Confectionary Grade Sesame Seed

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Production Capacity : 280t Confectionary Grade Sesame Seeds

Uploaded on : February 2009


Product and its Applications

The major portion of sesame seed produced in the country is used for extraction of oil. Sesame seed is also used in a variety of sweets, confectionery and bakery products. For utilization in the above food products, sesame has to be de hulled to remove the outer fibrous husk cover. This is usually done by soaking the seeds overnight in water, followed by drying and rubbing against a rough surface. The separated hulls are removed by winnowing. The method is laborious, time consuming and suitable for processing small quantities only. An improved wet de hulling process is now available which accomplishes easy removal of the husk. The de hulled seed can be expeller pressed for obtaining good quality oil. The cake is further solvent extracted to recover the residual oil and the protein rich cake is used for protein fortification of various food preparations.


Market Potential

The dehulled sesame has uniform white colour and is ready for use in cookery and confectionery. It is rich in protein (22%) and oil (60%). It has a large demand in comestic as well as export markets particularly for use in the confectionery industry.


Basis and Presumption

  • The unit would work for 200 days per annum on single shift basis.
  • The unit can achieve its full capacity utilization during the 3rd year of operation.
  • The wages for skilled workers is taken as per prevailing rates in this type of industry.
  • Interest rate for total capital investment is calculated @ 12% per annum.
  • The entrepreneur is expected to raise 20-25% of the capital as margin money.
  • The unit proposes to construct own building.
  • Costs of machinery and equipment are based on average prices enquired from 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

Technical aspects


Raw material

The important sesame growing states are Gujarat, Maharashtra, Madhya Pradesh, Orissa, Rajasthan, West Bengal, Karnataka, Tamilnadu, Andhra Pradesh and Uttar Pradesh. As such sesame seed are easily available all over the country.


Process of Manufacture

  • Preliminary cleaning and grading: Commercial quality sesame seed is cleaned to remove dust, fines, stones and other foreign matter using vibratory screening equipment, followed by de stoning.
  • Contacting with hot lye: The seeds are placed in a boiling solution of sodium hydroxide for a prescribed time. These are thoroughly washed by a stream of water.
  • Removal of skin and pigments: Washed seeds are brushed under a current of water to remove the hulls.
  • Drying: The dehulled wet seeds are dried in a cross-flow or fluidized bed drier.

Quality Control and Standards

PFA Specifications


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.


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 no leakage of steam in the pipe lines and adequate insulation should be provided.


Production Capacity

Quantity 280 tpa
Value Rs. 221.20 lakh
Installed capacity 2 tpa
Working days 200/annum
Optimum capacity utilization 70%
Manpower 19
Utilities  
Motive Power 18 kW
Water 8 kL/day

Financial Aspects


Fixed Capital


Land & Building

Particulars

Amount (Rs. lakh)

Land 60 m 2 01.50
Built up area 150 m 2 11.00
Total cost of land and building 12.50

Machinery and Equipment

Description

Amount

Sesame seed pre-cleaning unit, destoner, wire mesh basket, mixing tanks, vibratory screen, pulper and mechanical drier 18.00
Erection & electrification of machinery & equipment @10% cost 01.70
Office furniture & fixtures 01.70
Total 28.00

Pre-operative Expenses Amount (Rs. lakh)

Consultancy fee, project report, deposits with electricity department etc 03.00

Total Fixed Capital Amount (Rs. lakh)

(9.1.1+9.1.2+9.1.3) 37.00

Recurring expenses per annum


Personnel

Designation

No.

Salary Per month

Amount

Factory Manager 1 12000 01.80
Supervisory staff 2 8000 01.92
Office Assistant 2 6000 01.44
Marketing supervisor 2 5000 01.20
Unskilled workers (7 months) 8 2000 01.12
Skilled workers (12 months) 4 3000 01.44
      08.92
Perquisites @15 %     01.38
Total 19   10.30

Raw Material including packaging materials

Particulars

Qty (t)

Rate/t (Rs.)

Amount (Rs. lakh)

Raw sesame 315 46000 150.00
Soda alkali 12 14500 01.74
Hydrochloric acid 3 18000 00.54
Jute bags 5600 no 11 each 00.62
Miscellaneous     9.10
Total     163.00

Utilities

Particulars

Amount (Rs. lakh)

Power 3.40
Water 0.10
Total 3.50

Other Contingent Expenses

Particulars

Amount(Rs. lakh)

Repairs and maintenance@10% 2.15
Consumables & spares, others 1.61
Insurance @1% 0.44
Total 4.20

Total Recurring Expenditure Amount (Rs. lakh)

(9.2.1+9.2.2+9.2.3+9.2.4) 181.00

Working Capital Amount (Rs. lakh)

Recurring expenses for one month 15.00

Total Capital Investment Amount (Rs. lakh)

Fixed capital (Refer 9.1.4) 37.00
Working capital (Refer 9.3) 15.00
Total 52.00

Financial Analysis


Cost of Production (per annum) Amount (Rs. lakh)

Recurring expenses (Refer 9.2.5) 181.00
Depreciation on building @5% 000.55
Depreciation on machinery @10% 001.98
Depreciation on furniture @20% 000.34
Interest on Capital Investment @12% 006.23
Total 190.10

Sale Proceeds (Turnover) per year


Item

Qty

Rate (Rs.)

Amount (Rs.lakh)

Confectionary grade sesame seeds 280 79000 221.20

Net Profit per year

   

= Sales – Cost of production
= 221.20 – 190.10
= Rs. 31.10 lakh


Net Profit Ratio

   

Net profit x 100
---------------------

Sales


31.10 x 100
---------------

221.20

= 14 %


Rate of Return on Investment

   

Net profit x 100
------------------------

Capital Investment


31.10 x 100
-----------------

52

= 14 %


Rate of Return on Investment

   

Net profit x 100
------------------------

Capital Investment


31.10 x 100
-----------------

52

= 59.8 %


Annual Fixed Cost Amount (Rs. Lakh)

All depreciation 2.87
Interest 6.23
40% of salary, wages, utility, contingency 09.70
Insurance 0.44
Total 16.74


Break even Point

   

Annual Fixed Cost x 100
---------------------------------

Annual Fixed Cost + Profit

16.74 x 100
------------------
16.74 + 31.10

766
--------
47.84


= 35%


Addresses of Machinery and Equipment Suppliers

  • Jyothi Industries.
    31, Pampa Mahakavi Road
    Bangalore – 560 004
  • Raylons Metal Works
    Kondivita Lane
    Andheri, Mumbai
  • Shanti Engineering Works
    Figure of 8 Road
    Coonoor – 643 101
  • SIDVIN
    78, 5th Main, Saraswathipuram
    Mysore – 570 009
  • M/s Bajaj Maschinen (P) Ltd.
    7/20, 7/27, Jailaxmi Industrial Estate, Site IV
    Sahibabad Industrial Area
    Ghaziabad -201301
    Email : bajaj@del3.vsnl.net.in / bajajmachines@vsnl.com
    Web: www.bajajmachinen.com
  • M/s Narangs Corporation
    P -25, Connaught Place
    New Delhi -110001
    Email: narangs@appexmail.com
  • M/s S.S.P. (P) Ltd.
    13, Milestone, Mathura Road,
    Faridabad- 121003
    Email: sspgroup@del2.vsnl.net.in
  • M/s Marvel Machines Pvt Ltd.
    140, Anna Salai, Saidpet
    Chennai - 600015
    Email: marvel12@vsnl.com
  • M/s Sasib (India) Pvt. Ltd.
    B -30, Greater Kailash –I,
    New Delhi -110048
    Email: sasibnd@nde.vsnl.net.in
  • M/s Gee Gee Foods & Packaging Co. (P) Ltd.
    B -188/2, Savitri Nagar,
    Malviya Nagar
    New Delhi -110017
    Email: swantour@satyam.net.in
  • M/s D.K. Barry & Co. (P) Ltd.
    11/35, West Punjabi Bagh,
    New Delhi -110026
    Email: dheerajbahry@rediffmail.com
  • M/s M. Son Industries
    D -33, Sector 2,
    Noida -201301
    Email: mson@nda.vsnl.net.in
  • M/s SAK Simpex (India)
    B -5/ 160 (2 nd Floor), Safdarjung Enclave,
    New Delhi – 110029
    Email: saksimpex@yahoo.com
  • M/s Sanjivan Industries
    A -13, Karimsheth Indl. Estate,
    Wagdevi Nagar, Near Valishali Nagar
    Dahisar (E), Mumbai -400068
    Email: sanjivanind@roltanet.com
  • M/s Biotech & Food Systems (P) Ltd.
    435 –P, Sector 14,
    Gurgaon -122001
    Email: dharamwal@yahoo.com
  • M/s Pharamalab India Pvt. Ltd.
    Star Metal Compound,
    LBS Marg, Vikroli (W)
    Mumbai -400083
    Email: mkt@pharmalab.com
  • M/s Larsen & Toubro Ltd.
    L &T House, Ballard Estate,
    Mumbai -400001
    Web: www.larsontoubro.com
  • M/s Shiv Engineers
    Patel Avenue, Plot No. 165,
    Flat No.1, Right Bhusari Colony,
    Paud Road, Pune -411038
    Email: shivenginerrs@rediffmail.com
  • M/s Hightek Engineers
    702, GIDC, Phase II, Gundiav,
    Valsad -396035 (Gujarat)
    Email: info@hightekengineers.com
  • M/s Geeta Food Engineering
    Plot No. C-7/1, TTC Indl Area,
    Pawane MIDC, Thane –Belapur Road,
    Behind Savita Chemical
    Navi –Mumbai -400705
    Email: geetafoodengg@yahoo.co.in
  • M/s Bombay Industrial Engineers
    13, Crystal Apartments,
    Gulmohar Cross Road,
    11, JVPD
    Mumbai -400049
    Email: ijsehgal@bom5.vsnl.net.in

Contact for more information

Information Manager
TIMEIS Project
E-mail: timeis@ficci.com