Project Feasibility Report On Automatic Bread Making Plant Food Processing

1. MARKET SURVEY CUM DETAILED TECHNO ECONOMIC FEASIBILITY REPORT (PROJECT FEASIBILITY REPORT) O N Published Date: 23 March 2014 For Latest Report – Visit www.eiriindia.org AUTOMATIC BREAD MAKING PLANT INDENTIFICATION & EVALUATION DIVISION FOR HI-TECH PROJECTS E I R I C O N S U L T A N T S & E N G I N E E R S * REGD. OFFICE * 4449, NAI SARAK, MAIN ROAD, NEAR CHANDNI CHOWK, DELHI - 11 00 06. (INDIA) (BETWEEN MARWARI KATRA AND ROSHAN PURA), PH : 91-11-23918117, 23916431, 45120361, 64727385, 23947058 E-Mail : eiriprojects@gmail.com, eiribooks@yahoo.com Web: www.eiriindia.org, www.eiribooksandprojectreports.com 1 Visit https://www.eiriindia.org for latest Formulations, Books and Bankable Project Reports

2. C A U T I O N This project report has been prepared on the basis of information available with M/S. ENGINEERS INDIA RESEARCH INSTITUTE. The intention here is to provide preliminary information to the prospective entrepreneur. Prior to making a firm decision for investment in the project the entrepreneur must verify the various feasibility aspects together along with the addresses for the procurement of plant & machinery and raw materials independently. The information supplied in this report is obtained from the reliable sources but it is not guaranteed and the money once paid will not be refunded back in any case. Claims for incomprehensiveness of the project report will not be entertained and no legal action in this regard would be entertained in any case (Subject to Delhi Jurisdiction only). Any matter relating to our standard points covered in the report may be modified with in 5 days time only from the date of purchase. ENGINEERS INDIA RESEARCH INSTITUTE, 4449 NAI SARAK, DELHI-110006 2 Visit https://www.eiriindia.org for latest Formulations, Books and Bankable Project Reports

3. AUTOMATIC BREAD MAKING PLANT [EIRI/EDPR/1074] J.C.9718 CONTENTS INTRODUCTION BAKERY DEVELOPMENT PROPERTIES USES AND APPLICATIONS TEST OF BAKERY PRODUCTS DETERMINATION OF MOISTURE DETERMINATION OF ACID INSOLUBLE ASH DETERMINATION OF CRUDE FIBRE DETERMINATION OF ACID INSOLUBLE ASH DETERMINATION OF VOLUME/MASS RATIO FOR BREAD SAMPLING OF BAKERY PRODUCTS MARKET SURVEY OF BREAD INDUSTRY BREAD MANUFACTURERS/SUPPLIERS PROCESS OF MANUFACTURE WITH FORMULATION BREAD MAKING PROCESS WITH FORMULATION PROCESS FLOW SHEET FLOW CHART BREAD MANUFACTURING PROCESS PROCESSING BREAD BREAD INGREDIENTS BREAD MAKING FLOW CHART BREAD MAKING METHODS PRINCIPLES OF PLANT LAYOUT PLANT LOCATION FACTORS EXPLANATION OF TERMS USED IN THE PROJECT REPORT PROJECT IMPLEMENTATION SCHEDULES PLANT LAYOUT OF BREAD MAKING PLANT COMPLETE PLANT AND MACHINERY SUPPLIERS FOR BREAD MAKING UNIT SUPPLIERS OF RAW MATERIALS PLANT AND MACHINERY 5 7 17 18 21 22 23 25 27 29 31 32 41 44 46 49 51 52 54 55 68 71 78 84 89 92 95 96 100 120 3 Visit https://www.eiriindia.org for latest Formulations, Books and Bankable Project Reports

4. APPENDIX – A : 1. COST OF PLANT ECONOMICS 2. LAND & BUILDING 3. PLANT AND MACHINERY 4. FIXED CAPITAL INVESTMENT 5. RAW MATERIAL 6. SALARY AND WAGES 7. UTILITIES AND OVERHEADS 8. TOTAL WORKING CAPITAL 9. COST OF PRODUCTION 10. PROFITABILITY ANALYSIS 11. BREAK EVEN POINT 12. RESOURCES OF FINANCE 13. INTEREST CHART 14. DEPRECIATION CHART 15. CASH FLOW STATMENT 16. PROJECTED BALANCE SHEET 4 Visit https://www.eiriindia.org for latest Formulations, Books and Bankable Project Reports

5. AUTOMATIC BREAD MAKING PLANT [EDPR/1074] J.C.9718 INTRODUCTION the scarcity of time now human beings changes their food habits. No body can pay much more time for their preparation of food, every body wants to get ready made fresh food, such that human being can save their time. They do not want to loss their valuable time in the preparation of daily food. By this thiming now a days these different kind of food materials developed, like instant tea, instant coffee, instant milk, instant rice etc. On the above point of view bakery products are cheaper, largely accepted ready made food. Now the advancement of age use of bakery foods will gradually increases and utilization will be around the proportional of certain percentage of population increase. Modern days are changes with the advance of scientific discovery. Due to nutritive value. They are easy to digest and compact in size, therefore, its consumption is increasing very fast. Bread is most consumable wheat-based bakery product. It contains high 5 Visit https://www.eiriindia.org for latest Formulations, Books and Bankable Project Reports

6. houshold sectors. First bakery in India was set up in 19th century. At present there are 21 units in organized sector and many more in small scale, cottage and house-hold sectors. Breads are manufactured from flour, sugar, salt shortening (one type of fat), dried bakery yeast, vegetables, fruits etc. Bread is manufactured through fermentation and baking process. The manufacturing process and techniques are so simple that they can easily be adopted for production at any level. Recently Government has reserved production of bread for small scale sector. Indian bakery industry is spreaded over all small scale, large scale and 6 Visit https://www.eiriindia.org for latest Formulations, Books and Bankable Project Reports

7. BAKERY DEVELOPMENT Discovery of grinding stones dating back to 75000 years has been taken to mean that even then man had begun to grind seed in order to prepare food in a form that has finally developed into today's. The history of human civilization is not much older. The history of development of today's leavened bread does, therefore, reflect, even though partially, man's march from prehistoric times into the modern day civilization. Though first traces of rubbing stones are available for a period dating back to 75000 years ago, their relatively common use has been established only to about 12000 years ago, in the Azilian Times in Europe. It is believed that it is only at this time that seeds had become an important part of man's diet and his search for a convenient form in which to consume grounded seed became intensified. perhaps this development process took about next 2000 years, because only about 10,000 years ago the oak grove Indians in Southern California are believed to have made use of grounded acorn and other seeds to produce a crude bread as food This bread might have been made of coarsely baked by covering with hot ashes. It is believed that at about the same times Swiss Lake dweller had also developed a primitive art of baking. The Swiss archaeological finds dated about 2500 B.C. establish that their art of baking was based on use of club wheat (a true bread wheat) as the predominant species. The first good picture of primitive baking, however, comes from the ancient tombs of Egypt. Scenes from the tomb of Ti, 2600 B.C. show the milling and bread making process from the removal of the grain from the granary through the grinding on stones and sifting to the mixing and kneading of the dough and subsequent baking of bread in large pots. The milled flour was separated into whiter (fine) flour and darker (coarse) four with the help of use of sieves. The white flour was used to bake bread for the elite and dark flour to bake bread for others. Egyptians are also credited with the first use of leavening. They maintained a stock of sour doughs, a crude culture of desirable fermentation organisms and mixed portions of this material to fresh doughs. This method continues to be in use ever since and a number of bakeries in Egypt as also in India continue to rely on this method of fermentation. 7 Visit https://www.eiriindia.org for latest Formulations, Books and Bankable Project Reports

8. The first over, to match the needs of baking was also developed with the help of baked Nile-clay. The oven, cylindrical in shape had two chambers, the lower one for fire and the upper one for baking. the pieces of dough were placed in the baking chamber through a hole provided at the top. Egypt thus can be truly described as the motherland of the present day bread since it is here that methods of baking similar in principle to those prevailing today we first developed. As the art of baking developed and spread across continents the bread forms also multiplied. The availability of the enclosed baking utensil or the oven made the baking of thicker loaves and cakes possible. At the same time development of knowledge of fermentation made it feasible to make the loaf structure lighter and more digestible. The next obvious development was addition of appealing flavours to cater to individual and class testes. The task of development of bread by addition of unique ingredients to dough was largely carried out in early Greece. When Roman legions took some Greeks to serve as slaves, the ancient art of baking received some further finishing touches in ancient Rome. Thus only through a series of developments did the bread from change from the ancient flat bread of which Mexican tortilla made of processed corn or Indian chapati usually made of wheat are more sophisticated versions, into the conventional form of leavened bread now in common use in most countries of the world. Early baked products were made of mixed seeds with perhaps predominance of barley. However, when it was observed that doughs or gurells made of different seeds held for several hours before baking exhibited different response to the puffing or leavening action of fermentation and wheat flour responded the best by producing a light porous structure in baked products, bakers naturally opted in favour of wheat flour for bakery products. It is believed that in early civilizations art of baking was closely connected with brewing. Both involved fermentation. The thicker dough was good for baking. The thinner mash produced beer. But when experience suggested that wheat was good for baking whereas barley was good for brewing, a kind of separation between the two trades started. 8 Visit https://www.eiriindia.org for latest Formulations, Books and Bankable Project Reports

9. Baking for a long time remained a domestic skill with few changes in equipment or processing methods. It is only when relatively large-scale milling developed that baking on a commercial scale came into being. Commercial baking first began in Rome where towards the first century B.C. well-to-do families wishing to avoid frequent and tedious bread making chores began to patronize professional bakers, at that time largely consisting of freed slaves. They baked loaves moulded by hand into a spheroid shape. These generally had a weight of about a pound each and were baked in behive shaped ovens fired by clay. Gradually guilds were formed by the miller-bakers of Rome. At the same time State introduced a food dole which initially consisted of free distribution of grain but was later converted to distribution of bread. This made miller-baker a very important link between the state and the people. It is possible because of this important role of miller-baker that in 2nd Century A.D. Emperor Trojan organized a "College" and defined the duties and obligations of the bakers. Thus reduced baker to a kind of civil servant with limited freedom of action. Here was the beginning of what later developed into a kind of industrial serfdom in Europe. This period also saw a relative stagnatio in the development of baking techniques. It is only towards the middle of middle ages that guilds were revived and expanded. Admission to a bakers guild needed several years of training. The rise of these guilds also reflected in a considerable improvement in baking techniques. Guild regulations strictly controlled size and quality. At outside the cities bread continued to be largely baked at home. But each country or more correctly each culture produced its own variety of bread since bread did lend itself to the manufacture of endless varieties. As the cultures intermigled so did the bread varieties. In Germany, USSR and Scandinavian countries rye bread gained predominance with some mixture of wheat flour to improve gluten content. In Mexico and latin America tortillas continue to remain popular. IN Middle East and India breads are dry and flat even f they are leavened as in most part of Middle East. In India and other Asian and African countries millet cakes are also favoured. In Ethiopia injerra bread is popular. Injerra is a flat leavened bread made of flour from teff, a high protein content grain grown in that country. Also popular is a bread variety prepared from ensete or "false banana". The ensete is ground, made into a dough and "cured" in the earth where it is also stored until needed. Ireland bread is leavened with baking soda and butter milk and contains no yeast. 9 Visit https://www.eiriindia.org for latest Formulations, Books and Bankable Project Reports

10. Although far eastern communities traditionally preferred riece the western variety of bread is becoming more popular here since the second half of the twentieth century. In particular in Japan bread making industry using U.S. process is expanding rapidly since World War II. Vienna and French breads are long, narrow and cursty. Other forms of raised breads include rolls and buns, chemically leavened quick breads and yeast leavened sweet products that are rich in sugar and shortenings. The leavened breads as thus produced had, however, an important limitation. These breads in all their various varieties had a limited shelf life. These breads were, therefore, not suitable for long journeys to be frequently undertaken in those days by sea. Those undertaking long sea voyages either for discovery, trade or warfare, therefore, demanded a bread form which had a much longer shelf life of more than a few weeks and even months. The answer to their problem was found in "Biscuits". "Bis" means twice and "cuit" means baked which suggests that the product was intended originally to be twice baked. If properly prepared, biscuits were observed to be capable of being kept for a long time and hence these came to be used as a common form of bread at sea. With the development of biscuits came the development of several other products based on unfermented dough, both saltish and sweet. This brought about a dichotomy in the bakery technology which was require to attend to rather different baking needs of fermented and unfermented doughs. The extensive pressures of urbanization, industrialization and wars further helped in considerable improvement of baking techniques. Although raised breads originally depended upon spontaneous fermentation, bakers gradually learned to produce and control fermentation with yeast. Specific strains have been developed with useful bread making qualities, including stability, rapid fermentation capacity and the ability to withstand high temperatures all permitting products of a uniform and consistent quality. Greater use was also made of ingredients other than flour such as milk, shortenings, salt, sugar, eggs, fruits etc. 10 Visit https://www.eiriindia.org for latest Formulations, Books and Bankable Project Reports

11. Technological improvements partly successfully carried out and partly under development include temperature control and improvements in handling method. Various mixing methods such as the straight dough method, the sponge dough method and never continuous mixing methods are also under development include temperature control and improvements in handling method. Various mixing methods such as the straight dough method, the eliminates several individual operations. An interesting new development in the area of bread making is that of bread fortification. Probably 95 percent of the white bread sold in U.S.A. receive a considerable portion of their calorie in take as well as much of their calcium, iron, thiamine and protein intake from bread. Feeding trials show that addition of 0.5 percent L. Lysine and 0.1 percent to 0.2 percent thiamine considerably improves the protein quality of bread. Both bread and biscuits have thus been identified as very useful carriers of nutrition supplementation. Within reasonable limits the input composition of both can be freely and frequently changed to meet nutrition requirements of specific target groups. These target groups; could be identified either by geographical location or by socio-economic and demographic groups and the nature and level of nutrition supplementation can be suitably altered in such manner as to precisely meet the pre-identified nutrition supplementation requirements of target groups at minimum cost per beneficiary. Bakery industry in India in the modern form developed largely to meet the needs of the British army. It is for this reason that a large part of this industry has its origin in Calcutta which can probably be traced back to the days of East India Co. For somewhat to meet the needs of foreign visitors who arrived in India through this gateway either for war or for trading. Biscuits appear to have been first manufactured in India more than three centureis ago to meet the needs of European travellers. The industry was then localized a important sea ports where European ships called more frequently. Perhaps the India bakers first learnt the art of making conventional biscuits from their European customers. 11 Visit https://www.eiriindia.org for latest Formulations, Books and Bankable Project Reports

12. Though the beginning towards the manufacture of conventional bread and biscuits of modern variety was made fairly early its development in the pre- independence era has been very slow. The first organised factory for the production of biscuits was set up at Calcutta in 1897. Soon afterwards two other factories were set up one each at Bombay and Delhi. IN the next four decades i.e. till the beginning of the second world war only four more factories started production. These factories also produced bread and confectionary besides biscuits. However, when the war started and supplies from abroad were curtailed this industry, like several other industries, received a major stimulus for growth. The pre-Independence history of bakery industry in India in its modern commercial form is thus fairly brief and is largely limited to urban areas. Its impack on rural areas was nil or negligible. Whereas the growth of bakery industry in its modern form is largely a post- independence phenomenon a fairly large traditional bakery industry did exist and continues to exist in this country. The most popular products of this industry are buns, kulcha, nan, and such like items. Some of these are produced in cylindrical ovens popularly known as "tandoors". Others in manually operated bakeries. 12 Visit https://www.eiriindia.org for latest Formulations, Books and Bankable Project Reports

13. continues to be very popular. The principal items of production here are: chauswhroo, Girdha, Kulcha and Bakerkhani. These items are produced in about 1000 tandoors in the State. It is estimated that current consumption of all bakery products in Jammu an Kashmir alone is about 60 tonnes per day of which over four-fifth takes place in the form of traditional bakery items. Jammu and Kashmir thus has the distinction of having highest per capita consumption level of bakery products among all the States in India. Also most of the bakery items used in this State are native to it and are not in use anywhere in the rest of the country or even rest of the world except perhaps for Girdha which finds some acceptance in Hyderabad and also in West Pakistan around Lahore. Each State, thus, has its own traditional bakery products which continue to be in use side-by-side with modern conventional arieties of bread and biscuits and other bakery products. A study of these varieties, State-wise, the quantity in which these are consumed, their recipes, their manner of production and also their manner of consumption (i.e. consumption alone or as a complementary food i.e. with tea or milk or some other complementary food can form an interesting subject of study for students of bakery industry both in India and abroad. The art of making yeast leavened baked grain products has been traced back to the ancient Egyptians is in 2000 B.C. Bread in its many forms continues to constitute an important part of the human diet in most cultures because it is both an energy food and source of valuable nutrients. At the present time, the bakery products industry represents a major portion of the food industry because of its high volume of production and large number of employees. Bakeries in the united states produce more thus, forty million pounds of bread daily and employ more workers than any other food industry. The character of the industry has changed over the years. In the past, because of the shortshelt life bread, each community had its bakery which produced bread on a daily basis and sold it directly to the consumer. With the introduction of preservatives and improved mechanical methods of making bread, these appeared increasing numbers of whole sale baking companies which produced bread in massive quantities and sold it to retails over a wide distribution area. The whole sale type of bakery dominantes the multibillion dollar baking industry today. In particular in Jammu and Kashmir the traditional bakery industry 13 Visit https://www.eiriindia.org for latest Formulations, Books and Bankable Project Reports

14. The baking industry generally knew little or nothing about scientific control principles for another 50 years after the pioneer work had begun, but believed that only long and arduous experience would suffice for a knowledge of dough fermentation. Consequently, in spite of the development of new bread making machinery for almost every step in the process, those in charge of production were handicapped by each seasonal fluctuation or milling variation in the flours they used. With the advent of the machine age, all industries benefited by the application of new machine design, especially when steam power gave way to electric motive power that could be applied to individual machines. In the case of the baking process, practically every mechanical development designed to substitute the machine for hand work imposed modifications of the dough to some degree in order for the machine to handle it satisfactorily. Therefore the "almost" automatic baking factory of today has imposed many variations in the dough making process and consequently in the finished baked products. Because of, or inspite of these changes in mechanical handling, the present products of the baking industry are now much better than the old in uniformity, tastefulness, and nutritional value. 14 Visit https://www.eiriindia.org for latest Formulations, Books and Bankable Project Reports

15. 1900's followed the convenience of more general distribution through the grocery stores. The added convenience of wrapped and sliced bread together with the practices of better sanitation, which followed by a few years the economic and social changes resulting from the first World War, speeded the growth of larger baking companies. Discovery of profit potentials by the bankers of the early 1920's led inevitably to financing of combinations of individual plants with the consequent formation of large corporations. These corporate entities, operating many centralized control and purchasing power, were soon to feed the competition of another form of organized baking group, the chain store bakeries. One large plant could produce and distributed breads to many chain store outlets in the surrounding marketing areas through their own established warehouse and trucking system, with a large saving over the regular sales and delivery cost of the independent or corporation bakers. Besides having the price advantage, the chain store organization was able to control more closely the sales of their baked products. A great fear of competition from both corporation bakeries and the chain stores caused the remaining independent bakers, who were limited to there own marketing areas, to seek such technical help as was available. This was found chiefly in the cooperative bakery service organizations an in the technical service personnel maintained by the larger allied distributors of machinery, flour shortenings, yeast and other ingredients. Men trained in cereal chemistry and in associated food sciences began to be sought to spread the word of technical baking knowledge and lead in the production of better products and in better production control. The stimulus of World War I to scientific knowledge brought new candidates in the sciences by the thousands to our colleges and universities. Of these, the relatively few advanced students in cereal chemistry and baking technology were absorbed it the baking and allied industries where they continued the study of baking science and the development of new products and better methods. The American Institute of Baking was organized by the American Bakers Association in 1919 to serve the industry and help teach the fundamental principles of baking. Fortunately, consumer acceptance of the bakers' product during the early 15 Visit https://www.eiriindia.org for latest Formulations, Books and Bankable Project Reports

16. schools then offering short course of training in the baking field. Stimulation and more active support of research in cereal technology by the industry resulted in new knowledge for better control of the baking process and improvement of the products therefrom. Fundamental research was simultaneous in many other fields that contributed significantly to baked foods. The phenomenal advances in biochemistry, physical chemistry, food technology and nutrition during the years since 1900 have revolutionized the baking industry through application to the economics and controls of production. Wheat culture studies in the agricultural experiment station of many states paced the development of new strains of wheat better suited to special requirements of flours for a variety of cereal foods, from breads to macaroni. Mill chemist showed the way to blend and mill wheats from different growing areas and with somewhat diverse baking value into a flour that could be duplicated for more uniform baking use. Analytical and mechanical testing methods were worked out as an approach to specifications for and control of ingredients. There were only a few scientists in the bread making fiel in the early 1920's but they had a profound influence on the development of baking technology. Also influential were the few individuals whose engineering skill and imagination led the industry toward more modern automation in bakery production. And it is here that science must take over from the so-called practical operator to maintain control of the hysiochemical and biochemical processes that make up the mass production of baked products of uniformly high quality and nutritive values. A large part of the total production of land, shortening and certain other plastic fats is consumed in the manufacture of commercial baked goods. The average percentage of fat in some of the more popular bakery goods are approximately as follows: pie (rusk 35-50, Pound Cake 15.30, dough Nuts 15-20, Cookies and water 5-20, white and yellow layer cakes 12-15, soda crackers 8-12 pretzels 5 and white bread - 3. The American Institute of Baking was an addition to the several trade 16 Visit https://www.eiriindia.org for latest Formulations, Books and Bankable Project Reports

17. PROPERTIES 17 Visit https://www.eiriindia.org for latest Formulations, Books and Bankable Project Reports

18. USES AND APPLICATIONS to a few households or classes of performs. Even then, unlike advanced countries where breads are considered basic essentials of a household budget, in India the element of capacity to pay "continues to play a significant role. The outlay on bread, thus shares the character of "discreationary" expenditure rather than expenditure on basic necessities. This i more so in the case of biscuits than in the case of other bakery product. Variants of breads such as rusks have also found much acceptance among relatively poor households and workmen but other bakery products such as cakes, pastries, etc. specifically remain items of "class consumption". Bakery products in India are now in common use and are no more exclusive because these products are considered easy, convenient and rather inexpensive means of taking food in hygienically prepared ready to eat form. A particular role in this direction is being played by use of both bread and biscuits as means of nutrition supplementation for large number of children, and locating and nursing mothers who are covered by various feeding programmes run by number of social welfare agencies operating both at the state and the central level. Much attempt is being made to popularize bakery products among all 18 Visit https://www.eiriindia.org for latest Formulations, Books and Bankable Project Reports

19. pattern, spread of industry and commerce and general change in eating habits shall gradually improve the share of rural consumption in the total market for bakery products. Indian consumption of bakery producers per capita basis in in table I and in table II showing the per capita consumption in different countries. It is hoped that increased modernization, influence of urban consumption house be it male head, female partner or children contribute to this consumption. House-wives and continental cooking pattern also contribute to such consumption of bakery items. Cooking habits abroad are relatively. Simpler and therefore bread consumption is especially very high. The family system and equally effection role played by everyone from a 19 Visit https://www.eiriindia.org for latest Formulations, Books and Bankable Project Reports

20. FOR WHITE BREADS REQUIREMENT FOR WHITE BREAD 20 Visit https://www.eiriindia.org for latest Formulations, Books and Bankable Project Reports

21. TEST OF BAKERY PRODUCTS FOR BREADS Testing will be done by the following confideration: The bread shall be considered as having a good volume the volume/mass ratio is not less than 2.5 when tested. The bread shall be baked in the conventional form or any other form as agreed to between the purchaser and the vendor. The crust shall be free from blisters and shal be of uniform, golden to light brown colour. The crust shall not be burned and shall be free from blisters and shall be of a uniform, golden to light brown colour. The crust shall not be burned and shall be free from soot and any foreign matter. The loaf shall have a good volume. The crumb shall have small pores uniformly distributed throughout and with thin cell walls. It shall be free from non-porous mass, from splits and large holes, from lumps of flour or salt or any other evidence of in complete mixing or baking. There shall be no hollow between the crust and the crumb. The flavour shall be characteristics of fresh, well baked bread, free from bitterness or any other objectionable flavour or taste. The bread shall also be free from indication of rope "rope" or "mould". 21 Visit https://www.eiriindia.org for latest Formulations, Books and Bankable Project Reports

22. DETERMINATION OF MOISTURE APPARATUS PROCEDURE 22 Visit https://www.eiriindia.org for latest Formulations, Books and Bankable Project Reports

23. CALCULATION 23 Visit https://www.eiriindia.org for latest Formulations, Books and Bankable Project Reports

24. DETERMINATION OF ACID INSOLUBLE ASH APPARATUS REAGENT 24 Visit https://www.eiriindia.org for latest Formulations, Books and Bankable Project Reports

25. PROCEDURE Weigh accurately about 20 g of the biscuit power in the dish and ash in the muffle furnace at 600 + 20oC until light grey ash is obtained. Remove the dish from the furance and allow it to cool at room temperature. Add 25 ml of the hydrochloric acid to the dish, cover with a watch-glass and heat on the water- bath for 10 minutes. Mix the contents with the tip of a glass rod and filter through Whatman filter paper No. 42 or its equivalent. Wash the filter paper with water until the washings are free from acid when tested with a blue litmus paper. Return the washed filter paper to the dish for ashing in the muffle furance as above. Cool the dish in a desiccator and weigh. Again ignite the dish for half an hour in the furnace, cool and weigh. Repeat this operation until the difference between successive weighings is less than 1 mg. Filter 25ml of the hydrochloric acid through a blank filter paper, wash, ash and weigh it as in the case of acid insoluble ash. Subtract its mass from the mass of insoluble ash of the sample. CALCULATION 25 Visit https://www.eiriindia.org for latest Formulations, Books and Bankable Project Reports

26. 26 Visit https://www.eiriindia.org for latest Formulations, Books and Bankable Project Reports

27. DETERMINATION OF CRUDE FIBRE REAGENTS Petroleum Ether Dilute Sulphuric Acid - 1.25 percent (m/v), accurately prepared. Sodium Hydroxide Solution - 1.25 percent (m/v), accurately prepared. Ethyl Alcohol - 95 percent by volume. PROCEDURE 27 Visit https://www.eiriindia.org for latest Formulations, Books and Bankable Project Reports

28. CALCULATION 28 Visit https://www.eiriindia.org for latest Formulations, Books and Bankable Project Reports

29. DETERMINATION OF ACID INSOLUBLE ASH REAGENT Dilute Hydrochloric Acid - 5 N, prepared from concentrated hydrochloric acid conforming to IS :265-1976*, by diluting 1 volume of hydrochloric acid with 2.5 volume of water. PROCEDURE Cut the slices of bread into fine pieces and accurately weigh about 10 g i a porcelain dish. Place the dish with the contents in an air-oven maintained at 105 + 2oC for about 4 hours. Cool in a desiccator. Ignite the material in the dish with the flame of a suitable burner for about one hour. Complete the ignitition by keeping in a muffle furnace at a temperature between 550 and 600oC for one hour. Cool the dish in a desiccator. To the ash contained in the porcelain dish, add 25 ml of dilute hydrochloric acid; cover with a watch-glass and heat on a water-bath for 10 minutes. Allow to cool and filter the contents of the dish through Whatman filter paper No 42 or its equivalent. Wash the filter paper with water until the washings are free from the acid. Return the filter paper and residue to the dish. Keep it in an electric air- oven maintained at 135 + 2oC for about 3 hours. Keep the dish in a muffle furnace at a temperature between 550 and 600oC for one hour. Cool the dish in a desiccator and weigh. Heat the dish again at a temperature between 500 and 600oC for 30 minutes, cooling and weighing until the difference between the two successive weighings is less than one milligram. Record the lowest mass. 29 Visit https://www.eiriindia.org for latest Formulations, Books and Bankable Project Reports

30. CALCULATION 30 Visit https://www.eiriindia.org for latest Formulations, Books and Bankable Project Reports

31. DETERMINATION OF VOLUME/MASS RATIO FOR BREAD EQUIPMENT Wooden Box - Large enough to contain a loaf of bread in such a manner that the top surface of the loaf remains about 1.5 cm below the top level of the box, when the loaf is placed over a thin layer of rape seeds in the box. Graduated Cylinder - 500 ml capacity. Rape Seeds. Weighing Scale. PROCEDURE Determination of Density of Rape Seeds - Weigh a 500 ml graduated cylinder on the weighing scale. Fill it to the 500 ml mark with rape seed and reweigh. Take the average of three readings. Calculate the density of the seeds in the following manner: Density of seeds (D), g/ml = (B - A) / 500 Where B = average mass in g of the cylinder filled with the seeds up to the 500 ml level, and A = mass in g of the cylinder. 31 Visit https://www.eiriindia.org for latest Formulations, Books and Bankable Project Reports

32. Determination of Volume of Loaf - Weigh the loaf after it is cooled to room temperature and record the mass. Fill the wooden box place. Weigh the box with the seeds. Take two such reading and record the average. Empty out the seeds leaving a thin layer at the bottom of the box. Place the loaf on this layer of seeds and fill the rest of the space in the box with rape seeds. Level off the surface of the seeds b a wooden average. Note 1 - Precaution: Do no press the loaf while keeping in the box. It should be placed on the layer of the sees. The upper surface of the seeds should be leveled off with the sides of the box. Note 2 - Testing shall be done before slicing. CALCULATION 32 Visit https://www.eiriindia.org for latest Formulations, Books and Bankable Project Reports

33. SAMPLING OF BAKERY PRODUCTS GENERAL REQUIREMENTS FOR BREAD The samples shall be placed in clean and dry bottles and shall be stored in such a manner that the material is not unduly affected. Each container containing the samples shall be sealed air-tight, and marked with full details of sampling, such as date and time of sampling, batch or code number, name of the manufacturer, and other relevant particulars. BREAD PACKING - The bread shall be wrapped or packed as such or in sliced form in clean waxed paper, or any other suitable non-toxic wrapper to preserve freshness. MARKING - The following particulars shall be clearly and indelibly marked on each pack of bread on the outer side of the wrapper; printing, if any, shall be done by non-toxic and non-transferable ink: a) Name of the material; b) Name and address of the manufacturer; c) Trade name, if any; d) Mass of the load when packed; and e) Any added ingredients, for example, Nutriments like vitamins or minerals. Each pack may also be marked with the ISI Certification Mark. 33 Visit https://www.eiriindia.org for latest Formulations, Books and Bankable Project Reports

34. MARKET SURVEY OF BREAD INDUSTRY The bread market Major players The major players in the bread industry that hold about 90% of the market share are Britannia and Modern Industries Ltd. Bakery Products The Indian bakery industry is dominated by the small-scale sector with an estimated 50,000 small and medium-size producers, along with 15 units in the organized sector. Apart from the nature of the industry, which gravitates to the markets and caters to the local tastes, the industry is widely dispersed also due to the reservation policies (relating to the small scale industries) of the government. 34 Visit https://www.eiriindia.org for latest Formulations, Books and Bankable Project Reports

35. and they account for 82% of all bakery production. The unorganized sector accounts for about half of the total biscuit production estimated at 1.5 million tonnes. It also accounts for 85% of the total bread production and around 90% of the other bakery products estimated at 0.6 million tonnes. The last includes pastries, cakes, buns, rusks and others. Biscuits are estimated to enjoy around 37% share by volume and 75% by share by value of the bakery industry. The organized sector caters to the medium and premium segments, which are relatively less price-sensitive. The organized sector is unable to compete at the lower price range due to the excise advantage enjoyed by the informal sector. The organized segment in biscuits has witnessed a steady growth of about 7.5%, conforming broadly to the growth rate of GDP. Biscuits constitute about 7% of the Rs 878 billion FMCG markets in India. During 2009-10 biscuits market grew at double digit (about 11%) compared to a growth of 1.4% for the FMCG industry as a whole, and 4.4% average growth over last five years (2009-2010). Britannia has rationalized its product portfolio pruning the number of its brands. The company moved into the mass market for biscuits introducing low- priced varieties under the umbrella brand, Tiger. The success of this brand has enabled Britannia to expand its market share in the glucose biscuit market. Its other major brands are 50:50, Mariegold, Bourbon, Pure Magic, Nice, Snax Coconut Crunchies, Glucose-D, Pure Magic, Good day. Its bread portfolio consists of Britannia, Britannia Premium Bake, Tiger and Chekkers. Biscuits and bread which are considered to be the major bakery product 35 Visit https://www.eiriindia.org for latest Formulations, Books and Bankable Project Reports

36. processed food producers of Europe - ranking seventh globally. It has a 22% equity stake in Britannia. Britannia has the option to draw from the product portfolio of Groupe Danone. Over the past couple of years, it has launched a number of dairy products (processed cheese, flavoured milk, butter, ghee and dairy whitener) and ethnic snack foods such as alloo bhujiya and chana choor. Although MNCs, like Nabisco, Arnotts and United Biscuits ventured into the market, Britannia enjoys a premium position. It has dispersed plants geared to the four metros, which account for a major slice of sales (65%). It also has 20 dedicated small units around the metros to help produce about 50% of biscuit production. Britannia Industries launched chocolate-based products and was exploring several variants in cheese, cakes and biscuits. The company has decided to enter into areas where it will have the potential of becoming number one operator. Britannia started selling lassi and cold coffee in tetrapak. Britannia was also extending its successful biscuit brand, Tiger, into categories like milk or milk powder. Britannia’s French partner, Danone, may consider taking the mass biscuit brand to its other Asian markets like Malaysia and China as well as Russia. Britannia Industries has acquired 49% stake in Kwality Biscuits. It has also acquired Kwality Chef and several other trademarks along with copyrights, designs in labels and packing material. The four group companies to be merged with Kwality Biscuits are Vajram Traders, Camilla Investments, Malakala Traders, Mytrayasa Traders. The domain of Kwality Biscuits includes baking, manufacture of biscuits, cakes, breads, buns, cornflakes and other breakfast foods, popcorn, wheat shreds, pastries and flour. Britannia is looking for more acquisitions in food business. Britania Industries has made an investment of Rs 600 million for its capacity expansion project at Pantnagar. Parle is the second largest producer of biscuits in the organized sector. In the popular brands segment, its Parle G remains a popular brand in the glucose biscuit segment. In the premium segment, its Hide and Seek is attracting competition due to the sway it holds in the market place. In the saltish biscuits, Monaco has been quite popular, especially in the cocktail circuit. Parle's, however, derives a major part of its revenues from the low- priced products. The company has, nevertheless, outpaced the industry growth in Britannia has a tie-up with Danone of France. Danone is one of the largest 36 Visit https://www.eiriindia.org for latest Formulations, Books and Bankable Project Reports

37. step with the market leader Britannia. Parle Products is setting up a new biscuit manufacturing unit at Pantnagar, Uttaranchal. Kellogg's, known worldwide for breakfast cereals, entered a new product segment - biscuits. It has launched Kellogg's choco-biscuits, an extension of its Chocos cereal. Kellogg's found that there was an opportunity to carve out a niche for itself in the market by leveraging the core equity of some of its large cereal brands. SmithKline has succeeded with the launch of Horlicks (a healthfood brand) biscuits. Nestle has recently taken over the biscuit manufacturing joint venture with Dabur, Excelsia and converted it into a wholly-owned subsidiary. Dabur India has divested its entire 40% stake in the controversial joint venture Excelcia Foods with Swiss major, Nestle SA, thus exiting the biscuit business altogether. Lancer Foods is launching cookies, biscuits and namkeens. Vita Gold is positioned against Parle's Glucose brand. Lancer Food Products, a late entrant in the biscuit market, had planned to set up two additional manufacturing plants at Noida, UP. The new plants of Lancer have a biscuit manufacturing capacity of 150 tonnes a day. Some 85% of the company's total production is exported to countries in Africa and the Middle East. Priya Food Products set up with an investment of Rs 26 mn had a capacity to produce 5 tonnes of biscuits per day. In the past near two decades, it has come a long way and today commands a significant share of the biscuit market. A study has shown that Bakeman's market share has remained stagnant. In contrast, older players like Britannia, Parle and SmithKline Beecham and a host of new players like Kellogg's have seen their shares expand. On the other hand, Bakeman is planning a major expansion which is expected to make it the largest biscuit plant under one roof in Asia and the third largest in the world. The size of the bread market is estimated at Rs 15 bn. There are a number of producers in both sectors, organized and unorganized. Modern Foods, a Central public sector undertaking, and a leader in the bread segment was privatized by the government in a strategic sale to Hindustan Lever at a price of Rs. 1054 mn. 37 Visit https://www.eiriindia.org for latest Formulations, Books and Bankable Project Reports

38. the resolutions. The deal marks HLL's entry into bread making, having already forayed into ice creams and marketing of flour under the brand name Annapurna. This was its first foray into baking business. Modern Foods had nearly half of the organized market to itself. Britannia’s bread market share declined sharply in 2008-2009 and continued till 2010-2011 mainly because of the competition from Modern Foods. However with the takeover of Modern Foods and the time spent in restructuring has enabled Britannia to have a major share of the bread market. Earlier, Britannia introduced Premium Bake, premium bread. The brand created a high-end segment for the daily staple item used by all segments. Britannia has since been joined by other bread manufacturers like Candico (India), Elite Breads and a host of others with small market presence. From a low priced commodity, bread has graduated into a branded product with discriminating prices. Barring Premium Bake, the others are priced high - almost double the standard bread brands. Premium Bake comes closer to the 'normal' price, a mid-way pricing strategy. INCREASING CONSUMPTION OF BAKERY PRODUCTS IN INDIA Bread The later was to induct a fresh equity of Rs 200 mn into the company, while government retained 26% equity, giving it the right to block special 38 Visit https://www.eiriindia.org for latest Formulations, Books and Bankable Project Reports

39. Market Structure Lead Players Modern Foods,Britannia Inds are the lead players in biscuit in the market. Market Growth Rates 1990-91 - 1996-97 1996-97 - 2001-02 2001-02 - 2006-07 2004-05 - 2009-10 2009-10 - 2014-15 Sensitivity Coefficient5.6% Product Variation Segment Milk Bread Brown Bread Fruity Nutritional and other specialty Leading Brands 5.4% 7.9% 6.9% 6.0% 5.0% Share (%) 85 10 3 2 39 Visit https://www.eiriindia.org for latest Formulations, Books and Bankable Project Reports

40. Britannia, Modern, Bakeman Sujana, Premium Bake, Whyte Kollar, Ovenfresh, Premium Bake, Gardema are the leading brands in biscuits. Are you looking for a large market ? Stop looking. There is no bigger market than in India. India has a population of one billion and more. In terms of population India is likely to overtake China and soon will become the largest populated country in the world. Here are some more facts for you to consider. * One out of six persons in the world is now an Indian * India is a mature democracy and business climate is very good. * Indian economy is third largest in Asia after Japan and China. * Indian economy is sixth largest in the world and with the present growth rate; it soon will be the fourth largest economy in the world. * With inflation under control, lower interest rates and comfortable forex reserves, the Indian economy is projected to grow by 8 to 8.5 per cent during the current fiscal year (2009-10). (One of the fastest growing economies in the world.) There are certain demongraphic changes that are happening through out the world and India in particular that you need to know. This will 4 guide you to the age group of people you can target to market your products. * In the first stage, the proportion of young people in the population rises. * In the second stage, the proportion of young people declines, that of the old increases modestly, and that of adults of working age increases significantly. * India is just entering the second stage and its share of the working age population is expected to increase until 2035 and beyong. * In the third stage, the proportion of working age adults falls while that of old people rises. Where will your customers be living? Throughout the world people are migrating to cities to seek employment, new opportunities and new life styles. The number of people engaged in rural agriculture is declining due to 40 Visit https://www.eiriindia.org for latest Formulations, Books and Bankable Project Reports

41. migration to cities. This has resulted in the growth of big, small and mega cities that act like magnet to rural youngsters and even to whole families. Cities provide immense economic opportunities to migrants. * The urban population has been growing more rapidly than the rural population. Within the urban areas, the population of mega cities has been growing even more rapidly. * Added to the natural increase is migration of people from rural areas, towns and smaller cities. * It is projected that by the year 2015, five Indian cities will be among the 30 largest cities in the world. These are Mumbai, Kolkata, Delhi, Hyderabad and Chennai, Mumbai will be the second largest city in the world, next only to Tokyo. What kind of purchasing power the people India have. Can they afford to buy high quality bakery products ? Sure they can. The disposable income of most people have gone up and there is new affluence every where. People have become quality consicious and also demand and buy a great variety of products to consume and own from quality foods, cell phones, garments, motorbikes, cars to homes. India annually produces 120 million tones of wheat and is one of the largest producers in the world. India also has a large and under utilized milling capacity to mill products like flour etc needed by the bakery Industry. The milling industry has become quality conscious due to modernization, competition and demanding customers. * According to the estimate made by the Ministry of Food Processing Industries (2003), the total market of bakery product, bread and biscuit is estimated at 1.5mn ton and 1.1mn ton respectively. * The cake market is estimated at 0.4mn ton. Bread market is estimated to be growing at around 7% pa in volume terms. * The organized segment of the biscuit market is estimated to be 0.44 mn tons whereas the unorganized sector accounts for the balance 0.66mn tons. 41 Visit https://www.eiriindia.org for latest Formulations, Books and Bankable Project Reports

42. * Biscuit market in the recent years has witnessed a little higher growth at around 8-10% pa. Within the biscuit category, cream and specially biscuits are growing at faster pace at 20% pa, while the popular segment is growing. Large joint family system has given way to compact nuclear families. These days, a household may even consist of one person or a double income no-kids (DINK) family, Often both husband and wives goes to work. Number of meals cooked at home is declining dramatically and consuming convenience foods such as bakery foods and eating out are increasing. The per capita consumption of bakery product like bread, biscuits, cakes and other baker's speciality products are very low by world standards. It is expected that with increase in nuclear families, rise in standard of living and rapid urbanization, the demand and consumption of bakery products will go up many folds. Bank loans are easily available from banks at low interest rates. The ministry of food processing as well as state government encourages starting of bakery units and gives subsidies and tax holidays in select places. Every kind of bakery equipment, both domestically made and imported, is now available to the Indian bakers. Many Indian firms now represent foreign manufacturers and help in proper selection, import, installation, training and service of bakery machines. A limited of amount technical know is also available from the manufacturers. A large variety of bakery additives, that will be useful for preparing world class bakery products, as found in western world, are now available for the Indian bakers. Along with the additives, again some amount of basic technical help is also available to use such sophisticated additives. Recently American Institute of Baking, USA, the world renowned bakery training organization has commenced correspondence courses and specialized training in India on bakery production, engineering, GMP and HACCP etc which can be taken advantage of by Indian bakers. Short and long term training in many other aspects including that of specialty products are also given by AIB at their facility at Kansas, USA. Similarly CFTRI and many other Indian institutions have courses tailored for the Indian needs. The stage is now set for bakers to vastly expand and improve their production, marketing, quality and variety of bakery product to the people of India. 42 Visit https://www.eiriindia.org for latest Formulations, Books and Bankable Project Reports

43. BREAD MANUFACTURERS/SUPPLIERS 43 Visit https://www.eiriindia.org for latest Formulations, Books and Bankable Project Reports

44. 44 Visit https://www.eiriindia.org for latest Formulations, Books and Bankable Project Reports

45. 45 Visit https://www.eiriindia.org for latest Formulations, Books and Bankable Project Reports

46. 46 Visit https://www.eiriindia.org for latest Formulations, Books and Bankable Project Reports

47. PROCESS OF MANUFACTURE WITH FORMULATION BREAD THEORY : Bread manufacturing is a process of mixing o bread ingredients and prepared a proper dough of the Ingredients, after complete making of doughing dough is divided, rounded, moulding and proofing, after proofing the products is further pass through the baking own to complete bake the product. The product i.e. bread is ready for cooling, slicing and packing for marketing. GENERAL RAW MATERIAL : 1. Wheat Flour, 2 . Yeast, 3. Sugar, 4. Salt, 5. Water, 6. Shortening agent (like vanaspati), 7. Milk or milk powder etc. 47 Visit https://www.eiriindia.org for latest Formulations, Books and Bankable Project Reports

48. There are different types of bread of whose formulas are given below: WHITE BREAD (NORMAL) INGRIDIENTS PERCENTAGE ON WT. BASIS OF MAIDA 48 Visit https://www.eiriindia.org for latest Formulations, Books and Bankable Project Reports

49. BREAD MAKING PROCESS WITH FORMULATION Ingredients: Wheat flour, Sugar, Yeast (ADY), Calcium propionate. Acetic acid, Salt, Ice-crystal, Water Process: 49 Visit https://www.eiriindia.org for latest Formulations, Books and Bankable Project Reports

50. Mass Balance: Raw materials input: 69.82 Kgs Yield: 82.5 Kgs (220 Pkts X 400 Gms) Role of chemicals: 1. Acetic acid: Prevents the formation of off smell in bread when storage time increases (2-3 days) 2. Calcium propionate: Acts as a preservative 3. Ice-crystal: It is only added in summer (in hot condition) to regulate the temperature during mixing and improves mixing process. Dissolve the yeast in partly water with the complete addition of sugar in it, stirred the ingredients until it will not formed a homogeneous solution. Temperature of the mixture will be 30oC - 35o. Now added salt in another pot containing residual water. Mix Diet throughly to make a homogeneous solution. Now yeast sugar solution and salt solution is ready. Took the proper amount of flour, first mixed with sugar yeast solution by mixing machine, after complete mixing added to it salt solution to form proper dough. After complete water, sugar and salt mixing, added the shortening in the dough mixer to make a smooth and soft dough. Keep the smooth dough for one hour for fermenting the dough. After one hour, the dough has gone to knock-back operation, after knock-baking of the dough is pass through the divider and rounder. From the rounder to it should go to moulder, in the moulder it is kept for final proofing. AFter final proofing in the mould It will take 40-70 mintues at temperature 40oC) it is pass through baking open where temperature control around 200oC - 300oC ad the baking time around 15-30 mintues. After complete baking of the dough, that is hot form of bread is allow to pass in cooling zone to cool the bread at 30oC, it will take time around 2-3 hour. 50 Visit https://www.eiriindia.org for latest Formulations, Books and Bankable Project Reports