Detailed Project Report

on
Establishment of a Bakery Unit
by
PACS
 Contents

Abbreviations ............................................................................................................................................

Introduction ...............................................................................................................................................

Project Profile ...........................................................................................................................................

The Proposal .............................................................................................................................................

Business Model .........................................................................................................................................

Project Details ...........................................................................................................................................

Assumptions..............................................................................................................................................

Implementation schedule ..........................................................................................................................

Statutory & Government Approvals .........................................................................................................

Manufacturing Process..............................................................................................................................

Process flow Chart ....................................................................................................................................

Financial Statements .................................................................................................................................

Project Financing ......................................................................................................................................

Business Projections .................................................................................................................................

Cash Flow .................................................................................................................................................

Feasibility Assessment ..............................................................................................................................

SWOT Analysis ........................................................................................................................................

Risk Assessment & Management .............................................................................................................

Training & Development ..........................................................................................................................

Monitoring and Control ............................................................................................................................

Conclusion ................................................................................................................................................

Annexure ...................................................................................................................................................

Financial Analysis & Ratios

e
Abbreviations

AC Air Conditioner
CAGR Compound Annual Growth Rate
CU Capacity Utilization
DCCB District Central Cooperative Bank
DSCR Debt-Service Coverage Ratio

FSSAI Food Safety and Standards Authority of India

GoI Government of India
GST Goods and Service Tax
HTCL Haryana Tourism Corporation Limited
IBRTC International Bakery Research & Training Centre
IRR Internal Rate of Return
ISO International Organization for Standardization
MoFPI Ministry of Food Processing Industries
NCDC National cooperative Development Corporation
NCR National Capital Region
NIFTEM National Institute of Food Technology Entrepreneurship and Management
PACS Primary Agriculture Cooperative Societies
RO Reverse Osmosis
SKU Stock Keeping Unit

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Introduction

Bakery products, due to high nutrient value and affordability, are an item of huge
consumption. Due to the rapid population rise, the rising foreign influence, the emergence
of a female working population and the fluctuating eating habits of people, they have
gained popularity among people, contributing significantly to the growth trajectory of the
bakery industry. A number of healthy products have been launched in the bakery segment
and are gaining popularity at a high rate.

The Indian bakery industry is one of the biggest sections in the country’s
processed food industry. Bakery products, which include bread and biscuits, form the
major baked foods accounting for over 82 per cent of the total bakery products produced
in the country. It enjoys a comparative advantage in manufacturing, with an abundant
supply of primary ingredients required by the industry, and is the third-largest biscuit
manufacturing country (after the United States and China). The bakery segment in India
can be classified into the three broad segments of bread, biscuits and cakes. India’s
organised bakery sector produces about 1.3 millions tonne of bakery products out of 3
million tonnes while the balance is produced by unorganised, small-scale local
manufacturers.

Despite the fact that there are many automatic and semi-automatic bread and
biscuit manufacturing units in India, many people still prefer fresh bread and other
products from the local bakery. The popular biscuit variants in India are glucose biscuits,
Marie, cream biscuits, crackers, digestive biscuits, cookies and milk biscuits.

As far as the Indian biscuit market is concerned, the shares of the branded and
organised sector and the unbranded and unorganised sectors are 60 per cent and 40 per
cent respectively. Indian bakery products, especially biscuits, are in great demand in
developing countries.

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 Baked goods are expected to grow by constant value at a compound annual growth
rate (CAGR) of two per cent over the forecast period. The bakery industry in India has
witnessed an annual growth rate of more than 15 per cent during the past years. As the
business and the industry thrives, the challenges accruing out of it are also growing
expediently.

Like many industries, retail bakeries see rising costs in fuel, healthcare and other
expenditures cut into their bottom lines and increase the costs of doing business. Driven
by the evolving perception of bakery products in India and the changing consumer
preferences, the Indian bakery industry would touch levels of Rs. 500 billion in the next
five years.

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Project Profile

Vision: To establish a bakery unit which can enhance the PACS income by 40%
after value addition in wheat.

Mission: To mobilize the idle resources of PACS and to involve women members in
productive economic activities.

Objectives: The project is to be considered to achieve the following objectives:

 To generate employment in PACS by production activity

 Provide financial benefits to member farmers of the PACS
 Develop an attitude of business in PACS.
 Women empowerment by generating employment for women
 To utilise idle land resources of the PACS and make them business
generation entity.

The Proposal

It is proposed here to manufacture khari (bakery puffed biscuits), rusk (toast)

and Aata biscuits with an installed capacity of total 500 kg/day, in which, 20% khari,
40% rusk and 40% assorted bakery Atta biscuits.

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Business Model

Key Partners Key Activities Value Customer Customer

Proposition Relationships Segments
 Members of  Production
the PACS of  Inventory  Provide  Long term  High
Haryana- for Management Customers relationship income
providing  Sales and healthy and to sustain in Group of
raw material Marketing digestive the market Delhi –
 NCDC atta biscuits  Maintain NCR and
 DCCB  Crispy and hygienic Chandigarh
 Machinery, nutritional production  Villagers of
repairs and ingredient the PACS
ingredient Key Resources  Availability Channels  Tourists
suppliers of product  Students
 Fund provided on demand  Shopping
by NCDC and malls, Big
DCCB bazaars etc.
 Training to  Local
personnel Retailer
provided by Shops
NIFTEM  HTCL shops,
hotels and
resorts
Cost Structure Revenue Streams
 Fixed Cost for Plant and Machinery  Value added product generate
 Attractive Packaging revenue
 Distribution and Sales  Products are produced as per market
 Cost for product replacement in case of segments- High, Middle, Low level
packets are braked. income group and occasional
customers.
 Prices are little lower than
competitors.

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Project Details

Assumptions

1. The Project Profile has been prepared on the basis of Single Shift of 8 hours

a day and 300 working days in a year at 80% efficiency.

2. It is presumed that in the first year, the capacity utilization (CU) will be

70% followed by 75%, 80%, 85% and 90% onwards in the subsequent

years.

3. Raw material consumption is 80% for first year then 90% and after that

100% in subsequent years.

4. For Calculation purpose CU is adjusted in hike of raw material cost too.

5. The selling price of the products is kept fixed for calculation purpose.

6. The rate of salaries and wages for skilled workers and others are on the

basis of the minimum rates in the State of Haryana.

7. The PACS have Land and Building and have sufficient amount of primary

raw material i.e. Wheat.

8. The flour machine and RO water plant is already installed in the PACS.

9. The payback period may be 5-years after the initial gestation period.

10. The gestation period in implementation of the project may be to the tune of

6 to 9 months which includes making all arrangements, completion of all

formalities, market surveys and tie-ups etc.

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Implementation schedule

The implementation of the project includes various jobs/exercises such as

procurement of technical know-how, market surveys and tie-ups, preparation of
project report, selection of site, registration, financing of project, procurement of
machinery and raw materials etc., recruitment of staff, erection/ commissioning of
machines, trial production and commercial production etc. In order to efficiently and
successfully implement the project in the shortest period, simultaneous exercises are
carried out. Project implementation will take a period of 8 months from the date of
approval of the scheme. Breakup of activities with relative time for each activity is
shown below:-
Activity Period (In Months)
Scheme Preparation and approval 0-1
SSI Provisional Registration 1-2
Sanction of loan 2-5
Clearance from State Pollution Control Board 3-4
Placement of order for machinery and delivery 4-5
Installation of machines 6-7
Power connection 6-7
Trial run 7-8
Commencement of Production 9 onwards

Statutory & Government Approvals

It is mandatory for the bakeries to acquire licenses from FSSAI, GST, Local
Municipality, Police Eating House, Fire Department and State Pollution Control
Board. Out of these, the FSSAI, GST and local Municipal Health permits are of
priority before starting the unit.

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Manufacturing Process

KHARI

Weigh all ingredients as per formula. Make soft dough in a dough kneader still
it becomes smooth and glossy. Roll the dough into sheets of required dimensions and
thickness, apply flour dusting as required. Apply ghee on layers and fold it still of
required size. Repeat the process still layers are formed. Refrigerate it for 15 minutes.
Remove from refrigerator, cut into pieces of required size and dimensions. Place all
the pieces in baking oven and bake at 200 °C 20-25 minutes. After that lower the
temperature and bake at 180° C for another 15-20 minutes. Cool the pieces, pack as
per weight decided of SKU into poly bags and then put into corrugated carton for
dispatch.

RUSK (TOAST)
Pre-mixing of ingredients as per formulation to form dough of proper
consistency. The dough is then divided and pieces put into moulds for proofing,
followed by first baking, cooling, second baking and again cooling and packing. First
baking to do at 200° C and second baking at 180° C.

ATTA BUISCUIT

Weigh all ingredients and make soft dough with addition of sugar, ghee and
water as per formula. Beat the dough still it becomes soft and fluffy. Add yoghurt and
best again. Keep it in such condition for 10-15 min. Press the dough into flatten
rounds and make incision with knife at centre. Sprinkle cardamom, coconut or sesame
seeds just for decoration. Bake the rounds at 200° C for 20-25 minutes.

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Process flow Chart

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Financial Statements

Project Financing

1. Cost of the Project

Sl. No. Heads Amount
1 Land Own
2 Building Own
3 Plant & Machinery* 40,00,000
4 Contingency 8,00,000
5 Other capital Investment 12,00,000
Total 60,00,000

* Machinery Particulars are as under:

Sl. Equipment Quantity Rate Total Amount
No. (Rs./Unit) (Rs.)
1 Baking Ovens 4 1,25,000 5,00,000
2 Dough Mixers 2 1,00,000 2,00,000
3 Cutter, Divider, Sheeter 3 3,00,000 9,00,000
4 Rusk Making Machine 1 1,00,000 1,00,000
5 Flour Sifter, Sugar Pulveriser, 3 80,000 2,40,000
Biscuit Grinder
6 Trays, Scoops, SS Bins, 1 60,000 60,000
Pellets,
7 Packing Equipment 2 3,00,000 6,00,000
8 Miscellaneous Equips: Small - - 15,00,000
RO Plant, small flour mill
Total 40,00,000
Note: The rate may vary as per market

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 2. Working Capital Requirement

(i) Raw Material

Ingredients Qty./yr. MT Rate/MT Amount
Maida/Atta 120 Own Own
Ghee 55 1,00,000 55,00,000
Edible oil 7 1,20,000 8,40,000
Sugar 4 30,000 1,20,000
Salt 2 10,000 20,000
Other Ingredient 6 1,00,000 6,00,000
Packaging Material - - 2,40,000
Total 73,20,000

(ii) Manpower Requirement

Particular Number of Salary/ Wages Amount Total

Employees Per month per Amount
month Per year
Technical Staff 3 12,000 36,000 4,32,000
Admn. Staff 3 12,000 36,000 4,32,000

Marketing Staff 6 10,000 60,000 7,20,000

Labour 10 8,000 80,000 9,60,000
Total 2,12,000 25,44,000
Note: The rates are taken in round figure for the ease of calculation.

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Business Projections

Installed plant capacity = 500 Kg/day

Efficiency @ 80% = 400 Kg/day

Production for 300 working days = 1, 20,000 kg

Sales

Khari @ 20%@Rs. 100/ Kg = Rs. 24,00,000/-

Rusk @ 40% @ Rs. 120/Kg = Rs. 57,60,000/-

Atta Biscuits @ 40% @ Rs. 150/Kg = Rs. 72,00,000/-

Total sales = Rs. 1,53,60,000/-

Since capacity utilization (CU) is taken different for different years therefore,
projected sales will be:

Year 1 2 3 4 5 6
CU @ 70% 75% 80% 85% 90% 90%

Sales 10752000 11520000 12288000 13056000 13824000 13824000

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 Cash Flow

Project Cost Rs 60.000 lakhs

Promoter's Capital Rs. 30.000 lakhs
Loan from NCDC @11.10% Rs 20.000 lakhs
Subsidy from MoFPI @ 25% of the plant and
machinery Rs 10.000 lakhs
Total Assistance Rs 30.000 lakhs
Year 1 Year 2 Year 3 Year 4 Year 5 Year 6
CU 70% 75% 80% 85% 90% 90%
Sales 10752000 11520000 12288000 13056000 13824000 13824000
Expenses
raw material 5856000 6588000 7320000 7320000 7320000 7320000
salary 2544000 2544000 2544000 2544000 2544000 2544000
other expenses @ 10% of sales
1075200 1152000 1228800 1305600 1382400 1382400
(electricity, insurance and others)
depreciation @ 10% 400000 400000 400000 400000 400000 400000
Loan due 2000000 1666666 1333333 1000000 666667 333333
Interest on Term loan 222000 185000 148000 111000 74000 37000
Loan instalments 333333 333333 333333 333333 333333 333333
Total Expences 10430533 11202333 11974133 12013933 12053733 12016733
Gross Profit 321467 317667 313867 1042067 1770267 1807267
tax @ 10% 32147 31767 31387 104207 177027 180727
Net Profit 289320 285900 282480 937860 1593240 1626540

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Feasibility Assessment

Technical

• Raw Material for this business is wheat, which is readily available in PACS.
• The machines and equipments are not very costly so it can be easily affordable.
• The machines and equipments become semi/fully automatic so operation is an
easier task.
• The manufacturers of different machines also provide the facility of installation
and repair service for free.
• PACS have large storage area and big godowns for storage of raw materials
and finished bakery products.

Socio – Economic

• Bakery unit can generate extra income to PACS members and upgrade their
socio-economic status.
• Youth of PACS villages can be employed here and it will create the
employment opportunity to young persons.
• People can be trained as a salesman, machine operator or manager.
• The entrepreneurial zeal and managerial skills of village women will be used
which otherwise wasted.
• The entrepreneurial and managerial skills will be developed in PACS members.
• Idle resources can be turned into profitable one.

Market
• There is always a place of Rusk, Khari & Biscuits in all retail shop. So these
products have good market potential always.
• Haryana is a developed state of India. The people of Haryana love the deshi
products. Bakery being pure deshi product has market throughout the Haryana.
• Mall culture is spread all over Haryana. In the big cities the bakery products
can be placed in malls and organized retail shops.

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 • Big Bazars and other big retail stores can be approached to sell these products.
• Proximity to Delhi – NCR and Chandigarh is on advantage to PACS of
Haryana. The people of these cities are health conscious and they are ready for
pay for good bakery products.
• PACS itself has a market for the products. Every PACS almost contain 8-10
villages so the PACS can put the products in shops of its villages too.
• Khari and Rusk are treated as a product of foreign touch. The population of
Chandigarh and Delhi NCR, who has to use these products, may create a good
potential.

Financial
Bakery products are value added products. These have higher value (price)
than that of raw materials. The financial aspects are elaborated in Annexures –
attached.

This business have IRR 22% and DSCR = 2.95.

So, this project is financially viable.

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 SWOT Analysis

Strengths

• The PACS of Haryana have ample amount of wheat throughout the year.
• PACS have enough area of operation and ample storage space is available.
• The labour and raw material is easily available for PACS.
• Since Haryana is located near Delhi and Chandigarh so healthy bakery
products are in high demand especially atta biscuit which is easily digestible.
• Low Capital Requirements for this business.

Weakness
• Bakery products are perishable items.
• Sensitive to commodity price fluctuations.
• Scarcity of Skilled Human Resource
• Lack of experienced staff
Opportunities

• The increasing township and mall culture have created market potential for
bakery products.
• Haryana have different stores located at bus stops (especially for AC busses)
where these products can be sold to passengers.
• The nutritional value and attractive packaging of the products can also create
an opportunity.
• The High income group having lavish living standard have passion to use
bakery products instead of packaged products available in market.
• The fooding habit of villagers are also been changed and they are also a good
consumer of bakery products.

Threats

• Tough competition with other big brands

• Price wars among competitors
• Product Substitution
• Technology Up gradation

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Risk Assessment & Management

 Bakery products are perishable in nature; therefore Material management is

required for avoidance of the wastage.
 There is a tough competition in the market so product mix approach is
applicable to this industry. PACS should produce quality products to sustain in
the market.
 Proper study of consumer behaviour should be conducted and accordingly
the products can be produced.
 The shelf value of these products is very less therefore demand for these
products can be generated through proper advertisement and promotion.
 The financing of these types of industries depends on the market factors,
though demand for these products are high but financial institution does not
easily finance these products. The financing agency must be ensured through a
proper business plan.
 The packaging of product should be attractive. It creates additional demand
for products.
 Proper certification of plant is required from the authorities. Food safety
standards should be followed.
 PACS may approach for ISO certification for ensuring the quality standards of
products.
 Internal Checklist should be in plant / unit and it must be supervised
periodically.
 Waste disposal - The main waste in the bakery unit is of unused dough,
fondant, burnt product. These need to be removed in a timely manner. Dough
and fondant may lead to fungal growth in the manufacturing premises,
whereas burnt product will contaminate the finished product. Waste should be
disposed immediately in covered bins to avoid contamination.

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Training & Development

National Institute of Food Technology Entrepreneurship and Management

(NIFTEM) located at Sonepat district of Haryana, is an autonomous institution under

Ministry of food Processing Industries, Government of India. This institute offers

short term training programmes and workshops on bakery. The PACS may approach

to this institute and provide training to its employees on bakery processing at nominal

fees.

International Bakery Research & Training Centre (IBRTC) is opened in the

NIFTEM to undertake the work of training, teaching, research and technology transfer

in the area of: Science of Baking, Bakery Machinery, Hygiene and Sanitation, Bakery

Management, Production Method, New Product Development, Quality Control and

Specification, Packaging and Presentation of Products.

Apart from this there are several private institutes also which provide training

and skill development in bakery and food processing. These institutes are located in

Ambala, Karnal, Chandigarh, Hisar.

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Monitoring and Control

 Making bakery products experienced skilled worker or qualified baker is

needed to check raw material quality, dough consistency, proofing, first and

second baking, etc.

 It is necessary to develop right taste, texture and consistency of the products.

 It is necessary to avoid waste during flour shifting, dough making,

rolling/sheeting, slicing/cutting etc. Because wastage increase the cost as well

disposal of it also cost.

 Proper selection of bakery equipment is very much essential.

 Water must be of good quality, preferably RO water if total dissolved solids are

high in source water.

 Disposal of solid and liquid waste are to work out properly as per pollution

laws.

 Good level of competence is needed to understand quality of raw materials,

formulation of products, functions of additives used in formulation, control of

process and machinery to produce end product of desired quality, taste and

texture, type of packing material to be used, market trends and penetration, etc.

 Technical knowledge and skills are needed for problem solving, and to ensure

good hygiene and safety in the workplace.

 Proper pest control is required for preventing insects and rodents.

 The guidelines listed in FSSAI manual should be followed strictly.

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Conclusion

Bakery products still remain the cheapest of the processed ready to eat products
in the country. The demand for bakery products will continue to increase in future.

Bakery products are becoming quite popular in rural areas as well. Nearly 55%
of the biscuits are consumed by rural sector. The higher consumption of biscuits in
rural area could be attributed to its position as a snack, longer shelf life and better taste
which is liked by different cross sections of population. There is no marketing
problem as every shop is a market for bakery products.

Bakery business is like venturing into spreading your labour of love. A love
that is devoured by millions for its freshness & taste and the warmth that it leaves
behind.

“If baking is any labour at all, it’s a labour of love.”

– Regina Brett

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 Annexure
Financial Analysis & Ratios

Calculation of IRR
Year 1 2 3 4 5 6 Total
Surplus 289320 285900 282480 937860 1593240 1626540 5015340
Dis. @ 20% 0.833 0.694 0.579 0.482 0.402 0.334
NPV @ 20% 241003.56 198414.6 163555.92 452048.52 640482.48 543264.36 2238769.44
Dis. @25% 0.8 0.64 0.512 0.4096 0.3277 0.2621
NPV @ 25% 231456 182976 144629.76 384147.456 522104.748 426316.134 1891630.098
Dis. @30% 0.769 0.591 0.455 0.35 0.269 0.207
NPV @ 30% 222487.08 168966.9 128528.4 328251 428581.56 336693.78 1613508.72
Dis. @ 40 % 0.714 0.51 0.34 0.26 0.186 0.132
NPV @40% 206574.48 145809 96043.2 243843.6 296342.64 214703.28 1203316.2

IRR = 22%

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 Calculation of DSCR
Project Cost Rs 60.000 lakhs
Promoter's Capital Rs. 30.000 lakhs
Loan from NCDC @11.10% Rs 20.000 lakhs
Subsidy from MoFPI @ 25% of the plant and machinery Rs 10.000 lakhs
Total Assistance Rs 30.000 lakhs
Year 1 Year 2 Year 3 Year 4 Year 5 Year 6
CU 70% 75% 80% 85% 90% 90%
Sales 10752000 11520000 12288000 13056000 13824000 13824000
Expenses
raw material 5856000 6588000 7320000 7320000 7320000 7320000
salary 2544000 2544000 2544000 2544000 2544000 2544000
other expenses @ 10% of sales (electricity, insurance and others) 1075200 1152000 1228800 1305600 1382400 1382400
depreciation @ 10% 400000 400000 400000 400000 400000 400000
Loan due 2000000 1666666 1333333 1000000 666667 333333
Interest on Term loan 222000 185000 148000 111000 74000 37000
Loan instalments 333333 333333 333333 333333 333333 333333
Total Expences 10430533 11202333 11974133 12013933 12053733 12016733
Gross Profit 321467 317667 313867 1042067 1770267 1807267
tax @ 10% 32147 31767 31387 104207 177027 180727
Net Profit 289320 285900 282480 937860 1593240 1626540
ICR = Profit before depreciation interest and tax/interest 3.249851351 3.879283033 4.823427132 12.99159459 29.32791727 59.65592552
Profit After Tax+Depreciation+interest 911320 870900 830480 1448860 2067240 2063540
Interest +installment of term loan 555333 518333 481333 444333 407333 370333
DSCR= (Profit After Tax+Depreciation+interest)/(Interest
+installment of term loan) 1.641033938 1.680194811 1.725375904 3.260753309 5.075061721 5.572121584
Average DSCR = 8192340/2776998 = 2.95

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