edp ghee 2

INTRODUCTION

Recent study shows that India is the largest producer of milk in the world which is nearly 10% of the world production. Various milk-based products which can be manufactured commercially in a rural industry are Paneer (Cheese), Dhahi (Curd), Ghee etc. These products can be manufactured by low cost traditional methods and machineries. This kind of industries can be located in area where abundance quantity of milk is available. The cost of these products would be considerably low compared to those of big companies. A good number of employment generations is possible with low investment. Ghee is widely used in Indian cuisine. All over India, rice is sometimes traditionally prepared or served with ghee (includingbiryani). In

Rajasthan, ghee is eaten with baati. All over north India, people sometimes dabroti with ghee. In Bengal(both West Bengal andBangladesh) and Gujarat, ghee is served withkichdi,

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which is an evening meal (or dinner) of ricewithlentilscooked

in curry made from yogurt, cumin seeds, curry leaves, ghee, cornflour, turmeric, garlic, and salt. Ghee is also used to prepare kadhi and used in Indian sweets such as Mysore pak, and different varieties of halva and laddu. Punjabi cuisine preparedin restaurants uses large amounts of ghee.Naan and rotiare sometimes brushed with ghee, either during preparation or while serving. Ghee is an

important part of Punjabi cuisine and traditionally, the parathas, daals, and curries in Punjab often use ghee instead of oil, to make them rich in taste. Different types of ghees are used in different types of cooking recipes; for example, ghee made from cow's milk is

traditionally served with riceor rotior just a generous sprinkle over the top of a curry or daal (lentils), but for cooking purposes, ghee made from buffalo's milk is used generally.

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MARKET OUTLINEMilk and its products are the essential item of daily life in

our country especially majority of Indians are vegetarian and thus milk and milk products are indispensable to Indians. The per capita consumption was 122 gms. Per day in 1979 against an availability of 281 gms. Today per capita consumption as well as production quantity has increased and there is a need to make available milk and milk products to the people at reasonable price which can be attained only by setting small scale model dairy units in different milk producing areas to cater to the local needs. There is a challenge of multi-national companies paying major role in this industry. So it would be better for rural industries to produce milk products with a traditional tinge. Rural industries can market their dairy products through Co- operative marketing channels. So that there product will no way get compared with that of large industries

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MANUFACTURING PROCESS

Raw Material (Milk)

Dump Tank Filtration / Clarification

Cooling & Storage

Preheating

Standardisation

Liuid Milk Cream

Homogenisation Ghee

Pasteurisation Packing

Packing Storage

Storage Distribution

Distribution

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Ghee Making Process:

Ghee is animal fat normally produced from Milk. Following are the step taken during ghee making process.

During pasteurization process milk cream is separated in the cream separatorwith 50 – 70 % fat content. (These equipments are not in our scope of supply.)

This cream is then churned in butter churn. This makes butter of 84 % fat.

Thewhey is drained in whey tank, which is used as by product. (These equipmentsare not in our scope of supply.)

Butter from the butter churn is taken in the butter trolley. (These equipmentsare not in our scope of supply.)

This butter either can be stored in the cold room, till sufficient butter isavailable for further processing. (These equipments are not in our scope ofsupply.)

Once sufficient butter is available, it is taken in the Ghee Kettle.

Open the condensate drain valve and remove all the condensate from thesteam jacket.

Steam valve in the ghee kettle is opened slowly and start supplying steam (1.5bar G.). This is to heat the butter and melt it.

Close the drain valve and open steam trap and let condensate pass through it.

Once enough butter is melted, start the agitator of the ghee kettle.

Continue supplying steam to the kettle.

The butter oil will start boiling and water from the butter will evaporate.

Let all the water evaporate.

Close slowly the steam supply valve and open vent valve on the jacket.

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Let all condensate from the steam jacket get drained.

Let ghee to cool down.

Continue agitating ghee with the help of agitator.

After ghee temperature has come down to around 70 Deg C, drain this in theghee filter tank.

1With the help of SS strainer, most of burned protein from the butter is filteredout.

Once all ghee is filtered, start the ghee pump.

The ghee should be fed to ghee clarifier, where ghee will be clarified.

The clarified ghee is collected in the balance tank.

Ghee from the balance tank, with the help of another ghee pump is transferredto jacketed ghee storage tank.

This storage tank has water jacket with electric heater. In case of very coldweather, switch on the electric heater. This is to keep ghee in free flowingcondition.

This is final product. Pack ghee in consumer packing. (These equipments arenot in our scope of supply.)

Clean the complete plant from inside and outside with warm detergentfollowed with water and wipe out all traces of butter / ghee.

Clean all pipes / valves.

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EQUIPMENT SPECIFICATIONS AND DESCRIPTIONS

Ghee Kettle. Description

This is three jacket, fabricated from SS 304 material. The inner jacket isclosed, by hemispherical dish from the bottom and top is covered. The platethickness is selected to suit pressure. The volume of the vessel is 500 ltr.The outer jacket is steam jacket. This is fabricated from SS material. Thisjacket has, steam inlet, condensate outlet, and safety valve connection. Thesteam is distributed in the jacket with the help of pipe.The kettle is then insulated by glass wool insulation and finally cladded withSS sheet.The following attachment and accessories are included,Scrapper type ghee agitator.Plug type ghee outlet valve.Ghee temperature indicator.Steam inlet valve and pressure indicator.Steam trap with isolation and by pass valve.Steam jacket safety valve.Legs support.Top cover.

InstallationSee attached layout plan. The height of the roof under this must be 4 mtrs.The place should be well ventilated to remove water vapors, which isgenerated during ghee making process. The front should be clear. The butterloading is done from the front of the kettle.

Routine Maintenance.1. After using kettle, drain completely the steam jacket.2. Keep vent valve open, when system is not in use.3. Clean the kettle with detergent from inside and outside.4. Check agitator and remove any dirt on the shaft.5. Check all valves for any leakage and stop it

Ghee Sieve Tank. Description

This is tank fabricated from SS 304 material. This has SS strainer at the top tofilter ghee. The following attachment and accessories are included,SSstrainerPlug type ghee outlet valve.Legssupport.Top cover.

Installation It should be kept near the ghee kettle. The pipe withvalve is provided alongwith the ghee kettle.

Routine Maintenance7

1. After using tank, drain completely.2. Clean the tank with detergent from inside and outside.3. Check all valves for any leakage and stop it.Encon Consulting Engineers

Ghee Pump C.1 Description

This is hygiene design centrifugal pump, manufactured from SS 304 material.Please refer attached manufacturer manual.

C.2 InstallationSee attached layout plan. It should be kept near the ghee kettle.

C.3 Routine MaintenanceRefer attached manual.

D. Ghee Clarifier D.1 Description

This is high speed centrifuge, used to clarify ghee. This will remove all materialfrom the ghee and clarified ghee will be dispensed in the balance tank. Pleaserefer attached manufacturer manual.

D.2 InstallationSee attached layout plan. This must be anchored with the help of foundationbolts. Refer manufacturer manual for proper installation of the clarifier.

E. Ghee Balance Tank E.1 Description

This is fabricated from SS 304 material and have following accessories.Ball feet legsOutlet ValveCover

E.3 Routine MaintenanceClean the tank from inside & outside with warm detergent solution.

F. Ghee Storage Tank F.1 Description

This is fabricated tank having water jacket. The jacket has electric heater withthermostat. The tank is fabricated from SS 304 material.

F.3 Routine Maintenance1. Drain water once in a week.2. Fill only soft water.3. Check electric heater and thermostat.4. Clean the tank from inside and outside after usage.

Financial Analysis8

1-Land and Building:The ‘Manufacturing unit of Desi Ghee” is about 1,500 Sq.ft. we have buy a 1200 Sq.ft shop at Sayantraa Complex, NagalaPark,Kolapur. Per Sq.ft rate is Rs.650 & the Infrastucture charges 1would be there around Rs. 2,00,000 .At Kolhapur (NagalaPark,Kolapur)

Land:1,200 sq.ft

Rate per sq.ft: 650 rs

Total Amount: 9,75,000

Infrastucture: 2,00,000

TOTAL:- 11,75,000

2-Equipments and Appliances;

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S.r no.

Particular Quantity Rate Value

1. Rotter pump 1no. 9,000 9,0002. Butter churner 1no. 12,000 12,0003. Ghee boiler 1no. 15,000 15,0004. Ghee clarifier 1no. 13,000 13,0005. Steam jacket 1no. 7,500 7,5006. Ghee settling tank 2no. 5,000 10,0007. Refrigerator 1no. 20,000 20,0008. Ghee kettle 10no. 1,000 10,0009. Milk settling tank 15no. 900 13,50010. Pan,kadai&other

Equipment- --- ----- 10,000

Total - 1,20,000

3-Raw Material Required:

4- Utilities:

Sr.no. Particular Q.P.M Amt per year1. Power 15,000 1,80,0002. Water 1,000 12,0003. Fuel 1,000 12,0004. Cooking gas 3,000 36,0005. Telephone 500 6,000

Total 2,46,000

5-Pre liminary& Pre -operative Expenses:

Sr.no. Particular Amt1. Cost of preparing project 20,0002. Cost of trail production 15,000

Total 35,000

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Sr.no Particular Q.P.D Q.P.M Q.P.Y R.P.I Amt per year

1. Milk 3,000 lit 90,000lit 10,80,000lit 22 rs 2,37,60,0002,37,60,000

6- Other Fixed Assets-

Sr.no.

Particular Quantity Rate Amt

1. Computer 1no. 25,000 25,0002. Furniture As required 35,000 35,0003. Air-Condition 1no. 23,000 23,000

Total 83,000

7-Sale per Annual:

Particular R.P.U Q.P.M Amt.PM Amt.P.yGhee 400 4,500kg 18,00,000 2,16,00,000Milk 30 75,000lit 22,50,000 2,70,00,000

Total 4,86,00,000

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8- Projected Annual Sales (PAS).

Projected Annual Sales = 4,86,00,000

Working Capital Requirement =25% of Annual Sale

= 4,86,00,000 x 25 100 =1,21,50,000

Margin Money= WCR/5 =1,21,50,000/5

=24,30,000

9-Project Cost.

Sr.no.

Particular Amt

1. Land & Building 11,75,0002. Plant &Machinery 1,20,000

3. Other fixed Assets 83,000

4. Margin Money 24,30,000

Total 38,08,000

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10-Manpower Requirement.

Sr.no.

Particular No.of person

Salary Total per year

1. Workers (for manufacturing) 06 5,500 3,96,0002. Account (clerk) 01 4,500 54,0003. Security 01 3,000 36,0004. Housekeeping 02 2,750 66,000

Total 5,52,000

11-Means of Finance:

Sr.no.

Particular Amt

1. Promoters Contibution(40%) 15,23,2002. Bank Loan (60%) 12 % interest 22,84,800

Total 38,08,000

12-Cost of Production:

Sr.no. Particular Amt1. Raw Material 3,78,00,0002. Utility 2,46,0003. Salary &Wages 5,52,0004. Contingencies 30,000

Total 3,86,28,000

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Profit before Interest :-

Profit= Sales- Cost of Production =4,86,00,000 – 3,86,28,000 =99,72,000

13-Interest &Depreciation:-

Sr.no. Particular Amt1. Depreciation on fixed assets @ 10% 40,3002. Instalment monthly loan (interest) 2,98,646

Total 3,38,946

Profit After Tax :-

Profit After Tax = Profit before Interest -Interest &Depreciation

= 99,72,000 - 25,99,276

=73,72,724

Net Profit =Profit After Tax –(33%)

=73,72,724*33 100 =73,72,724 – 2432998

=4939726

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Trading Account For The Year Ended 2015-16

Particular Amt Particular AmtTo purchase(Milk 3000 lit /Day) 2,37,60,000 By Sale 4,86,00,000

To Power 1,80,000

To Water 12,000

To Fuel 12,000

To Gas 36,000

To telephone 6000

By Gross Profit 2,45,94,0004,86,00,000 4,86,00,000

Profit & Loss Account Year Ended 2015-16

Particular Amt Particular AmtTo Salary and Wages 5,52,000 By Gross Profit 2,45,94,000

To Premliminary Exp. 35,000

To Contingency 30,000

To Other Exp. 83,000

To Interest on Loan 2,98,646

To Depreciation:Land & Building 1,17,500

Plant & Machinery 12,000Fixed assets 8,300

To Net Profit 2,34,82,524

2,45,94,500 2,45,94,000

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Balance Sheet as on 31st March 2015-16

Particular Amt Particular AmtPromoters 15,23,200 Land &Building 1,17,500

Net Profit 2,34,82,524 2,50,05,724 Less10%Dep 1,17,50 1,05,750

Bank Loan 22,84,800 Plant & Machinery 1,20,000

LessEMI 6,37,960 16,46,840 Less 10%Dep 12,000 1,08,000Fixed Assets 83,000

Less10%Dep 8,300 74,700

Investment –short term 3,00,000

-long term 70,00,000 73,00,000Debtors 60,00,000Bills Receivable 30,00,000Cash in Hand 30,00,000Cash in Bank 70,00,000Closing stock 64,114

2,66,52,564 2,66,52,564

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To Power 1,80,000

To Water 12,000

To Fuel 12,000

To Gas 36,000

To telephone 6000

By Gross Profit 3,43,14,0005,83,20,000 5,83,20,000










3,43,14,000 3,43,14,000

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Particular Amt Particular AmtPromoters 2,50,05,724 Land &Building 1,17,500




Less10%Dep 8,300 74,700

Investment –short term 1,00,00,000

-long term 2,00,00,000 3,00,00,000Debtors 80,00,000Bills Receivable 8,00,000Cash in Hand 1,00,00,000Cash in Bank 1,00,00,000Closing stock 1,03,708

5,91,92,158 5,91,92,158

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To Power 1,80,000

To Water 12,000

To Fuel 12,000

To Gas 36,000

To telephone 6,000

By Gross Profit 4,59,78,0006,99,84,000 6,99,84,000










4,59,78,000 4,59,78,000

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Particular Amt Particular AmtPromoters 5,81,83,278 Land &Building 1,17,500




Less10%Dep 8,300 74,700

Investment –short term 1,00,00,000

-long term 3,00,00,000 4,00,00,000Debtors 1,06,00,000Bills Receivable 30,00,000Cash in Hand 2,00,00,000Cash in Bank 3,00,00,000Closing stock 1,45,260

10,40,33,710 10,40,33,710

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edp ghee 2

Small Business & Entrepreneurship