Introduction
Bakery Industry is one of the fastest growing segments of food processing industry in our country. Bread, an important bakery product of mass consumption, has become an important nutritional food item in cities and towns. It has also played a vital role in popularizing wheat in traditionally non-wheat consuming areas of the country.
Product
Bread is a fast and convenient food based on wheat. There are many varieties of bread depending upon the local demand like whole flour bread, brown bread, bread fortified with vitamins & minerals, milk bread and bread for diabetic patients. It can be produced in different sizes and shapes.
Market
Bread is mainly consumed in metres & mini-metros, major towns and areas of industrial townships. Due to fast life and increase in standard of living the demand for breads is growing very fast, particularly with more and more women going out for work. Our per capita consumption of Bakery products is minimum in the world i.e. 1.27 kg against 50-70 kg in advanced countries. This leaves for substantial scope for bakery industry •
Standards and Specifications
Suggested Capacity
The minimum economic capacity of a unit manufacturing breads is 36 lakh loaves of 400 gms each per annum based on a single shift operation of 300 days working schedule in a year.
Land and Building
The unit may require about 1,000 sq.m. land with a covered area of about 600 sq.m. for setting up this project. Although in the cost of the project below it is proposed to purchase land and construct building, the unit should preferably acquire the land and building on rental basis.
Manufacturing Process
In Bangladesh
1. Flour 100.00kg.
2. Water 64.00kg.
3. Sugar 4.00 kg.
4. Salt 2.00kg.
5. Shortening or ghee 4.00 kg.
6. Compressed yeast 1.20kg.
7. Skimmed milk powder 4.00 kg.
Mineral yeast food or dough
conditioner 0.35 kg.
A loaf of 400 gms requires about 270-275 gms flour and corresponding amounts of other ingredients. First yeast suspension in a portion of water and sugar is made. Sugar, salt and yeast food are mixed with water. Flour mixed with milk powder is mixed into it. After short mixing yeast suspension is added. Shortening is added any time after the flour has been wetted and the dough has been formed. Mixing is continued until the mass becomes smooth and elastic and does not stick to the bowl. Mixing takes about 20-30 minutes, overmixing should be avoided.
The dough is then allowed to ferment, at about 27°C and 78 per cent relative humidity, to the desired extent. The dough is divided into uniform pieces of the desired weight (450 gms}. The dough pieces are rounded using a machine (rounder). The rounded dough is allowed to rest before being formed for panning. This time is called intermediate proofing (8-15 minutes), during this time dough recovers from being divided and rounded. The dough pieces are moulded (or shaped) so that they may form loaf of the desired shape.
The pieces are put in greased pans. The pans are put in proof box at about 37°C and 88 percent relative humidity to get the right extent of final proof. This usually takes about 60-70 minutes. The pans are next placed in an oven and heated to 205-230UC. The baking time depends on the size and shape of the loaf and its sugar content. When the crust of the bread assumes a brown colour the pan is taken out from the oven. The baked loaves are brushed with butter to give glaze and prevent cracking of the crust. The loaves are allowed to cool and sliced on a slicing machine and wrapped in a waxed printed paper
which is then heat sealed.
Raw Materials
The annual requirement of main raw materials for the manufacture of 36 lakh loaves of bread (400 gm each) per annum at 100% capacity utilisation is estimated as follows:
1. Wheat flour 695.00 M.T.
2. Sugar 28.00 M.T.
3. Salt 14.00 M.T.
4. Vegetable oil 28.00 M.T.
5. Yeast 7.56 M.T.
Mineral yeast dough conditioner, vitamins,
other chemicals, waxed paper, etc as reqd
Utilities
The unit may require a total connected load of about 30 KVA and a maximum demand load of about 25 KVA. Its annual requirement of water is estimated at about 12,000 KL.
Plant and Machinery
The main items of equipment and machinery
required for setting up this project are as follows:
1.Auto Flour sifters
2.Dough kneaders, capacity 100 kg
3.Hand dividers, capacity 400 gm (500-800 loaves per hour)
4.Moulding machine
5.Electric ovens, cap. 1 ton/day
6.Bread slicing cum sealing machines, cap. 400-500 loaves/hr.
7.Platform type weighing scale, 0-100 kg cap.
8.Counter scales, cap. 0-2 kg.
9.Other miscellaneous equipment e.g. vessels, trays, pans, work tables, cooling racks, laboratory equipment, etc
Personnel
The unit may provide employment to about 33 persons including factory workers and staff for factory supervision, administration and sales, and watch and ward, etc.
Estimated Cost of the Project
The cost of a 24657.53 loaves per annum capacity bread making project is estimated at
Rs. as follows:
1. Land and site development $ 6849.30
2. Buildings $ 32876.71
3. Plant and machinery $47945.20
4. Technical know-how and engg. fees $4109.58
5. Misc. fixed assets $6849.30
Preliminary and preoperative
expenses $4109.58
7. Margin money for working capaital $10958.90
8. Contingencies $5479.45
TOTAL $119178.08
Suggested Means of Financing
1. Long term loans from financial
institutions $79452.49
2. State cash subsidy $15068.49
3. Promoters capital $ 24657.53
TOTAL $119178.08
Subsidy is taken as 15% of the Fixed Capital Investment, however it varies from state to state, ranging from 10% to 25% depending upon the category of identified backward area.
