.00 70.00 70.00 70.00 70.00 70.00 70.00 70.00 70.00 560.00

5. Sundry Creditors 10.30 10.32 110.35 120.53 97.84 50.38 0.00 0.00 0.00 399.72

6. Other liabilities 0.00 0.00 64.84 64.82 49.83 0.00 0.00 0.00 0.00 179.49

Total Liabilities 472.77 853.29 951.85 954.52 968.93 971.95 1081.33 1330.00 1706.75 9291.40

B. Assets

1. Gross Block 401.19 595.30 595.30 595.30 595.30 595.30 595.30 595.30 595.30 5163.61

2.Depreciation 0.00 6.65 64.52 113.12 154.26 189.29 219.26 244.98 263.77 1255.85

3. Net Block 401.19 588.65 530.79 482.19 441.04 406.01 376.04 350.32 331.53 3907.76

4.Investment 0.00 0.00 0.00 0.00 0.00 0.00 0.00 200.00 400.00 600.00

5. Inventory 0.00 123.16 277.56 311.41 348.03 372.69 398.98 427.01 449.34 2708.18

6. Sundry Debtors 0.00 18.87 128.51 145.23 163.49 176.26 189.97 204.69 216.97 1244.00

7. Other Current Assets 0.00 0.00 0.00 0.00 0.00 0.00 98.76 129.79 290.74 519.29

8. Working Capital Margin 0.00 35.76 0.00 0.00 0.00 0.00 0.00 0.00 0.00 35.76

8. Pre Operative Expenses 69.93 69.93 0.00 0.00 0.00 0.00 0.00 0.00 0.00 139.86

9. Cash & Bank Balances 1.66 16.92 14.98 15.70 16.37 16.99 17.58 18.18 18.17 136.55

Total Assets 472.78 853.29 951.84 954.52 968.94 971.95 1081.33 1330.00 1706.75 9291.40


14.10 Calculation of DSCR

(Amount in Lacs)

2012-13 2013-14 2014-15 2015-16 2016-17 2017-18 2018-19 2019-20 TOTAL

Net Profit 48.26 97.82 86.71 146.29 194.51 253.96 319.11 376.75 1146.66

Depreciation 6.65 57.87 48.60 41.14 35.04 29.97 25.72 18.79 244.98

Interest 64.53 64.78 52.53 40.28 28.04 15.79 3.81 0.00 269.76

A. Total cash accrual

119.44 220.46 187.84 227.72 257.58 299.72 348.64 395.54 1661.40

Installment of Term loan

23.55 94.20 94.20 94.20 94.20 94.20 70.45 0.00 565.00

Interest 64.53 64.78 52.53 40.28 28.04 15.79 3.81 0.00 269.76

B. Total 88.08 158.98 146.73 134.48 122.24 109.99 74.26 0.00 834.76

DSCR = A/B 1.36 1.39 1.28 1.69 2.11 2.72 4.70 #DIV/0! 1.99

Average DSCR 1.99

14.11 Calculation of ISCR (Amount in Lacs)

2012-13 2013-14 2014-15 2015-16 2016-17 2017-18 2018-19 2019-20 TOTAL

Net Profit 48.26 97.82 86.71 146.29 194.51 253.96 319.11 376.75 1146.66

Depreciation 6.65 57.87 48.60 41.14 35.04 29.97 25.72 18.79 244.98

Interest 64.53 64.78 52.53 40.28 28.04 15.79 3.81 0.00 269.76

A. Total cash accrual

119.44 220.46 187.84 227.72 257.58 299.72 348.64 395.54 1661.40

Interest 64.53 64.78 52.53 40.28 28.04 15.79 3.81 0.00 269.76

B. Total 64.53 64.78 52.53 40.28 28.04 15.79 3.81 0.00 269.76

ISCR = A/B 1.85 3.40 3.58 5.65 9.19 18.98 91.57 #DIV/0! 6.16

Average ISCR 6.16


14.12 Draw Down Plans

(Amount in Lacs)

Month/Year Particulars Bank Loan Disb Promoters Cont. Total

Dec,2011 Land Acquisition 136.50 45.50 182.00

Dec,2011 Civil Work + Pre Operative Exp 146.76 48.92 195.68

Mar-12 For placing purchase order of plant & machinery 70.50 23.50 94.00

May-12 Final Payment to supplier of Plant & Machinery 70.50 23.50 94.00

Jul-12 Payment for Electrical Connections 45.00 15.00 60.00

Aug-12 Delivery Vehicle 9.00 3.00 12.00

Aug-12 Continengencies + Interest Exp + WC margin 86.74 33.05 119.79

Total 565.00 192.47 757.47

14.13 Project Implementation Schedule

Activity Commencement date Completion date

Acquisition of Land Nov,2011 Dec,2011

Development of Land Nov,2011 Dec,2011

Civil Works Dec,2011 Jan,2012

Plant & Machinery

a. Placement of order Feb,2012 Feb,2012

b. Delivery at site March,2012 May,2012

Erection & Commissioning March,2012 May,2012

Trial Run August,2012 August,2012

Commercial Production October,2012

14.14 Repayment Schedule

Entire loan will be repaid in 84 Months. Including 12 Months moratorium period.


project report of dmr marketing limited

Documents

birth residential

mouzataloja

designation

mamta residency

pneumatic

raigad equitable

critical control

local market