Protein Rich Biscuits

Uploaded on : September 2010

Product and its applications

Potatoes are grown all over the country with concentration in Uttar Pradesh. It is probably the most popular food item of Indian diet. It is a rich source of starch and contains phosphorus, calcium, iron and vitamins. Apart fro using fresh potatoes in vegetables and gravy they are dehydrated in the forms of slices and sticks, cubes or powder to impart better shelf life. Yet another popular use is to make wafers or chips to be consumed as snacks. Potatoes are grown and used in the Indian culinary since centuries with many end uses as stated.

Fresh potatoes have very limited shelf life, but processed properly packed can be stored over a long period. Under the present conditions and with know- how developed by CFTRI value addition is possible and it is possible to store it over a long period. The technology is available with CFTRI. Compliance with PFA Act for such a unit is essential.

Industry Profile and Market Assessment

Potato is a vegetarian delicacy and is a part of almost all Indian culinary dishes. It is easily digestible. It is also consumed in process form as a snack food. Their shelf life is enhanced by processing and properly packing in good quality polythene. This can then be stored and transported for selling in far of markets. It is a very popular item in most of the star hotels and in urban households. The processed potato in the form of chips has a good market in metropolitan cities and centre for tourists. The rural rich with changing lifestyle are also catching up with the urban tastes and eating habits. Processed and preserved potato ensures the availability through out the year. It is a good substitute as a snack food and is very popular among children. Competitive pricing and easy availability will create its own market. The local manufacturer will have to compete with international brands and pricing will be its advantage.

Manufacturing Process & Know How

Fully grown and ripe potatoes are thoroughly washed before peeling them. Then these potatoes are trimmed and put in brine water for 30-35 minutes to prevent browning. They are afterwards cut in the required sizes on slicing machine. These slices are then blanched in boiling water and are then placed on drying trays which are then put in the drying machine. The temperature of the dryer is maintained in the range of 140 to 150 F. After drying they are fried in edible oil to make them crisp and brown and packed in polythene bags. The chips could be salty or spiced. Some other flavours which are locally popular can also be tried. The process flow chart is as under:

Know how is available with Central Government research Laboratories. The machinery is all indigenously available.

The production capacity envisaged is 40 tonnes per year. It is assumed that the unit will achieve a capacity utilization of 60% during the first year.

Plant and Machinery

The main plant and machinery required for a capacity of 40 tons per year working for 300 days on Two shift basis shall comprise

• SS slicer with attachments - 1 nos.
• Electrically operated drier with trolleys - 1nos.
• Coal fired furnace. - 1nos
• Motorised potato peeling machine - 1 nos
• Automatic sealing machine - 1 nos
• Cutting peeling knives,aluminium utensils, weighing scales - 1 nos.

The total cost of machinery is estimated to be Rs.1.80 lakhs.

The unit will also require miscellaneous assets such as furniture, fixtures, storage facilities etc. the total cost of these is estimated to be Rs. 0.35 lakhs.

The total requirement of power shall be 10 HP, the unit will need 1000 lts.of water daily and coal about 1 ton per month.

Raw material and Packing Material

The all important raw material is good quality potato. Potatoes have high water content. Hence total loss during process shall be almost 30%. Potatoes are readily available hence procurement will not be a problem. Other ingredients like salt, spices etc can be easily procured from local market. Packing items like plastic bags and corrugated boxes, labels, strapping etc will be required.

The total cost of raw material and packing material at full capacity is estimated to be Rs. 7.26 lakhs. The total requirement for potato is estimated to be 58 tons. at 100% capacity. At 60% capacity in 1st year the total cost of raw material works out to Rs 4.35 lakhs.

Land and Building

For smooth operation of the unit, it will require 200 sq. mts of open land and a built up area of 100 sq. mts. The total cost of land and building is estimated at Rs. 3.10 lakhs.

Manpower

For smooth functioning of the unit the requirement of man power is expected to be around 8 persons.

Sales person	self
Skilled Workers	2
Semi skilled workers	2
Helpers	2

The annual salary bill is estimated to be around Rs.1.26 lakhs.

Sales Revenue: (100% capacity)

Selling price varies depending on the product quality and demand. An average price of Rs 55,000/- per tonne has been taken. the annual income at 100% capacity is Rs 22.00 lakhs.

Cost of Project

Sales	Rs. lakhs
Land & Building	3.10
Plant & Machinery	1.80
Other assets	0.35
Contingencies	0.50
P & P expenses	0.35
Margin money	0.49
Total	6.59

Means of Finance

Promoters Contribution	1.89
Term Loan	4.70
Total	6.59

Profitability: (60%capacity)

	Rs. lakhs
Sales	13.20
Raw material	4.35
Salary	1.26
Utilities	0.30
Stores & Spares	0.18
Repairs & Maintenance	0.24
Selling expenses	3.30
Administrative expenses	0.36
Depreciation	0.68
Interest on T.L	0.46
Interest on W.C	0.13
Cost of production	11.26
Profit	1.94

Requirement of Working Capital

		Margin	W.C	Margin Money
Packing material	½month	25%	0.18	0.05
Stock of finished goods	½ month	25%	1.00	0.07
Working expenses	1 month	100%	0.20	0.20
Sale on credit	½ month	25%	0.70	0.17
Margin money for W.C				0.49

Break Even point

33%

Machinery Suppliers

• M/S Archana machinery stores Guwahati.
• M/sEast End Engineering Co. Gopal Rai Thakur Road Kolkata 700035.
• M/S Industrial Equipment Guwahati.
• M/S Cowel Can Ltd. Barotiwala, Dist Solan,
• M/S Laxicon Engg. Sita Bardi, Nagpur
• FMC Technologies Hong Kong Ltd. Bhubaneshwar Housing Society Pashan Road Pune.

Contact for more information

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