Egg Powder Unit (Vibrant Gujrat)
Egg Powder Unit (Vibrant Gujrat)
Egg Powder Unit (Vibrant Gujrat)
Contents
Project Concept
Market Potential
Growth Drivers
Project Information
10
- Location/ Size
- Infrastructure Availability/ Connectivity
- Raw Material/ Manpower/ Machinery
- Potential Collaboration Opportunities
- Key Considerations
Project Financials
15
17
18
Page 2
Project Concept
The concept
The project envisages
setting up of Egg
Powder Manufacturing
Unit based on the raw
material strength of
Gujarat.
Egg powder
An egg consists of 3 main parts: the shell (10%), the albumen or egg
white (60%) and the yolk (30%). An average egg weighs about 55-60
gram. Egg, in full or parts, is used to prepare powder used in different
industries:
Whole egg powder (WEP) is used in classical food
applications where rising qualities are not essential,
such as crackers, cookies and pasta.
Egg processing
Manufacture of dried egg powder starts with breaking of eggs and removing egg-shells. After
removal of shells, the mixture is filtered and stored in storage tanks at about 4oC and then it is
taken to tabular heater, wherein it is dried at about 65oC for 8 to 10 minutes and it is filtered and
passed to high pressure spray drier with the help
p of high
g pressure pump. The material which
ly in
i dried form but also in powder form, which is
comes out of high pressure spray drier is not onl
only
ge yield
yyiiel
eld is
is around
aro
then packed in polylined boxes. The average
80%. A typical manufacturing process
flow is shown below:
Dried shell packing
and storage
Breaking
Whole egg
Filtering
Cooling
Liquid whole egg holding
Spray drying
WEP
Packing
Storage below 20oC
Storage at ambient
temperature
Page 3
Egg yolk
Filtering
Cooling
Liquid whole egg holding
Spray drying
EYP
Packing
Storage below 20oC
Storage at ambient
temperature
Egg albumen
Filtering
Cooling
Liquid whole egg holding
Spray drying
EAP
Packing
Hot room storage at
ambient temperature
Project Concept
Global market overview
Asia dominates the global egg production, accounting for around 60% of the total, followed by
Americas and Europe.
Asia encompasses five of the top 10 national producers of eggs, with India and Japan at third
and fourth positions in the world ranking.
Region
Country
Asia
40.0
Americas
14.0
10.9
China
28.8
USA
5.6
Europe
India
3.8
Africa
3.1
Japan
2.52
Oceania
0.3
Mexico
2.51
World
68.3
Country wise, China leads the egg production globally, followed by the US and India.
However, Chinas growth rate was slow as compared to the growth achieved by other Asian
economies - India, Indonesia, Pakistan and Malaysia.
Around the world, consumption of eggs is also increasing. This increase is particularly notable in
developing countries where changing diets have people consuming a greater number of calories
from protein sources like poultry meat and eggs.
Page 4
Market Potential
India is a small player in the global egg powder industry, currently. But Indian egg processors can
scale up their operations significantly to catch the market share, since India is the 3rd largest egg
producer in the world.
~ Shree Shivkumar, MD & CEO, SKM Egg Products
Worlds 2nd largest poultry market with an annual growth of more than
14%
Poultry - the most organised sector in animal agriculture valued at about INR 350 billion
Low cost of egg production, high productivity, rise in egg consumption in the north owing to
growing per capita income of a young and increasingly urban population and emerging export
markets are certain key growth drivers of egg production in India.
~ D.S. Rawat, National Secretary General, ASSOCHAM
Egg production:
CAGR 5.5%
60,267
63,024
66,450
69,731
2009/10
2010/11
2011/12
2012/13
74,752
2013/14
Egg availability:
51
2009/10
53
2010/11
55
2011/12
58
2012/13
61
2013/14
Page 5
Market Potential
India lowest-cost egg producer
The shell eggs are cheapest in India, though the inputs cost is not the lowest. However, due to
improved efficiencies achieved by the farmers by producing more eggs per hen, India ranks one of
the lowest in terms of price of egg production. Growth of the industry can be appreciated by
following figures:
Parameter
1990
2015
10
24
12
22
1.5
2.90
260
310
20,000
2,00,000
Separate brooding
10%
80%
Feed automation
10%
80%
Nil
Discounted
No
Important
Export of poultry products reached US$11.7 crores during 2015-16, a growth of 18% over 201415 (US$10.6 crores). Export of dried egg products reached US$4.8 crores during 2015-16, a
growth of 8.7% over 2014-15 (US$4.7 crores).
Export of dried egg products constituted over 40% of the export of poultry products.
Japan is the largest buyer of egg powder followed by Germany and Indonesia.
Hong Kong announced the opening of its market for eggs in December 2015. The Hong Kong
market for poultry products is worth $2 billion. If Indian exporters capture 10% of this in 2016-17,
Indias export of poultry products can triple to US$300 million from $106 million in 2014-15.
Kuwait allowed import of Indian poultry products, in 2015, with strict conditions for exporters
from India to follow health procedures laid down by the World Organisation of Animal Health.
Saudi Arabia, Indias largest destination for poultry products, opened its market in 2014.
Russia, a huge market for Egg yoke, opened up for imports in 2014.
Page 6
Growth Drivers
1
Increasing health
consciousness
Possibility of rising
domestic demand
Page 7
Rising foreign
demand, limited
processing units
Gujarat - Competitive
Advantage
1 Gujarat one of the top five states to over-achieve production targets
Uttar Pradesh, Punjab, Tamil Nadu, Sikkim, Gujarat, Chhattisgarh, Maharashtra, Andhra
Pradesh (including Telangana), Karnataka, Chandigarh, Haryana, Madhya Pradesh, Meghalaya,
Dadra & Nagar Haveli and Puducherry have achieved their egg production target during 201314.
Gujarat achieved 105% of its targeted egg production, but owing to the difference in the
production and consumption, the option of processing is worth exploring.
129
105
Nagaland
Kerala
Jharkhand
Mizoram
Orrisa
Arunachal
West Bengal
Rajasthan
Bihar
Tripura
Manipur
Himachal Pradesh
Uttarakhand
Assam
J&K
Puducherry
D&N Haveli
Meghalaya
Madhya Pradesh
Haryana
Chandigarh
Karnataka
Andhra Pradesh
Maharashtra
Chhattisgarh
Gujarat
Sikkim
Tamil Nadu
Punjab
Uttar Pradesh
26
1,555
(2.1%)
All India
74,752
CAGR 5.4%
1,427
1,555
1,456
1,327
2010/11
2011/12
2012/13
2013/14
Fowl, which contributes over 97% of Indias egg production, has an average yield of 276 and
107 respectively for improved fowl and desi fowl respectively.
Gujarats fowl yield is more than average for both improved and desi fowl.
Desi fowl
Improved duck
Desi duck
Gujarat
305
132
All India
276
107
176
111
Page 8
Gujarat - Competitive
Advantage
4
Gujarat
Poultry sector needs technical, diploma and certificate holders to work as farm supervisors.
In India, the growth rate of the graduate manpower is not commensurate with growth rates of
either livestock sector or poultry sector.
With a minimum expected growth rate of 10% per annum in the sector, poultry sector alone
needs 1,140 veterinary graduates in 2020.
Gujarat boasts of its premium Agriculture University Banaskantha, which focuses on animal
husbandry through its two colleges (as mentioned below). Apart from these two, Gujarat has
other colleges offering full time and diploma courses in polytechnic and animal husbandry.
University
College
Gujarat Agriculture
University
Banaskantha
Availability
Feeds account for about 60%-70% of the total cost of producing eggs or meat from poultry.
Maize is an excellent feed ingredient for both egg and meat laying birds and is extensively used
as an energy source. It is high in energy but low in protein. Other energy sources include
sorghum and millet.
Gujarat grows maize, both in Kharif and Rabi season, and hence ensures undisrupted supply of
key feed ingredient.
All India
Yield (kg/hectare)
0.46
(4.9%)
0.69
(2.8%)
1501
9.43
24.35
2583
Other
advantages
Well developed transport infrastructure like roads, rail, port and air connectivity with main egg
producing areas in the state offers good opportunities for development of domestic as well as
export market.
Furthermore, Gujarat is near to Gulf and Far East Asian countries, which have good export
potential of the product.
There is a regional and seasonal imbalance of demand and production of eggs. Therefore it is
quite logical to process eggs in surplus areas and at the time of glut. Major egg producing areas
are near to major consuming centres in South Gujarat and Maharashtra.
Page 9
Project Information
Suggested plant location
The preferred location will be Central and South Gujarat as major poultry farming activities are
conducted in this area and also consuming industries market is available in these areas. Anand,
Bhavnagar, Ahmedabad, Surat and Navsari are the top egg producing districts in Gujarat, which is a
prime factor for choosing the project location (closeness of key raw material producers).
Mehsana
Kutch
Ahmedabad
District
(% of Gujarats egg produce)
Anand
Surat
Navsari
Bhavnagar
Mega Food Park (MFP)
Egg producing district
Egg production
Million nos.
Anand (48)
702.9
Bhavnagar (16)
239.4
Ahmedabad (7)
100.3
Surat (5)
73.4
Navsari (4)
52.2
Location
Surat
Kutch
Mehsana
All the top egg producing districts of Gujarat lie in close proximity to Surats MFP Gujarat Agro
Mega Food Park. In addition Gujarat Agro Mega Food Park offers a host of facilities for food
processing units. Hence it serves as a suitable location for the proposed unit.
Site image
Page 10
Project Information
Plant capacity and cost
Estimated project cost for manufacturing of egg powder having 240 MT per year plant capacity is
INR 1.5 1.8 crores.
Existing players - Project capacity and cost (at the time of set-up)
Player
Capacity
Capacity
Location
Year
established
Cost (INR
crores)
SKM Eggs
Tamil Nadu
1997
35.5
Venkateshwara
Hatcheries
Andhra
Pradesh
1995
37.0
Ovobel Foods
Karnataka
1993
17.5
Western Foods
Ambala
1992
7.1
Note: The egg powder processing units in India are very few, with not all units functioning presently. SKM Eggs is the
biggest player in the industry. (Other players, apart from the ones mentioned above are Indo-Dutch Proteins
Hyderabad, Foods & Inn Mumbai, and A.G. Foods Ludhiana).
Larger units go for bulk purchases, seasonal purchases at harvest and even go for import of
feed ingredients. The production costs can be managed.
Mechanisation in feed production, feeding the birds and egg handling is possible with larger
units.
Long distance supplies, exports and further processing can be planned with mass production.
Larger units can adopt better technology like least cost feed formulations and biosecurity
protocols to prevent diseases.
Page 11
Project Information
Connectivity and Infrastructure
Gujarat Agro MFP is strategically located at Mangrol, near Surat (Gujarat), providing excellent
connectivity for a global footprint.
Proposed
A multi-modal transportation hub is planned to
be developed at Surat railway station
Proposed
Vadodara-Mumbai Expressway to be
extended to a 6-lane Ahmedabad Vadodara
Mumbai expressway
INR 90,000 crore Mumbai-Surat tunnel road
Distance from major airports in the region Ahmedabad airport 250 kms
Vadodara Airport 140 kms
Surat Airport 85 kms
Mumbai Airport 310 kms
Proposed
A commercial airport at Mundra (Gujarat) by
Adani Ports and Special Economic Zone
A new international airport at Dholera is under
development which is expected to become
operational by 2018.
All plots in Gujarat Agro MFP are equipped with Power, Water, Sewerage and Effluent
Treatment Plant (ETP) connections.
Cold storage (Central and Primary Processing centre) facility for upto 5500 MT capacity is
available; Warehousing capacity available.
Solar power generation to take care of common maintenance of MFP.
Page 12
Project Information
Raw material requirement
The major raw material required is fresh eggs and the daily requirement is ~20,000. Prior
confirmed arrangements for this quantity are necessary.
The unit can source its egg requirements by entering into long-term contracts with poultries in
Anand, Ahmedabad and other egg producing regions. Or, it can also plan for a poultry farm to
internally source part of its daily egg requirement, thereby reducing its dependency.
Manpower requirement
An estimated 26 people would be required, including both supervisory staff as well as workers, to
manage the facility. The unit would have to recruit both regular employees as well as contracted
labor.
Particulars
Number
Supervisory staff
Production Manager
Machine Operators
Accountant
Workers
22
Skilled labor
Semi-skilled labor
10
Salesman
Clerk
Total
26
Machinery suppliers
Belgium
Haryana
Denmark
Agra
Page 13
Project Information
Possible collaboration
CFTRI (Central Food Technological Research Institute), Mysore, can offer the technical knowhow. CFTRI has developed over 300 proven technologies and 1000 patents which can transform
food processing industries.
Additionally, it has established a Technology incubator called "NutraPhyto Incubation Centre"
for the entrepreneurs to experiment with model industries and take them forward towards
successful commercial ventures.
Key considerations
Raw material
procurement
Procuring eggs in lakhs per day is not easy to replicate by any new entrant
in this field. In order to overcome this challenge, the unit would have to
establish its own farms to source their requirement in part/full. However,
despite sourcing its egg requirements from own farms, any adverse change
in the price of feed ingredients may affect its raw material cost.
Import
restrictions
High quality
standards
Ensuring the quality of feed and arranging periodic visit of veterinary doctors
to ensure the health of birds is essential. Since the end consumers are large
MNC food companies, stringent quality standards are to be met.
High entry
barrier
Since the competition is mainly with foreign firms, it can take years to
establish the label of a reliable and quality supplier in overseas markets.
Page 14
Project Financials
The total cost of the 240 TPA project would be around INR 1.5 1.8 crores.
Plant and machinery constitute the major cost component in setting up the plant, i.e. ~54%,
followed by land and building at ~37%.
In terms of working capital, the major constituent is eggs ~20,000 eggs per day.
Cost element
Qty
Cost/ unit
Land
1,000
250
2.7
1,000
500
5.4
500
5,000
27.2
300
5,000
16.3
Building
Contingencies
10%
4.4
81.3
Egg breaker
50,000
2.2
Centrifuge
3,00,000
6.5
Filter
1,00,000
2.2
Storage tank
75,000
3.3
Feed pump
3,00,000
6.5
Tubular Heater
8,00,000
8.7
Balance Tank
75,000
3.3
Feed Pump
3,50,000
7.6
4,00,000
8.7
7,50,000
8.2
3,50,000
3.8
Packaging unit
5,00,000
5.4
4.4
15%
10.6
Contingencies
Miscellaneous Fixed Assets
7.2
1,00,000
1.1
2,00,000
4.4
Weighing scale
25,000
0.3
Others
50,000
0.5
Contingencies
15%
0.9
Pre-Operative Expenses
7.5
Establishment
2,90,000
3.2
Professional Charges
1,00,000
1.1
Security Deposits
3,00,000
3.3
Total cost
Page 15
152.0
Project Financials
Implementation model
The project can be a joint venture between the owner company and the states agriculture
department, i.e. Gujarat Agro Industries Corporation Ltd.
The company may have to enter into a tie up with a foreign collaborator for technology/ for
sourcing plant and machinery. Technology tie up can also be made with CFTRI (Central Food
Technological Research Institute), Mysore, as mentioned previously.
Balaji Venkateshwara
Hatcheries
Ovobel Foods
Western Foods
Page 16
Joint venture between SKM Animal Feeds and Foods (India) and
Tamil Nadu Industrial Development Corporation
Technological assistance for the unit from Belovo Engineering SC,
Belgium
Ovotec International of Belgium holds 6.92% of the equity in the
company
Technological assistance for the unit from Food Engineering
Services, US
Food Processing Ministry to hold a 5% stake in the company's
equity
Technical and financial tie up with Ovobel SA of Belgium
Financial collaboration with Haryana Agro Industries Corporation
Limited (HAIC) and Haryana State Industrial Development
Corporation Limited (HSIDC)
Foreign Collaboration Agreement with Sanovo Engineering,
Denmark for technical know-how for the project
The proposed unit will have to register itself with Secretariat of Industrial Approvals (SIA), Ministry
of Industries and Government of India, by filing Industrial Entrepreneurs Memorandum (IEM), if it
has plant and machinery investment of more than INR 10 million.
The unit will require registration of its products with Foods and Drugs Administration (FDA) in
exporting countries, apart from registration with Indian and state food administrations. The most
critical aspect of this product will be its shelf life for export consumers and hence there will be
need for meeting FDA regulations in consuming countries and Codex standards followed by
them.
The unit will register itself with Ministry of Food Processing Industries (MoFPI) for availing
subsidy benefits. The unit will also register itself with RBI, DGFT and with APEDA as registered
manufacturer exporter to avail export incentives.
India imposes no restrictions for poultry and egg exports, which include egg powder, table eggs,
specific pathogen-free (SPF) eggs, and frozen chicken meat to regional markets such as Asia,
Africa, and the Middle East.
Page 17
Approvals / Incentives
Incentives by Government of Gujarat
Gujarat government announced its Agri Business Policy 2016 with emphasis on promoting
food processing industry by developing the entire value chain of exporting locally grown farm
produces.
Capital investment subsidy at 25% of eligible project cost subject to maximum INR50 million for
cold chain, food irradiation processing plants and packaging houses
Back ended interest subsidy at 7.5% on term loan with maximum amount of INR40 million for a
period of 5 years for setting up infrastructure project in Agro & Food Processing sector
(including packaging houses)
Freight Subsidy will be available to Micro, Small and Medium Enterprises (MSME)
MoFPI-approved project - Hence easier release of subsidy funds of MoFPI Schemes to Food
Processing Units.
Zero stamp duty on land lease (Exclusively to Gujarat Agro Infrastructure Mega Food Park)
Term loan at concessional rate of interest from NABARD under food processing fund exclusively
available to units in food parks
Lower import duty on imported machinery
Exemption from income tax for 5 years from commissioning date
Benefit under Government of Gujarat's Scheme of assistance to manufacturing sector"
Short start-up time ready availability of non-agriculture converted plots and sheds
Note: Please refer Gujarat Agro Industries Corporation website for comprehensive Agro-Business policy (2016-21).
Page 18
Page 19
Industries Commissionerate
www.ic.gujarat.gov.in
This project profile is based on preliminary study to facilitate prospective entrepreneurs to assess a prima facie scope.
It is, however, advisable to get a detailed feasibility study prepared before taking a final investment decision.