FRENCH FRIES MANUFACTURING PLANT (CAP: 120 MT/DAY)
[EIRI/EDPR/4617] J.C.: 2834XL
The global frozen food market comprises retail as well as business customers. Retail customers of frozen food are individuals and households, whereas business customers include hotel chains, fast-food outlets, caterers, and other business buyers. Retail customers mostly prefer cooked and semi-cooked ready-to-eat food, meat, and soups amongst the class of available products in the market. While business customers majorly use frozen meat, sea food, frozen pizza crust, bread, frozen dough, potatoes, and vegetables as the key ingredients for preparing food for end customers. Based on geography, Europe is the largest market, closely followed by North America.
The growth of the frozen food market would primarily be driven by the growing demand and consumption of frozen foods in the developing markets across the Asian countries such as India and China. Increase in disposable incomes coupled with change in lifestyle and food habits are major factors that boost the market growth in these regions. Moreover, a rapid increase in number of large retail chains including hypermarkets and supermarkets has bolstered the demand of frozen food in the developing Asian countries. However, lack of proper refrigeration facility in retail stores and inadequate distribution facility in semi-urban and rural areas are the major challenges for the industry in developing markets. The developed markets are expected to continue their growth at a moderate pace, majorly driven by the mounting consumer preference for healthy frozen foods.
COST ESTIMATION
Plant Capacity 120 MT/Day
Land & Building (5 Acres) Rs. 15.99 Cr
Plant & Machinery Rs. 52.66 Cr
Working Capital for 3 Months Rs. 52.48 Cr
Total Capital Investment Rs. 127.05 Cr
Rate of Return 99%
Break Even Point 23%
CONTENTS
INTRODUCTION
FROZEN FOOD INDUSTRY MARKET OVERVIEW:
FRENCH FRIES
CONTRIBUTION TOWARDS THE GDP
GROWTH AND TREND OF THE INDUSTRY
ABOUT POTATO
NUTRITIONAL SIGNIFICANCE OF POTATO
VALUE ADDITION AND PROCESSING OF POTATO
POTATOES PROCESSING – GLOBAL
GROWING CONDITIONS FOR FRENCH FRIES POTATOES
POTATOES IN INDIA
POTATO PRODUCTION IN INDIA
INDIAN PRODUCTION OF POTATO
FSSAI SPECIFICATION
STYLES
THE DIMENSION OF CROSS SECTION
STANDARDS ARE AS FOLLOWS
MAJOR PLAYER
MAJOR PRODUCTS
HERE ARE SOME FROZEN FOOD MAJOR PRODUCTS:
POTATO FARMING
VARIETIES
SOIL
CLIMATE
POTATO PROPAGATION
SELECTION OF SEED TUBER
TRUE POTATO SEED (TPS)
LAND PREPARATION
SEASON OF PLANTING
METHOD OF PLANTING
INTERCULTIVATION
WEED CONTROL
EARTHING UP
CROP ROTATION
INTERCROPPING
MANURE AND FERTILIZERS
IRRIGATION
PLANT PROTECTION
HARVESTING AND YIELD
POTATO HARVESTING
YIELD
PROCESSING OF FRENCH FRIES
1. POTATOES RECEIVING
2. SIZING
3. STEAM PEELER
4. DE-SKINNER/WASHER
5. PRE HEATER/METERING TANK
6. SORTING/CUTTING
7. DEFECT REMOVAL
8. BLANCHING
9. FLUMES
10. DRYER
11. FRYER
FLOW DIAGRAM FOR MAKING FRENCH FRIES
AUTOMATIC FROZEN FRENCH FRIES PLANT LAYOUT
LIST OF MACHINERY & EQUIPMENTS
1. POTATO WASHING AND PEELING MACHINE
2. FRENCH FRIES CUTTING MACHINE
3. MESH BELT POTATO BLANCHING MACHINE
4. VIBRATION DEWATERING MACHINE
5. AIR BLOWING POTATO DEHYDRATING MACHINE
6. FRENCH FRIES CONTINUOUS FRYING MACHINE
7. VIBRATION FRENCH FRIES DE-OILING MACHINE
8. FRENCH FRIES PRE-COOLING DEOILING MACHINE
9. TUNNEL TYPE FRENCH FRIES FREEZING MACHINE
10. AUTOMATIC FROZEN FRENCH FRIES PACKING MACHINE
11. LIFTING BELT OF LIFTING MACHINE
12. HIGH-PRESSURE BUBBLE WASHING MACHINE
ADVANTAGES OF TUNNEL QUICK-FREEZER
1. RAW MATERIAL
2. SPECIAL COLD STORAGE DOOR
3. INSIDE OF FREEZER
4. DRIVING MOTOR
5. EVAPORATOR AND FAN
6. IN AND OUT OF THE FREEZER
7. ELECTRIC CONTROL PART
INTRODUCTION OF FRENCH FRIES BLAST FREEZER
PLANT LOCATION: STATE
LICENSES REQUIRED
LIST OF DOCUMENTS:
OTHER LICENSES REQUIRED FOR THE SETUP:
PRINCIPLES OF PLANT LAYOUT
PLANT LOCATION FACTORS
PRIMARY FACTORS
1. RAW-MATERIAL SUPPLY:
2. MARKETS:
3. POWER AND FUEL SUPPLY:
4. WATER SUPPLY:
5. CLIMATE:
SPECIFIC FACTORS
6. TRANSPORTATION:
A. AVAILABILITY OF VARIOUS SERVICES AND PROJECTED RATES
7. WASTE DISPOSAL:
8. LABOR:
9. REGULATORY LAWS:
10. TAXES:
11. SITE CHARACTERISTICS:
12. COMMUNITY FACTORS:
13. VULNERABILITY TO WARTIME ATTACK:
14. FLOOD AND FIRE CONTROL:
EXPLANATION OF TERMS USED IN THE PROJECT REPORT
DEPRECIATION:
FIXED ASSETS:
WORKING CAPITAL:
BREAK-EVEN POINT:
OTHER FIXED EXPENSES:
MARGIN MONEY:
TERM LOANS:
TOTAL LOAD:
LAND AREA/MAN POWER RATIO:
FRENCH FRIES PRODUCTS
PACKAGING TYPES
FROZEN FOOD PACKAGING MARKET SEGMENTATION:
ON THE BASIS OF FOOD TYPE, THE GLOBAL FROZEN FOOD PACKAGING MARKET IS SEGMENTED INTO:
ON THE BASIS OF PRODUCT TYPE, THE GLOBAL FROZEN FOOD PACKAGING MARKET IS SEGMENTED INTO:
LIST OF FRENCH FRIES MANUFACTURERS
SUPPLIERS OF PLANT AND MACHINERY
CONVEYOR BELT
BUCKET ELEVATORS
WEIGHING MACHINES
BAG SEALING MACHINE
D.G. SET
LABORATORY TESTING EQUIPMENT
EFFLUENT TREATMENT AND DISPOSAL
STANDARDS
TOLERANCE LIMITS FOR INDUSTRIAL EFFLUENT DISCHARGE
WASTE TREATMENT
PRIMARY TREATMENT
SECONDARY TREATMENT
TERTIARY TREATMENT
SOLIDS CONCENTRATION
TYPICAL WASTE SOLIDS CHARACTERISTICS
EQUIPMENT REQUIREMENTS
EQUIPMENT REQUIREMENTS
MANPOWER
GENERAL
BASIS OF ESTIMATION
UTILITIES
WATER
WATER QUALITY PARAMETERS FOR PROCESSED WATER:
STEAM
UTILITIES (EQUIPMENT)
WATER TREATMENT PLANT
STEAM GENERATING SYSTEM
REFRIGERATION SYSTEM:
POWER
WORKING
TOTAL MANPOWER AND PAYROLL
QUALITY CONTROL OF FRENCH FRIES
MACHINERY PHOTOGRAPHS
RAW & FINAL PRODUCTS PHOTOGRAPHS
SWOL ANALYSIS
STRENGTHS:
WEAKNESSES:
OPPORTUNITIES:
THREATS:
ORGANIZATION CHART
PLANT LAYOUT
CONSULTANT
ADDRESSES OF RELEVANT GOVERNMENT OFFICES
ADDRESSES OF FINANCIAL INSTITUTIONS
IMPLEMENTATION SCHEDULE
APPENDIX – A:
01. PLANT ECONOMICS
02. LAND & BUILDING
03. PLANT AND MACHINERY
04. OTHER FIXED ASSETS
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 (5-10 YEARS)
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