Detailed Project Report (DPR) on fat powder and soya sauce powder

FAT POWDER AND SOYA SAUCE POWDER
[CODE NO.3729]  


Fat Powder

Fat powders with high fat content using three types of fats/oils, namely semi-solid fats like vanaspati, Trans free speciality fat, and liquid oils like safflower or flax seed, are prepared by spray drying. Sugar and tricalcium phosphate are found to improve flowability of the powders. The quantity of fat encapsulated depends on type of fat or oil and found that semi-solid fats could be encapsulated at a higher percentage compared to liquid oils. The moisture of powders is 1–2 g/100 g, bulk density 0.3–0.4 g/cc, surface fat 15–19% and angle of repose 50–55◦. The powders with bakery fat or speciality fat are lighter (creamish) in appearance compared to those with safflower or flax seed oils, which are light yellow due to the colour of the parent oil.

Soy Sauce

Soy  sauce  is comparatively a recent introduction  in  the market.   Various  other types of tomato sauce were  used  either sweatened  or  salted  coupled with spices.  Soya  sauce  is  the development  of soya bean based sauce which has its merits.   The soya sauce is heavier, smooth and voluminous.  It has more unique appearance.  It is low cost compared to other chinese sauce  like chill sauce.

Various tomato sauce have been tried by imparting  different starchy products like starch, potatoes.  Maize and other  starchy vegetables.  Some of these are still used.  Soya sauce is another development  of  this  series.   Soyabean  has  great  food   and nutrition value.  Addition of this product not only increases the nutritive value of the sauce but also enhance the smoothness  and taste.

Soya sauce is consumed is good amount by all the people  all over   the  world.   The  main  consuming  centers  are   hotels, restaurant, hostels, bars, messes, canteens besides shops, houses and  kitchens.   It  is the product of  modern  civilization  and therefore  big  cities have more craze for  chinese  style  food, sauces and other products. Besides the country demand, soya sauce has  a very secured export market too.  Among the wide  range  of Indian  export of food products, tomato sauce, chili sauce,  soya sauce,  various  ketchups, squashes etc.  had  figured  precisely since  the inception of various sophisticated plants having  been set  up  in the various metropolitan cities who launched  out  to manufacture these products in India much over 50 years ago.  From their  records it would appear that in recent years,  consumption of  various sauces in Indian and Foreign markets,  has  increased manifold.   It is quite fortune that India is quite rich  in  the cultivation  of  soybean.  The main producing states  are  U.P., Bihar,  M.P.,  Rajasthan,  Gujarat, H.P, Jammu  &  Kashmir,  West Bengal, Manipur & Maharashtra.  In fact it is scattered all  most everywhere  in the country.  The cultivation has since  increased manifold  due  to  better fertilizers available  now  and  modern techniques of cultivation.

The soya sauce and the like products are marketed in various packs like glass bottles, cans, plastic containers and tins.  Out of  these packs, glass bottles are the best and most  attractive. It is packaged with a multivolour strips pasted on it.  Following information are imparted on the packaging :

1.    Name of the manufacturer.

2.    Trade name of the Product, if any.

3.    Net weight when packed.

4.    Date and Batch No. of manufacture.

5.    Price, excluding local taxes.

6.    Directions for use etc.

7.    I.S. marks if any.



COST ESTIMATION


Plant Capacity            2 Ton/Day       
Land & Building (2000 sq.mt.)      Rs. 2.89 Cr         
Plant & Machinery                      Rs. 1.55 Cr     
Working Capital for 2 Months     Rs. 2.02 Cr
Total Capital Investment              Rs. 6.66 Cr
Rate of Return            40%                   
Break Even Point             49%                

 
INTRODUCTION    
FAT POWDER    
SOY SAUCE    
PROPERTIES OF SOY SAUCE    
USES AND APPLICATION OF SOY SAUCE    
APPLICATION AND PHYSICAL PARAMETERS OF SOYA SAUCE POWDER    
PHYSICAL PARAMETERS    
CHEMICAL PARAMETERS    
SOYA SAUCE POWDER    
GRADES AND COMPOSITION OF SOY SAUCE    
CHEMICAL COMPOSITION OF SOY SAUCE    
TYPICAL COMPOSITIONS OF FIVE VARIETIES OF SOY SAUCE    
DESCRIPTION OF FAT POWDER    
INGREDIENTS    
STORAGE    
MARKET POSITION OF FAT POWDER    
GLOBAL INSTANT FAT POWDER: SEGMENTATION    
ON THE BASIS OF TYPE, THE INSTANT FAT POWDER IS SEGMENTED INTO    
ON THE BASIS OF END USE, THE INSTANT FAT POWDER IS
   SEGMENTED INTO    
ON THE BASIS OF SALES CHANNEL, THE INSTANT FAT POWDER
   IS SEGMENTED INTO    
ON THE BASIS OF PACKAGING, THE INSTANT FAT POWDER
   IS SEGMENTED INTO    
MARKET OVERVIEW OF SOY SAUCE POWDER    
MARKET OVERVIEW OF NUTRACEUTICALS    
1. FORTIFIED/ FUNCTIONAL PACKAGED FOOD IN INDIA    
2. DIETARY SUPPLEMENTS IN INDIA    
3. FUNCTIONAL BEVERAGES IN INDIA    
DEMAND DRIVERS FOR HEALTH SUPPLEMENTS
   AND NUTRACEUTICALS IN INDIA    
1. NUTRITIONAL STATUS OF THE POPULATION OF INDIA    
MALNUTRITION    
MICRONUTRIENT DEFICIENCY    
2. AFFORDABILITY    
3. AWARENESS    
4. AFFLUENCE    
MANUFACTURERS/COMPETITORS OF FAT POWDER
   AND SOYA SAUCE POWDER    
MANUFACTURING PROCESS OF SOY SAUCE AND SOYA SAUCE POWDER    
THE CULTURE INCLUDE    
PROCESS FLOW DIAGRAM FOR SOYA SAUCE AND POWDER    
PRODUCTION DETAILS OF SOY SAUCE    
LARGE-SCALE SOY-SAUCE PRODUCTION    
MAKING SOY-SAUCE AT HOME    
TYPES    
CHINESE SOY SAUCE    
MANUFACTURING PROCESS    
PROCESS FLOWSHEET    
FERMENTED SOYA PRODUCTS    
FORMULATIONS    
COMPOSITE SOY SAUCE    
STALEY SOY SAUCE    
CHINESE SOY SAUCE    
PRODUCTION OF FERMENTED SOY SAUCE    
KOJI PRODUCTION    
BRINE FERMENTATION    
REFINING    
SOY SAUCE PRODUCTION BY THE ACIDHYDROLYSIS PROCESS    
MANUFACTURING PROCESS OF FAT POWDER    
FORMULATION OF FAT POWDER    
FORMULATION AND PROCESS OF FAT POWDER FOR SOUP    
FORMULATION AND PROCESS OF FAT POWDER FOR FODDER    
DETAILS OF SPRAY DRYING    
STAGE 1: ATOMIZATION    
PRINCIPLE OF ATOMIZATION    
CLASSIFICATION OF ATOMIZERS    
ROTARY ATOMIZERS    
RATIONALE FOR ATOMIZER CLASSIFICATION.    
PRESSURE NOZZLE (OR HYDRAULIC) ATOMIZER    
ULTRASONIC ATOMIZERS    
ELECTROHYDRODYNAMIC ATOMIZERS    
STAGE 2: SPRAY-AIR CONTACT    
EVAPORATION OF MOISTURE    
STAGE 4: PARTICLE SEPARATION    
CYCLONE SEPARATOR    
BAG FILTER    
ELECTROSTATIC PRECIPITATOR    
PLANT LAYOUT    
SUPPLIERS OF RAW MATERIALS    
SUPPLIERS OF PLANT AND MACHINERY


APPENDIX – A:

01.    PLANT ECONOMICS    
02.    LAND & BUILDING     
03.    PLANT AND MACHINERY    
04.    OTHER FIXED ASSESTS    
05.    FIXED CAPITAL    
06.    RAW MATERIAL    
07.    SALARY AND WAGES    
08.    UTILITIES AND OVERHEADS    
09.    TOTAL WORKING CAPITAL    
10.    TOTAL CAPITAL INVESTMENT    
11.    COST OF PRODUCTION    
12.    TURN OVER/ANNUM    
13.    BREAK EVEN POINT     
14.    RESOURCES FOR FINANCE    
15.    INSTALMENT PAYABLE IN 5 YEARS    
16.    DEPRECIATION CHART FOR 5 YEARS    
17.    PROFIT ANALYSIS FOR 5 YEARS    
18.    PROJECTED BALANCE SHEET FOR (5 YEARS)