Detailed Project Report (DPR) on soya products (soya milk, flavored milk, curd, yogurt, tofu & okara)

SOYA PRODUCTS

(SOYA MILK, FLAVORED MILK, CURD, YOGURT, TOFU & OKARA)

[CODE NO.3914] 

Soybean is recognized as an oil seed containing several useful nutrients including protein, carbohydrate, vitamins, and minerals. Dry soybean contain 36% protein, 19% oil, 35% carbohydrate (17% of which dietary fiber), 5% minerals and several other components including vitamins.

It is well known that protein yield per hectare by growing soybeans is the highest among all sources of protein - plant or animal. The protein content of soybean is about 40%. No other natural source has as much protein. Nutritionally, soy protein is the most balanced plant protein for human consumption. These facts were recognized in the orient over two thousand years ago.

Mahatma Gandhi introduced soya bean use in India in 1935 in the form of cooked whole or split beans. However, because of the extensive cooking required to make them digestible by humans, soya beans did not significantly enter the Indian diet at that time. 

The cultivated soy bean Glycine max is a member of the Leguminosae family and related to clover and peas. It’s an annual and non frost tolerant plant. The seeds are contained in pods. Depending on the variety the seed size is 3600 – 8000 seeds/kg. The mature bean normally has a light yellow colour and has a moisture content of 13-14%. 

If the water content is higher than 13.5% the beans must be dried prior to storage; otherwise enzyme activity is leading to oxidation of the fats. Soy beans have approximately 40% protein, 35% carbohydrates and 20% oil calculated on the dry matter. Further, it is rich in vitamins and minerals. Soy beans contain all the essential amino acids making it a valuable protein source in human nutrition.

In early 1960s Mr. Mahadeo Shahra creates dawareness on the potential of soya crop amongst the farmers in the state of Madhya Pradesh in India. He was instrumental in bringing up a small green revolution in the state, by introducing and encouraging soyabean cultivation on a commercial scale. Today Madhya Pradesh is considered as soya bowl of the country, and contributes to approximately 60%of its production.

The soybean (Glycine max) is often called the miracle crop. It is the world's foremost provider of protein and oil. The bushy, green soybean plant is a legume related to clover, peas and alfalfa. Farmers plant soybeans in the late spring.

During the summer, soybeans flower and produce 60-80pounds, each holding three pea-sized beans. In the early fall, farmers harvest their crop for these beans which are high in protein and oil.

A 60-pound bushel of soybeans yields about 48pounds of protein-rich meal and 11 pounds of oil.

The soybean (Glycine max) is the world's foremost provider of protein and oil. The Chinese have been cultivating (/knowledge/Tillage.html) soybeans for thousands of years. The first written record of Chinese cultivation dates to the third century B.C. Many believe that the Chinese have been making soy milk for centuries—it has been sold in cafes and from street vendors for generations. So important to the Chinese are soybeans for the production of soy milk and tofu that soybeans are considered one of the five sacred grains along with rice, wheat, barley, and millet. Soybeans made their way to Japan by the sixth century and to Europe by the seventeenth century.

The beans came to the United States on ships from Asia and were used as ballast and often discarded once the ships docked. But soldiers during the Civil War substituted soy beans for coffee beans and were thus making their own form of soy beverage. By the nineteenth century, soy beverages were available in Europe as well. 

However, the popularity of soybean products, including soy milk, came slowly to the United States. African-American agriculturist George Washington Carver began studying the soybean and touting its nutritive value in the early twentieth (/knowledge/20th_Century_Fox.html) century. Shortly thereafter, doctors became intrigued with their use for its nutritional value, particularly for children unable to drink cow's milk. Soybean production has increased in the United States throughout the twentieth century and is a staple crop for many midwestern farmers, allowing soy milk producers a steady supply of the main ingredient. Soybeans are grown in 29 states and are our second largest cash crop.

Soybean protein is one of the least expensive sources of dietary protein. Soybean protein is considered to be a good substituent for animal protein , and their nutritional profile except sulfur amino acids (methionine and cysteine) is almost similar to that of animal protein because soybean proteins contain most of the essential amino acids required for animal and human nutrition.

Soybeans contain two small storage proteins known as glycinin and beta-conglycinin.

COST ESTIMATION

Plant Capacity                                 2700 Ltr/Day

Land & Building (330 sq.mt.)       Rs. 28 Lac

Plant & Machinery                            Rs. 17 Lacs

Working Capital for 1 Month         Rs. 55 Lacs

Total Capital Investment                 Rs. 1.32 Cr

Rate of Return                                  55%

Break Even Point                             54%

• INTRODUCTION
• FUTURE OF SOY PRODUCTS IN INDIA
• SOYA ARE USED AS FOLLOWING
• SOYA FOODS
• SOYA DRINKS
• DAIRY ALTERNATIVE
• SOYMILK
• TOFU
• OKARA
• SOYMILK POWDER
• DISADVANTAGES OF SOY MILK POWDER
• NUTRITIONALVALUE
• PLANT LOCATION
• MAP OF DISTRICT
• CLIMATE
• TRANSPORTATION
• BY FLIGHT
• BY TRAIN
• BY BUS
• CROP CALENDER &MAJOR CONSTITUENTS OF SOYBEAN
• GLOBAL SOYBEAN CROP CALENDAR
• INDIAN SOYBEAN CROP CALENDAR
• MAJOR CONSTITUENTS OF SOYABEAN
• PRODUCTION OF SOYA BEAN IN INDIA
• SOYBEAN GROWING AREAS IN INDIA
• MAJOR TRADING CENTERS OF SOYA BEAN
• SOYA MILK VS COW’S MILK
• UNIQUE FEATURE OF SOYA MILK
• ECOLOGICAL
• MARKET SURVEY
• INTRODUCTION OF DAIRY SECTOR IN INDIA
• REASON OF BUYING OF SOYA PRODUCT
• SOYBEAN: DOMESTIC SCENARIO
• SOYBEAN PRICE SCENARIO
• PROCESS FLOW
• BELOW IS THE FLOW FOR 1 KG OF BEANS OUTPUT
• QUALITY CONTROL
• QUALITY CONTROL AND STANDARDS
• PRODUCT SHOULD CONFORM TO THE PFA (PREVENTION OF FOOD 
• ADULTERATION), ACT, 1955
• POLLUTION CONTROL:
• IMPLEMENTATION SCHEDULE
• PLANT LAYOUT FOR SOYA MILK & ITS PRODUCT
• SOY BASE PRODUCTION
• INDUSTRIAL PRODUCTION OF SOY MILK BASE
• BELOW THE STEPS IN SOY BASE PRODUCTION ARE DESCRIBED:
• PRODUCTION OF SOY MILK
• SOYA MILK PRODUCTION PROCESS
• RAW MATERIALS
• THE MANUFACTURING PROCESS
• PROCURING THE RAW MATERIALS
• DE-HULLING
• ROUGH GRINDING
• FINER GRINDING
• EXTRACTING
• BLENDING
• ASEPTIC STERILIZING
• HOMOGENIZING
• COOLING
• STORING
• PACKAGING
• BYPRODUCTS/WASTE
• METHOD OF MANUFACTURING SOYA TOFU
• SOAKING, GRINDING AND COOKING THE SOYBEANS
• SEPARATING THE SOY MILK
• COAGULATING THE SOY MILK
• PRESSING THE TOFU
• PASTEURIZING THE TOFU
• METHOD OF MANUFACTURING SOYBEAN CURD
• QUALITY CONTROL
• MACHINERY DETAILS
• COMPANY PUSHPANJALI AGRO TECH.
• GST EXTRA AS APPLICABLE
• TERMS & CONDITIONS:
• PRODUCTION CAPACITY
• AS PER CUSTOMER REQUIREMENT SOYA MILK REQUIREMENT/DAY (12 HRS)
• SO, MATERIAL REQUIREMENT BASIS ON REQUIREMENT-
• RAW MATERIAL SUPPLIER
• MACHINERY MANUFACTURER
• RAW MATERIAL PHOTOGRAPH
• PRODUCT PHOTOGRAPH
• SOYA MILK
• SOYA CURD
• SOYA YOGURT
• TOFU
• OKARA
• MACHINERY PHOTOGRAPH

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)