redesigned mould for bread b plan

8/12/2019 Redesigned Mould for Bread B Plan

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TECHNOLOGY MANAGEMENT LAB

BUSINESS PLAN REPORT

SNAP Group

SUBMITTED BY

Sagar Morakhia (AM0912)

Nirmal Kathiriya (AM0612)

Adit Shah (AM2012)

Prajitha Chowdhury (AM0212)

DATE

25 JULY 2013


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Index

Sr. No. Topic Page No.

1 Executive Summary 3

2 Company Description 4

3 Business Model 114 Industry Analysis 11

5 Marketing Details 13

6 Operations Details 17

7 Financial Details 18

8 References 32


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Executive Summary

The bakery business in India is huge in terms of volumes and revenues. The business is divided

majorly in two parts, Sandwich bread and Toast bread. The local Ahmedabad market of Sandwich

bread is about 216 Crore annually.

SNAP baking unit, a firm established by four MBAs of CEPT University is focused on innovation

in the bakery sector. The unit is majorly focused on reducing the wastages by innovative solutions.

The unit is to be established in Ahmedabad looking at the potential of the market i.e. 216 Crores

(approx.).

The report present below shows the details of the business plan, i.e. the marketing, operating and

financial details of the firm.


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Company Description

Mission statement

To initiate the trend of new bakery that aims in reduction in the wastage of unused bread and

continue innovating to achieve the minimum wastage through new mould designs and in bread

making process.

Product/Service Description

We are willing to establish a new bakery in which we will produce breads using modified system of

bread making. We have modified all the equipments used in bread making process. This

modification in conventional bakery will help us to gain 38% more profit as compare to

conventional bakeries in Ahmedabad and Gujarat.

We have invented new design of bread making moulds, slice cutter, bhatthi and respective handling

tools/equipments.

Following are the photographs showing existing and improved equipment.

Bread Mould:

Existing Mould


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Existing mould: (single unit)

Specification:

1Kg mouldside by side

Wastage: 350 gms

System optimized for 2 kg

mould

Existing mould rhino model

New Designed Mould: 1

Specification:

2Kg mould

2 Bread loafs

Traditionalmouldwastage: 700gm

Waste aftermodification:540gm

Reduction : ~ 23%


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Actual Mould:

Iteration-1 in Mould:1

Reasons for selection (for existingbakery):No change in existing system

Workers familiar with 2Kg loaf

Add on:A mark-up helps to cut bread in two

halves


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After

Before

New Designed Mould: 2

Rhino Model

Specification:

6Kg mould

6 Bread loafs

Traditional wastage of bread

from conventional mould:

2100gm

Waste of bread from new mould:

1365gm

Reduction: ~35%


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Actual Model of mould-2:

Iteration-1 of Mould: 2

Breads by new designed Mould-2


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New designed Mould-3

Rhino Model

Bread cutter (slicer) New design:

7 kg mould and decrease in wastage

38%


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Form of organization

We are a team of 4 people currently are estimating to hire around 10-15 more people. The form

will be mostly flat organizational structure.

SNAP Baking Unit is a start-up organization.

It will be formed as an Ahmedabad based L.L.P firm.

The partnership formation was chosen as a way to minimize personal liability issues for

the owner and avoiding the double taxation found in traditional corporations.

Company Ownership

Sagar Morakhia Co-founder

Nirmal Kathiriya Co-founder

Adit Shah Co-founder

Prajita Chowdhury Co-founder

Venture Capitalists Financier


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Business model

The SNAP baking unit will have a state of the art bread manufacturing facility. Few of the

features that the manufacturing plant will have are as follows:

Emphasis on Hygiene

Fresh Bread production on daily basis

Sourcing of its flour from ISO certified companies

New manufacturing facilities

The SNAP baking unit will be producing and distributing the bread on its own in the

initial years, later on well be looking for giving franchises to others in different parts of

the country

The business is focused on getting solution of the problems according to the existing Indian

Bakeries.

Industry Analysis

There exists extremely sophisticated technologies of manufacturing bread in various countries

in Europe and United States. However, target market are those bakeries that work the manual

bread manufacturing techniques.

The bread manufactured for sandwiches is different from that being made for daily consumption

as toast bread and so they are not manufactured in Ovensbut in Bhatthi

I ndustr y size

Currently there are 200 bakeries in Ahmedabad that manufacture the sandwich bread. On an

average, 1 new bakery is installed almost every three to four months.

On an average the bakery produces 1200 kg bread on daily basis, i.e. 1200 bread loafs on 1kgeach and there are total 200 bread making units in Ahmedabad

Thus the annual production of the bread loaf comes out to be of 7Crore 20lakh

(i .e. 1200 breads/day * 200 manufactur ing units * 300 days a year (taking in account of f season))

The average price of a bread loaf was found out to be 30 Rs/loaf that makes the whole annual

market of Ahmedabad to be 216 CRORE


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Key Success Factors

Reduction in wastage by 38% and saving of around Rs. 1, 80,000 for a production of 1200 loafs

a day per month

Better quality of product at same price (i.e. 30rs per 1 Kg Loaf)

Orsame quality at Lower cost

Use of the existing supply pattern

No extra effort in cutting edges

Giving two slices extra in a loaf

I ndustry Trends

Currently industry trends rely more on improving technologies for automated process. In

manual processing, not much have been done.

Moreover the type of bread being consumed in Indian market is also different from that being

consumed globally so the problems faced here are not solved by the innovations that take place

in foreign countries.

Our Innovative Business model based on the system designed by us solves the problems of the

existing Indian Bakeries.

Competitors

The competitors of our business are the existing baking units that cater to the hawkers and other

food joints of the city, and on the later stage the competitors we will face are the National and

State giants in baking business.

More over as the business is very huge there is a full scope of entry for organized bakeries in the

market.


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Marketing Plan

Segmentation, Target &Positi oning

Demographically, the main market targeted is in Ahmedabad and will later spread out to

Gujarat.

The size of Sandwich bread market in Ahmedabad is almost 216 Crore. More over the

market of the State and Nation holds much more potential

Market sur vey & its resul t

We did a deep study of the market and found out that 35% of the bread loaf is being wasted

in terms of sides being cut out and thrown out

Objective of the study

Survey of wastage produced in bakeries using current moulds were done in bakeries in

Ahmadabad. The main objective was to know the bakery owners feedback on using new

mould designs that would be profitable for them.

Methodology

New mould designs were tested in the bakeries. The moulds were fabricated and welded

using aluminium. After the testing, feedback of bakery owners and the workers wererecorded.

Findings

It was found that the using the new mould designs, savings of around 38% are generated.

Also, some altercations are required in some of the processes but these altercations are not

that major to affect the profitability.

I nf erences

Buyer Behaviour

Awareness, Desirability& Demand of product/service

The bakeries that use the manual processing techniques of manufacturing are using it for

more than a decade or so with very few advancements in some of the processes. However,


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there is a lack of awareness among them that the decrease in the bread wastage can also

increase their savings to a large amount. To address this gap is our main motivation of

setting up this business.

Market Segmentation and choice of target segment(s)

Market segmentation: Bakeries using Manual processing techniques for manufacturing in

Ahmedabad.

Marketing Mix

Product positioningThe new bread mould equipment will be positioned as an innovative

patented design that saves 25% of the overall cost saving Rs.1.8 lakhs per month

Pricing strategyWe will be choose a dynamic pricing strategy to capture market. For first

we will try to sell our bread at the same existing price and if we find the competitor gaining

advantage over our strategy well decrease the price of our strategy as we can decrease the

price more by 38% as we have an advantage over the existing bakeries

Promotion strategy- One to one lead generation through cold call and

demonstration/presentation of the product to the bakery owners. Initial promotion will be

done through contacting the baker owners personally.

Place/Distribution channelsIn the distribution channel selection we will use the existing

channel i.e. distributing through the rickshaw which we will be purchasing on inception.

The place we selected is shown below as circled places.

The reason we selected this place as there is already a cluster of baking units in this areas

and thus we will be able to access the raw materials easily


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Source: Google Maps

SWOT Analysis

Strengths:

Our new proposed design saves cost by 35%

Weakness:

New in the market. Penetration may take time.

Opportunities:Number of bakeries is in the order of hundreds; so scope of business is high.

Threats:

Existing designers can use our design for inspiration and give good competition to us

because of their longer time in industry.


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Unique Selling proposition

Unique design of bread mould that reduces bread wastage and costs by 35%. This design is

new in the market and gives better efficiency.

Anticipated Demand

The number of bakeries in our initial target place in Ahmedabad is in the order of hundreds.

Thus, the bakery owners would be willing to adopt our new design to save their huge costs.

Growth Potential

Initially our target market is in Ahmedabad. We plan to expand our businesses to other

metro cities in Gujarat and later to towns. As the penetration in metro cities increase and

bakeries use our design, more and more bakery owners will be willing to buy them. Thus

increase the scale of our business in the order of thousands of bakeries in the state of Gujarat

only.

Competitor Analysis

Our competitors include the manufacturing companies that produce the instruments and

standard mould designs and supply in the market. These industries operate in small scales.

Monitoring marketing activities

To achieve the sales targets, the sales executives will be given certain target units to achieve

to sell in a given period of time. Subsequently, the targets will be increased. Monitoring will

be done by tracking how much time it takes to convert a cold lead to a client by each

salesperson. Proper training will be provided to salespersons to achieve their target results.


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Operations Plan

Supply Chain Management

Raw materials/Semi-processed goods

Logistics

Tempo Cost + Diesel cost

100kms/day * 3rs/km *23 days a month *12months

(2 Tempo)

82800 RS/- (For One Tempo)

165600 RS/- (For Two Tempo)


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Financial Plan

Assumptions

Capacity of bhatti - 50

moulds

We are selectiing

40 Moulds

40 * 7Kg

280 Kg

12Shift a day

12*280

3360 kg

Capacity/day

sales 3200kg /day

3200*35

112000 per day

23 days a

month

Yearly Sales 3.09 crore

15897600 15897600

Power and Fuel 15000 /month

1.8 lakh

per year

Direct Labour 28.8 lakh

10 labourers 3 Shifts a day @

8000 per person

Other Mfg exp 7.2 lakh

5 marketing persons @12000

per month

Water bill .5 lakh Water tax

4.8 lakh

Building Rent @ 40000 per

month

Depriciation 4 lakh /year 2.8 lakh Mould

.30 lakh Bhatthi @30% per year

Atta maker 3.5lakh / 10 year life.5 lakh 5 lakh Slicer .85 lakh/ 10 year life

Weighing m/c+ trolley+ misc

equips of .65 lakh

.4 lakh 4 lakh 2 tempo @2 lakh per tempo

Closing stock 11.04 lakh

One month RM

stock(3200*15*23)

.58 lakh

One day Finished goods stock

(3200*18)

11.62

lakh

Selling and General admin

expenses 1.5 lakh Office cost + Misc

1.66 lakh

Diesel

cost

100 kms @ day *3rs. Per km

*23 days a month *12months

82800

165600 (2 tempo)

Building 5.5 lakh

rent

40,000

office

infra === 4.8+0.7


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CMA data Sheet

FORM II : OPERATING STATEMENT

Sheet 1

AMOUNT INRs : Lakhs

Branch

NAME OF THE UNIT For the year ending 31st March

2014 2015 2016 2017 2018

Proj. Proj. Proj. Proj. Proj.

1 GROSS SALES I II III IV V

i. Domestic sales 309.00 340.00 374.00 412.00 454.00

ii Export Sales

Total 309.00 340.00 374.00 412.00 454.00

2 Less excise duty

Deduct other items

3 Net sales ( item 1 - item 2 ) 309.00 340.00 374.00 412.00 454.00

4 % age rise (+) or fall (-) in net - - 10.00 10.16 10.19

sales compared to previous

year (annualised)

5 Cost of Sales

i.) Raw materials (including 132.00 145.00 159.50 175.45 193.00stores and other items used

in the process of manufacture)

(a) imported

(b) Indigenous -

ii) Other spares - - - - -

(a) Imported - - - - -

(b) Indigenous -

iii) Power and fuel 1.80 1.98 2.18 2.40 2.64

iv) Direct labour 28.80 28.80 28.80 28.80 28.80

(Factory wages & salary) -

v) Other mfg. Expenses 12.50 13.75 15.13 16.64 18.30


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vi) Depreciation 4.00 4.00 4.00 4.00 4.00

vii) SUB TOTAL (I TO VI) 179.10 193.53 209.60 227.28 246.73

viii) ADD: Opening stocks-in-Process) - - - - -

Sub-total 179.10 193.53 209.60 227.28 246.73

Form II : Sheet 2 2014 2015 2016 2017 2018

0 Proj. Proj. Proj. Proj. Proj.

ix) Deduct : Closing stocks-in-

process -

x) Cost of Production 179.10 193.53 209.60 227.28 246.73

xi) Add : Opening stock of

finished goods - - 12.78 14.06 15.47

SUB-TOTAL 179.10 193.53 222.39 241.34 262.20

xii) Deduct closing stock of

finished goods 11.62 12.78 14.06 15.47 17.01

xiii) SUB-TOTAL (Total cost of Sales) 167.48 180.75 208.32 225.88 245.19

6 Selling general and administrtive

expenses 3.16 3.48 3.82 4.21 4.63

7 SUB-TOTAL (5+6) 170.64 184.22 212.15 230.08 249.81

8 Operating profit before interest 138.36 155.78 161.85 181.92 204.19

( 3-7 )

Working Capital Interest 1.40 1.40 1.40 1.40 1.40

Term Loan Interest 1.12 1.12 1.12 1.12 1.12

9 Total Interest 2.52 2.52 2.52 2.52 2.52

10 Operating profit after interest (8-9) 135.84 153.26 159.33 179.40 201.67

11 (i) Add other non-operating income

(a) Interest on Bank Deposits -

(b) Prior period adjustments - - - - -


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(c) Duty Draw Back - - - - -

(d) Others (Misc. Receipts)

Sub-total ( income ) - - - - -

(ii)

Deduct other non-operating

expenses

(a) P&P expense inncluding - - - - -

all book entries written off

(b) Prior period adjustments - - - - -

(c) - - - - -

(d) - - - - -

Sub-total ( expenses ) - - - - -

(iii) Net of other non-operating - - - - -

income/expenses

12 Profit before tax/loss[10+11(iii)] 135.84 153.26 159.33 179.40 201.67

13 Provision for taxes 40.75 45.98 47.80 53.82 60.50

14 Prior Years Adjustment(if any)#

15 Net profit/loss for the year ( 12-13 ) 95.09 107.28 111.53 125.58 141.17

16 (a) Equity dividend paid-amt

(Already paid+ B.S. provision) -

(b) Dividend Tax Including Surcharge -

(c) Dividend Rate

(d) Transfer to General Reserve -

17 Retained profit ( 14-15 ) 95.09 107.28 111.53 125.58 141.17

18 Retained profit/Net profit (% age) - 100.00 100.00 100.00 100.00

# (-)ve for expense/provisions and (+) ve for gains


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Ratio Analysis

2014 2015 2016 2017 2018

Particulars Proj. Proj. Proj. Proj. Proj.

Domestic Sales(Gross) 309.00 340.00 374.00 412.00 454.00

Export Sales 0.00 0.00 0.00 0.00 0.00

Net Sales 309.00 340.00 374.00 412.00 454.00

% rise/fall (-) in net sales 10.00 10.16 10.19

Operating Profit 135.84 153.26 159.33 179.40 201.67

Profit Before tax 135.84 153.26 159.33 179.40 201.67

PBT/ Sales (%) 43.96 45.08 42.60 43.54 44.42

Profit After Tax 95.09 107.28 111.53 125.58 141.17

Cash Accrual 99.09 111.28 115.53 129.58 145.17

Paid Up Capital 2.00 2.10 2.50 3.10 3.50

TNW 2.00 109.38 221.31 347.49 489.06

Adjusted TNW 2.00 109.38 221.31 347.49 489.06

TOL/TNW (times) 33.97 0.65 0.32 0.22 0.17

Adjusted TOL/TNW 33.97 0.65 0.32 0.22 0.17

NWC 2.08 114.23 224.71 354.94 500.44

Current Ratio 1.03 2.74 4.19 5.64 7.19

Other Ratios

Operating Cost/ sales % 56.04 54.92 57.40 56.46 55.58

Net Sales /TTA (times) 4.42 1.88 1.28 0.97 0.80

PBDIT 142.36 159.78 165.85 185.92 208.19


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Balance Sheet

LIABILITIES STATEMENT

FORM III

Sheet 1 AS PER BALANCE SHEET AS AT 31st MARCH

0

0Rs

in Lakhs

Sl.LIABILITIES

2014 2015 2016 2017 2018

No. Proj. Proj. Proj. Proj. Proj.

CURRENT LIABILITIES I II III IV V

1 Short-term borrowings from

banks(including bills purchased,

discounted & excess borrowing

placed on repayment basis)

(i.) From applicant banks 8.00 8.80 9.20 10.10 10.70(ii.) From other banks

(iii) Of which BP & BD

SUB TOTAL 8.00 8.80 9.20 10.10 10.70

2Short term borrowings fromothers 10.00 10.10 10.50 11.00 11.50

3 Sundry Creditors (Trade) 2.21 2.30 2.50 2.70 2.90

4 Advance payments from custo-

mers/deposits from dealers

5 Provision for taxes 40.75 44.25 48.20 52.50 55.606 Dividend payable

7 Other statutory liabilities

(due within one year)

8 Deposits/instalments of term 0.10 0.11 0.12 0.12 0.13

loans/DPGs/Debentures,etc.

(due within one year)

9 Other current liabilities &

provisions(due within 1 Yr)

(specify major items)

SUB-TOTAL (B) 53.06 56.76 61.32 66.32 70.13

TOTAL CURRENT LIABILITIES 61.06 65.56 70.52 76.42 80.83

TERM LIABILITIES As on 31st March

11 Debentures (not maturing

within one year)

12 Preference shares

(redeemable after one year)


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FORM III

Sheet 3 AS PER BALANCE SHEET AS AT : 31st MARCH

0

0Rs.

in Lakhs

Sl.ASSETS

2014 2015 2016 2017 2018

No. Proj. Proj. Proj. Proj. Proj.

I II III IV V

26 Cash and bank balances

Fixed Deposits with Banks

28 (i) Receivables other than 51.52 94.50 208.75 336.92 564.25

deferred & exports (include

bills purchased and

discounted by Banks)

(ii) Export receivables(include - 72.51 72.41 78.97 -

bills purchased and

discounted by banks)

29 Instalments of deferred

receivables(due with in one yr.)

30 Inventory: 11.62 12.78 14.06 15.47 17.01

(i)Raw materials(including stores

& other items used in the

process of manufacture)

(a) Imported(b) Indigenous

(ii) Stock-In-Process - - - - -

(iii) Finished goods 11.62 12.78 14.06 15.47 17.01

(iv) Other Consumable Spares - - - - -

(a) Imported

(b) Indigenous

31 Advance to suppliers of raw -

materials & stores and spares

32 Advance payment of taxes

33 Other Current assets

Income tax for earlier yearsInterest accrued on FixedDeposits

Other Current assets -

(Specify major items) - - - - -

34 TOTAL CURRENT ASSETS 63.14 179.79 295.22 431.36 581.26

FIXED ASSETS


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35 Gross Block(Land & Building 5.50

machinery, work-in-process)

36 Depreciation to date - 4.00 8.00 12.00

37 NET BLOCK 5.50 - (4.00) (8.00) (12.00)OTHER NON-CURRENTASSETS

38Investment/bookdebts/advances/ 1.20 1.00 0.98 0.80 0.75

deposits which are not current

assets

(i) a) Investment in subsidiary

Co./affiliates

b) Other Investments

(ii) Advances to suppliers of

capital goods & contractors

(iii)Deferred receivables(maturity

exceeding one year)

(iv)Others (a) Debtors> 6months

(b) Security Deposits 1.20 1.00 0.98 0.80 0.75

Project Surplus

39 Non-consumables stores &

spares

40 Other non-current assets incl-

uding dues from Directors

41 TOTAL OTHER NON-CURR. ASSETS 1.20 1.00 0.98 0.80 0.75

42 Intangible assets (patents,

goodwill, prelim.expenses, bad/

doubtful exp.not provided foretc)

43 TOTAL ASSETS(34+37+41+42) 69.84 180.79 292.20 424.16 570.01


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Break-even Analysis

BREAK EVEN RM COST INCREASE BY 5.00%

Year

Proj.% increase inRM

2015.00 Cost

Sales 340.00

Total VC% FC%VCAmt

VCAmt FC(Amt)

Raw Material 145.00 100 0 145.00 152.25 0.00

Spare and consumables 0.00 75 25 0.00 0.00 0.00

Power and Fuel 1.98 85 15 1.68 1.68 0.30

Direct Labour 28.80 50 50 14.40 14.40 14.40Other ManufacturingExpenses 13.75 50 50 6.88 6.88 6.88

Depreciation 4.00 0 100 0.00 0.00 4.00Selling General & AdmnExpen 3.48 25 75 0.87 0.87 2.61

Interest - WC 1.40 100 1.40 1.40 0.00

Interest - Term Loan 1.12 100 0.00 0.00 1.12

Others 100 0.00 0.00 0.00

Difference in stock -12.78 100 -12.78 -12.78 0.00

Total 186.74 157.45 164.70 29.30

Contribution 182.56 175.31

Fixed Cost 29.30 29.30

Break Even sales 54.57 56.82

Cash Break Even 47.12 49.07


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FUNDS FLOW STATEMENT

As on 31stMarch As on 31st March

Rs in Rs in Lakhs

2015 2016 2017 2018 2019


Long Term Sources 113.08 115.95 130.36 145.62 -2.75

Long Term Uses 1.03 5.48 0.12 0.13 17.14

Surplus/Deficit 112.05 110.48 130.24 145.49 -19.89

Movement of TNW (Corporate)As on 31stMarch As on 31st March

Rs. in Rs. in Lakhs

2015 2016 2017 2018 2019


Opening balance 2.00 109.38 221.31 347.49 489.06

1 Add.

i Profit/(-)Loss after Tax 107.28 111.53 125.58 141.17 -17.01

ii Increase in Capital 0.10 0.40 0.60 0.40 -3.50

iii Dec./(-) Inc.in Intangible

Assets 0.00 0.00 0.00 0.00 0.00iv Inc../(-) \ Dec.in Reserves 0.00 0.00 0.00 0.00 0.00

v. Adjust prior year expenses 0.00 0.00 0.00 0.00 0.00

2 Less

Div Paid(Incl.Div.Tax)/Withdrawals 0.00 0.00 0.00 0.00 0.00

TNW 109.38 221.31 347.49 489.06 468.54


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Movement of TNW (Non Corporate)As on 31stMarch As on 31st March

RS in RS in Lakhs

2015 2016 2017 2018 2019


Opening balance 2.00 109.38 221.31 347.49 489.06

Increase in Capital # 107.38 111.93 126.18 141.57 -20.51

Dec./(-) Inc.in Intangible Assets 0.00 0.00 0.00 0.00 0.00

Dec./(-) Inc.in Reserves 0.00 0.00 0.00 0.00 0.00

Closing Balance 109.38 221.31 347.49 489.06 468.54


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References:

Zuberbhai Owner of United Bakery, Ahemdabad

Ashfakbhai Owner of Moti Bakery, Ahemdabad

Naeembhai Owner of Diamond Bakery, Ahemdabad

Ashokbhai Fabricator

Hanifbhai Fabricator

http://ejournalofsciences.org/archive/vol2no9/vol2no9_4.pdf

http://www.indianbiscuitplant.com/bread-making-baking-

machinery2.html

http://www.youtube.com/watch?v=adWIanNQTnU
http://ejournalofsciences.org/archive/vol2no9/vol2no9_4.pdfhttp://ejournalofsciences.org/archive/vol2no9/vol2no9_4.pdfhttp://www.indianbiscuitplant.com/bread-making-baking-machinery2.htmlhttp://www.indianbiscuitplant.com/bread-making-baking-machinery2.htmlhttp://www.indianbiscuitplant.com/bread-making-baking-machinery2.htmlhttp://www.indianbiscuitplant.com/bread-making-baking-machinery2.htmlhttp://www.indianbiscuitplant.com/bread-making-baking-machinery2.htmlhttp://www.youtube.com/watch?v=adWIanNQTnUhttp://www.youtube.com/watch?v=adWIanNQTnUhttp://www.youtube.com/watch?v=adWIanNQTnUhttp://www.indianbiscuitplant.com/bread-making-baking-machinery2.htmlhttp://www.indianbiscuitplant.com/bread-making-baking-machinery2.htmlhttp://ejournalofsciences.org/archive/vol2no9/vol2no9_4.pdf

redesigned mould for bread b plan

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