Detailed Project Report (DPR) on roasted & non roasted corn flakes manufacturing unit

Detailed Project Report (DPR) on roasted & non roasted corn flakes manufacturing unit
ROASTED & NON ROASTED CORN FLAKES MANUFACTURING UNIT
[CODE NO.4055]  
   
Cornflakes are a breakfast cereal made by toasting flakes of maize (corn). There are various brands of cornflakes available in the market. Cornflakes are usually served with cold milk and sugar. They are available in the market in various forms such as roasted, non-roasted, sugar frosted flakes, honey and nut flakes, and others. 
 
Cornflakes are very popular and are made by toasting flakes of corn. The roasted or non-roasted forms of cornflakes are believed to enable easier utilization of nutrients and vitamins as compared to non-milled counterparts. Both the roasted as well as non-roasted forms of cornflakes are orange-yellow in colour and have a crunchy texture. Cornflakes tend to soften with milk. 
 
The roasted and non-roasted forms of cornflakes were first produced by Kellogs, but there are numerous other brands available in the market now such as generic brands, sanitarium, gluten free brands, and others. The major ingredients of cornflakes include iron, sugar, milled corn, vitamins (A,B,C,D and E) and high fructose corn syrup. Cornflakes are considered to be high in thiamine levels. Thiamine is considered to be good for energy producton, cognitive functions as well as carbohydrate metabolism. 
 
Both roasted and non-roasted forms of carbohydrates are not rich in fiber. This can be achieved by adding up fruits and nuts to your bowl of cornflakes. There are various forms of cornflakes available such as ‘sugar-frosted flakes’, ‘honey-nut corn flakes’ and others. The roasted and non-roasted cornflakes are known to have buttery taste and are considered to be a good source of minerals, nutrients and vitamins. 
 
As mentioned before, cornflakes have high nutritional value as they have vitamins, minerals, proteins, dietary fiber, carbohydrates as well as folate. Folate is an important nutrient that assists in the formation of new cells and is important during pregnancy. It also prevents colon cancer and heart ailments. When cornflakes are consumed with fruits, it prevents constipation and related colon diseases. Due to rich iron content, cornflakes maintain healthy blood vessels and keep the brain alert. 
 
Cornflakes are also known to have nutrients such as niacin, vitamin A, vitamin B, vitamin B12, riboflavin as well as lutein (important for eye health). Both roasted and non-roasted forms of cornflakes are considered to be low fat foods which decrease the intake of unnecessary unhealthy food. Thus, this eventually leads to lack of cholesterol which ensures that the consumers maintain a good health and do not show any occurrence of heart diseases (probability of occurrence is reduced).  
 
COST ESTIMATION
   
Plant Capacity            2 MT/Day  
Land & Building (4000 sq.mt.)  Rs. 3.39 Cr    
Plant & Machinery                    Rs. 84 Lac 
Working Capital for 1 Month    Rs. 93 Lac 
Total Capital Investment          Rs. 5.45 Cr 
Rate of Return                          32%
Break Even Point                      55%
 
 
INTRODUCTION
PROJECT LOCATION
CITY MAP
CLIMATE
TRANSPORTATION
BY PLANE
BY TRAIN
BY CAR
BY BUS
PHYSICAL PROPERTIES OF MAIZE GRAINS
AVAILIBILITY OF RAW MATERIAL
RAW MATERIAL
NUTRITION OF CORN FLASK
USES AND APPLICATION
PRODUCT & ITS APPLICATION:
WAYS TO USE CORNFLAKES
1. CORNFLAKES UPMA
2. CORNFLAKES LADOO
3. PEAR ICE AND CRUNCH
4. BUTTER CRUNCH BISCUITS
5. NUTTY CORNFLAKE WHITE CHOCOLATE CLUSTER
6. FRIED ICE CREAM
7. CORNFLAKE CRUSTED FRIED CHICKEN
MARKET SURVEY
MAJOR COMPANIES
SITUATIONAL ANALYSIS USING SWOT:
STRENGTH:
WEAKNESS:
OPPORTUNITY:
THREATS:
TACTICS EMPLOYED IN ORDER TO ACHIEVE STRATEGIC OBJECTIVES:
PRODUCT:
PRICE:
PLACE:
PROMOTION:
PROCESS:
PRODUCT INSIGHTS
DISTRIBUTION CHANNEL INSIGHTS
REGIONAL INSIGHTS
MANUFACTURING PROCESS
THE PROCESS OF CORN FLAKES IS -
B.I.S SPECIFICATION
TOP 10 BEST CORN FLAKES BRANDS TO BUY IN INDIA
KELLOGG’S CORN FLAKES
MANNA CORN FLAKES PLUS
GO HEALTHY CORN FLAKES
SAVOUR CORN FLAKES
24 MANTRA ORGANIC CORN FLAKES
KWALITY CORN FLAKES
LAWRENCE MILLS CORN FLAKES
BAGRRY’S CORN FLAKES
PATANJALI CORN FLAKES
OHO CORN FLAKES
MARKET POTENTIAL AND MARKETING ISSUES, IF ANY
LEGAL LICENSE FOR FOOD BUSINESS IN INDIA
1. FOOD LICENSE
GST (GOODS AND SERVICE TAX)
PROFESSIONAL TAX
BASIC FSSAI REGISTRATION
MACHINERY SUPPLIERS
RAW MATERIAL SUPPLIERS
MANPOWER
GENERAL
BASISOFESTIMATION
PLANT LOCATION FACTORS
PRIMARY FACTORS
1.   RAW-MATERIAL SUPPLY:
2.   MARKETS:
3.   POWER AND FUEL SUPPLY:
4.   WATER SUPPLY:
5.   CLIMATE:
6.   TRANSPORTATION:
7.   WASTE DISPOSAL:
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:
PRODUCT PHOTOGRAPHS
MACHINERY PHOTOGRAPHS
BIG TYPE FLOUR MIXING MACHINE
SCREW ELEVATOR
SV52-II TWINSCREW EXTRUDER INCLUDES ONE SET OF DIES
WATER TOWER
CLOSED TYPE AIR BLOWER WITH DISCHARGING DEVICE
4M VIBRATION COOLING MACHINE
BIG TYPE AIR CONVEYOR 6.5M THREE LAYERS GAS TYPE DRYING MACHINE
CONVEYOR
GAS TYPE HIGH TEMPERATURE VIBRATION HOT AIR ROASTING MACHINE (SIMPLE VERSION)
SUGAR SPRAYING SYSTEM
SPREADING VIBRATION MACHINE
THREE LAYERS GAS TYPE EXTENDED DRYING MACHINE
5M COOLING CONVEYOR
FLAKER MACHINE
HIGH TEMPERATURE ROASTING MACHINE
RAW MATERIAL PHOTOGRAPHS
 
 
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)
 

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