Detailed Project Report (DPR) on Flour Mill plant (Atta Flour from Grains/Wheat) (Cap: 270 MT/Day)

FLOUR MILL PLANT 

[EIRI/EDPR/4140] J.C.: 2289US$, 2290INR

Atta (wheat flour) is one of the staple and basic foods to Indians not only that, it is basic food ingredients for all the men lives in the world.

 Wheat is grown in most parts of the world, from near-arctic to near-equatorial latitudes. It is the most important crop among the cereals by area planted and is followed in importance by corn, barley and sorghum. The amount of wheat traded internationally exceeds that of all other grains. Furthermore, the protein and caloric content of wheat is greater than that of any other food crop. Most wheat is consumed in the form of baked goods, mainly bread; therefore, wheat grains must be milled to produce flour prior to consumption. Wheat is also used as an ingredient in compound feedstuffs, starch production and as a feed stock in ethanol production.

Atta is manufactured from wheat which is cultivated in the winter session or just before it. Though there is development of tissue culture base seeds which can be cultivated throughout the year. Wheat has been collected from wheat field and store it in the godown and it has gone through for further processing.

Chakki plants are only used to produce whole wheat atta with full fibers with the same aroma of stones and taste you get from local street vendors. Rollers are used to damage the starch and extract fibers from the wheat flour, which is used in bakery products like bread, biscuits etc. The processing of whole wheat to wheat flour is generally concentrated in a few large mills. The resulting flour is used to make bread, biscuits, pasta, and other products. Because of its widespread geographic distribution, acceptance, stability, and versatility, wheat flour is a suitable vehicle for delivering micronutrients to mankind

COST ESTIMATION

Plant Capacity                                    270 MT/Day 

Land & Building (4080 sq.mt.)  Rs. 2.37 Cr    

Plant & Machinery                               Rs. 1.79 Cr 

Working Capital for 1 Month            Rs. 37.05 Cr 

Total Capital Investment                   Rs. 41.47 Cr 

Rate of Return                                      77%

Break Even Point                                18%

CONTENTS

• INTRODUCTION
  
• COMPOSITION OF WHEAT
• PROTEIN CONTENT
• PROJECT LOCATION
• DECIDE LOCATION
• AVAILABILITY OF RAW MATERIAL
• AVAILABILITY OF UTILITIES
• AVAILABILITY OF LABOR
• LOCATION OF THE PROJECT: - UMERKOT DISTRICT
• CLIMATE
• ROAD NETWORK INFRASTRUCTURE
• HISTORICAL BACKGROUND
• DEFINING THE PRODUCT
• RAW MATERIAL
• USES & APPLICATION OF WHEAT FLOUR
• PROPERTIES
• MARKET POSITION
• INDUSTRIAL AUTOMATION
• ANALYSIS INSTRUMENTS
• SKILLED AND SEMI-SKILLED PERSONALS
• WHEAT FLOUR MARKET:
• WHEAT FLOUR MARKET: DYNAMICS
• WHEAT FLOUR MARKET: SEGMENTATION
• WHEAT FLOUR MARKET: REGIONAL OUTLOOK
• WHEAT FLOUR MARKET: KEY PLAYER:
• TRADITION OF URBAN AND MODERN LIFESTYLES
• RISE IN AWARENESS ABOUT GLUTEN-FREE PRODUCTS
• PROJECTED DEMAND FOR WHEAT FLOUR (TONNES)
• WORLD WHEAT EXPORTER COMPETITION TO INCREASE
• OPPORTUNITY RATIONALE
• COMPOSITION OF FLOUR
• THE WHEAT HAVING THE FOLLOWING COMPONENTS:
• GERM:
• GLUTEN:
• STARCH:
• PROTEIN:
• VITAMINS:
• IRON:
• ANALYSIS OF FLOUR:
• MOISTURE:
• MALTOSE FIGURE:
• REAGENTS:
• SODIUM THIOSULPHATE SOLUTION:
• ACETIC ACID REAGENT:
• POTASSIUM IODIDE:
• SOLUBLE STARCH SOLUTION:
• METHOD:
• ASH:
• COLOUR:
• BLEACH FIGURE:
• CORRELATION OF “SPEAKER” BLEACH FIGURE WITH EMPIRICAL SCALE
• PH:
• GRANULARITY:
• ACIDITY: -
• CRITICAL FACTORS IN DECISION MAKING
• KEY SUCCESS FACTORS
• OPPORTUNITIES
• THREATS
• LIST OF MACHINERY
• INDUSTRIAL FLOUR MILL PLANTWITH PLANT SHIFTER – 240 TPD
• MANUFACTURING PROCESS
• RAW MATERIAL REQUIRED: -
• PLANT & MACHINERY REQUIRED:-
• PROCESS DESCRIPTION:-
• MANUFACTURING PROCESS FOR PRODUCTION OF WHOLE WHEAT 
• ATTA CLEANING SECTION:
• MILLING SECTION:
• PROCEDURE FOR LICENSING TO ESTABLISH FLOUR MILL
• FLOUR MILL BUSINESS OPPORTUNITY
• THERE ARE DIFFERENT TYPES OF FLOUR AND EACH TYPE DEPENDS UPON 
• THE RAW MATERIAL USED TO MAKE FLOUR.
• ESTABLISHING A FLOUR MILL IN PAKISTAN
• REQUIREMENTS TO SETUP A FLOUR MILL IN PAKISTAN
• THE CONTROLLER MAY FROM TIME TO TIME DIRECT THE PRODUCERS/FLOUR 
• MILLS OWNERS GENERALLY OR ANY PRODUCER IN PARTICULAR:
• THE CONTROLLER MAY APPLY OR CAUSED TO BE APPLIED SUCH TESTS AS HE 
• MAY CONSIDER NECESSARY TO SATISFY HIMSELF THAT:
• LIST OF LICENSES REQUIRED TO START A FLOUR MILL IN PAKISTAN
• REQUIREMENTS FOR FLOUR MILL LICENSE APPLICATION IN PAKISTAN
• PROCESS FLOW DIAGRAM
• LAYOUT FOR 240 TON FLOUR MILL
• CLEANING AND CONDITIONING
• CLEANING:
• CONDITIONING OR TEMPERING BY SUN THAT IS SUN DRYING PROCESS
• QUALITY AND GRADE
• QUALITY:
• GRADE:
• RAW MATERIAL SUPPLIERS
• MACHINERY SUPPLIERS
• PRINCIPLES OF PLANT LAYOUT
• MAJOR PROVISIONS IN ROAD PLANNING FOR MULTIPURPOSE SERVICE ARE:
• PLANT LOCATION FACTORS
• 1. RAW-MATERIAL SUPPLY:
• 2. MARKETS:
• 3. POWER AND FUEL SUPPLY:
• 4. WATER SUPPLY:
• 5. CLIMATE:
• 6. TRANSPORTATION:
• 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
• 1. DEPRECIATION:
• 2. FIXED ASSETS:
• 3. WORKING CAPITAL:
• 4. BREAK-EVEN POINT:
• 5. OTHER FIXED EXPENSES:
• 6. MARGIN MONEY:
• 7. TERM LOANS:
• 8. TOTAL LOAD:
• 9. LAND AREA/MAN POWER RATIO:
• MACHINERY PHOTOGRAPHS
• VIBRO PURIFIER
• BRAN REMOVER EMERY ROLL
• GRAVITY SEPARATOR
• SCREW CONVEYOR
• RAW MATERIAL PHOTOGRAPHS
• PRODUCT PHOTOGRAPHS

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 YEARS)