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Brief Project Report 
Food Processing Series 
Dal Mill – Pulses Processing Unit 
Food prices are going very high and with increasing population this will remain high. This is brief project report for Dal Mill or Pulses Processing Unit. This is bankable project based on the emerging market. Depending upon country and place we can develop detail project report. The currency is Indian Rupee as well as US Dollar. 
Dr. Zia Ahmed 
Venture Art http://www.ventureart.biz/ 
zia@milestonevision.com 
+96565510448
Dal Mill – Pulses Processing Unit 
zZia@ 
V e n t u r e A r t 
Page 1 
Contents 
1. Food in Global Environment ................................................................................................................. 2 
• Global Stock Market Performance in 2010 ....................................................................................... 2 
• FAO food price indices ...................................................................................................................... 3 
• FOOD PRICES AND INFLATION .......................................................................................................... 3 
2. 'INDIA REQUIRES IMPORTING 3.4 MN TON PULSES IN ......................................................................... 4 
3. Malawi Farmers Scramble to Produce Pulses for India ........................................................................ 6 
4. Market Potential ................................................................................................................................... 7 
CONSUMER TRENDS ............................................................................................................................. 8 
LENTIL SECTOR .................................................................................................................................... 10 
CHICKPEA SECTOR ............................................................................................................................... 10 
5. PRODUCTION PROCESS ....................................................................................................................... 13 
6. TECHNICAL ASPECTS: .......................................................................................................................... 17 
7. FINANCIAL FEASIBILITY........................................................................................................................ 18
Dal Mill – Pulses Processing Unit 
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1. Food in Global Environment 
There are riots in many African Countries recently. Especially the riots have significance looking at the strategic importance of these countries to the west, Algeria, Tunisia, Morocco, and Egypt. These are the countries who are staunch supporters of the western powers 
If we look at the other side of the story why this all is happening. Even though economy is slow, there is enough food for everyone and prices are going UP. 
According to World Bank “The world economy is moving from a post-crisis bounce-back phase of the recovery to slower but still solid growth this year and next, with developing countries contributing almost half of global growth, says the World Bank’s latest Global Economic Prospects 2011.” 
The World Bank estimates that global GDP, which expanded by 3.9% in 2010, will slow to 3.3% in 2011, before it reaches 3.6% in 2012. Developing countries are expected to grow 7% in 2010, 6% in 2011 and 6.1% in 2012. They will continue to outstrip growth in high-income countries, which is projected at 2.8% in 2010, 2.4% in 2011 and 2.7% in 2012. 
• Global Stock Market Performance in 2010 
The following are some of the key points from a review of the 2010 performance of equity markets around the world: 
Stock markets can rise despite low or poor economic growth. The U.S. market was a perfect example of this scenario. While the U.S. economy continued to struggle last year with high unemployment rates, slowing demand, more bank failures and other negative events, corporate profits rose and equities took off ending the year with double-digit returns for the S&P 500. 
It was a very good year 2010 for many markets with amazing returns. India gave a 16% odd returns in 2010. The MSCI Emerging Markets Index (+16.4%) had done enough earlier in the year to outperform the MSCI World Index (+9.6%) by a wide margin for the year as a whole.
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• FAO food price indices 
The FAO Food Price Index in December slightly surpassed its peak of early summer 2008. The indices of sugar and oils and fats increased the most. In Asia, domestic prices of rice further strengthened in December and are at record levels in several countries. Prices of wheat and wheat flour in importing countries of Asia, Latin America and Africa, remained at high levels. 
• FOOD PRICES AND INFLATION 
If all the food in the world were shared out evenly, there would be enough to go around. That has been true for centuries now - if food was scarce, the problem was that it wasn't in the right place. The poor, urban multitudes in these countries (including China and India) spend up to half of their entire income on food, compared with only about 10 per cent in rich countries. When food prices soar, these people quickly find that they simply lack the money to go on feeding themselves and their children properly - and food prices now are at an all-time high. Unfortunately we live in world which does not understand logic and rationales. Only vested interest of Global Powers and Power Brokers and lobbies prevail. No one care how many will die of hunger and poverty.
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2. 'INDIA REQUIRES IMPORTING 3.4 MN TON PULSES IN 
India is the world's largest producer of pulses; but last year the country had to import 1.8 million tons of pulses to meet the growing domestic consumption. During the year 2006-07, India imported 1.8 million tons of various pulses, especially from countries like China, Canada and Australia. For instance, the Kolkata Dock System alone handled over a million tons of pulses imported from these countries. This was a nearly 90 per cent jump over the previous year and over 50 per cent of the country's total import of pulses. Despite being the largest producer of the largest varieties of pulses, the demand for consumption of pulses is just growing. India harvests between 12- 15 million tons of pulses each year but the yield has been pretty much static for the last 30 years averaging between 500-600 lb./ acre. While the green revolution produced a three-fold increase in wheat yields in India, pulses have not received the same level of attention in research. Pulses are grown on dry land during the winter season under less than ideal conditions. All of the pulses in India are harvested by hand but losses due to insects and storage problems can be significant. What makes India such an interesting market is that India is best described as a very price sensitive market? India is the biggest importer and consumer of pulses and India government has initiated various programs to ensure that pulses output by the nation remain robust. In the budget for 2011-12, India Finance Minister had announced a number of measures to strengthen the agricultural sector particularly in the areas of pulses, vegetables and oil palm. The country is an importer of pulses and imported 2.79 tons in 2009-10. 
Compared to 3.5 million tons of pulses imports by India in 2009-10 crop year, the country is expected to import 3 million tons for the current crop year spanning July-June. This is attributed to the high output of pulses by India, said a report in Business Standard citing traders and importers. India is likely to come up with impressive pulses output figures for 2010-11 season at 17.29 million tons, up by 18%. This is when compared to 14.66 million tons in 2009-10, according to a report in The Times of India. Area under pulses climbed by 12% to 23.05 million hectares in 2010-11. Of the estimated production tur is expected at 3.2 million tons, urad at 1.8 million tons and moong at 1.4 million tons. Government -run trading firms like MMTC would import 0.6 mn tons to .7 mn tons of pulses in 2010-11 up from 0.3mn-- 0.4 mn tons Y-O-Y, said Business Standard quoting H S Mann, chief managing director of MMTC Ltd. The
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targeted import figures by MMTC forms almost one-fifth of India’s pulses imports. The rest is imported by private firms. Among imports, yellow pea accounts for half of the total figures and is sourced from Canada, Ukraine and the US. India’s State Trading Corporation, another government trading house, had invited bids for the import of 31,000 tons of pulses for sale in the domestic market, recently. Bidders were supposed to procure 25,000 tonnes of yellow peas and 2,000 tonnes each of desi chick peas (chana), black matpe (urad) and leamon tur (arhar) from Canada, Australia and Myanmar, said a report in The Hindu Business Line. 
Notwithstanding expected bumper production of pulses during 2011-12, India would require to import 3.40 million ton of the vital food grain item to match the enhanced demand. The production of pulses during 2011-12 as per the Second Advance Estimates released by Union Agriculture minister is estimated to be 16.51 million ton. Planning Commission has estimated that the demand for pulses in the country during the period is 19.11 million ton, Thomas said adding the gap of 3.4 million ton have to be met by imports. Given that the supply and demand mismatch with regard to pulses is likely to exist in the near future, the government has permitted imports of pulses at zero duty up to March 31, 2012 to increase domestic availability and stabilize the prices of pulses, he added.
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3. Malawi Farmers Scramble to Produce Pulses for India 
Farmers in the landlocked southeast African country of Malawi are shifting from their traditional crops to grow pulses to meet the increasing demand in the international market, especially from India. 
The government in Malawi is encouraging farmers to grow more pulses to meet the demand in India, said Malawi businessman John Jimu Banda, who was here to attend the CII-EXIM Bank India-Africa Business Conclave March 27-29. Apart from attending the meet, Banda intended to buy some equipment, but he is going back to his country with an export order for the supply of pigeon pea or tuar dal. "There is a big demand for pigeon pea in India. I have got orders for supplying 1,000 tonnes of pigeon pea from two parties," he said. Malawi is already exporting about 50,000 tonnes of pulses to India, but there is "good scope for increasing the quantity", according to Banda. 
"The government is putting emphasis on growing beans for the Indian market. It is telling farmers that there is a good market for the pulses abroad." The Malawi government has sought assistance from India for producing new varieties, and for research and training in growing early-maturing and high-yielding varieties of pulses. The main crop in Malawi, formerly known as Nyasaland, is maize, tea and tobacco, but farmers also grew beans of various kinds. Tobacco, tea and sugarcane provided 70 percent of Malawi's export earnings till the international prices of tobacco crashed. Since then the government has been encouraging growers to shift to other crops such as pulses, paprika, macadamia nuts and fruits. 
Farmers in Malawi grow soya, pigeon pea, chick pea or garbanzo or chole, green gram (moong), white cow peas (lobiya) and red beans or kidney beans (rajma). The red beans are of two varieties - a small deep-red bean and a larger bean with a red-speckled skin. "The difference is only in the colour, the taste of both is the same," Banda said. The Malawi businessman was looking to buy extractor machinery to make soya milk from soya bean. "I have signed a contract with an engineering company for a machine with the capacity to make 500 litres of soya milk in a day," he said.
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4. Market Potential 
Use of pulses is very common in Indian diet. Apart from the most popular use of making "Dal", they are used in making many food as well as snack preparations. They provide proteins. Many types of pulses are used in the country and pigeon pea is one of them. Pulses are used only after de-husking and splitting. This activity is going on since decades and even today some farmers employ these traditional techniques. But with growing demand, manual operations are taken over by the machines which have increased production as well as recovery. Per capita consumption of pulses in India is still very low and thus there is a need to increase it to ensure adequate intake of nutrients. Pulses are used only after de- husking and splitting. Conventional methods have been replaced by machines and today it has become a regular commercial activity and is the third largest processing industry after wheat and paddy. This note deals with de-husking, cleaning and splitting of pigeon peas. This project can be started in several states as pulses are cultivated in most parts of the country. This note considers Gujarat as a prospective location in view of ever increasing demand.ng 
While India is the largest producer of pulses in the world, it is also the largest consumer and has been unable to meet its own demand since the 1970s. As a result, many of the trade barriers which were in place prior to the 1970s have been removed to encourage cheap imports of pulse products for general consumption. 
A large percentage of the Indian population is classified as living in poverty and is, therefore, very price sensitive. Despite lower per capita consumption of pulses over the past 30 years, consumption is still increasing in volume and value. Pulses are still in high demand among Indians as they are a major source of protein and used in many traditional Indian dishes.
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CONSUMER TRENDS 
 Pulse consumption in India differs by region; pulses such as lentils are popular in northern India but are not the pulse of preference in southern India. 
 Pulses which are popular in all parts of the country include: Desi chickpeas, green peas, yellow peas, and black eye beans. 
 Pulses which are popular in northern India include: Kabuli chickpeas, lentils, and kidney beans. 
 Pulses which are more popular in southern India include: pigeonpeas and urd. 
 Low income, rural Indians tend to prefer horsegram (legumes from the tropics grown mostly under dry-land conditions) and khesari (European native pulse grown in the east of India). 
 Most pulses in India are either split or used in the production of flour. Generally speaking, only kabuli and green peas are consumed in whole form. Split and whole pulses are usually cooked and served as part of a meal with rice or traditional Indian bread. 
 Chickpea, urd and mung flours are generally very popular. All are important ingredients used in the preparation of snack foods in India. As snack food is also a fast growing market in India, due to rising incomes, pulse flours will be in higher demand. 
 Demand for pulses is on the rise due to economic growth in India. 
 Indian production of pulses is stagnant. 
 Pulses in India go through a large supply chain which drives up the price for consumers. This is generally due to the large number of intermediaries who take their “cut” of the value of the pulses. It is estimated that each middle-man in the pulse supply chain takes at least 1% commission on their sales. 
 The primary means of distribution is either through wholesalers or retail stores. Retail stores generally charge significantly higher prices than wholesalers, due to the number of intermediaries, profit-taking by the companies and overhead. 
 In addition, pulse importers generally buy on credit, something which may be scarce as a result of the economic downturn.
Dal Mill – Pulses Processing Unit 
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India 2006 2007 2008 2009 2010 Fresh Food 
171460.3 
187854.8 
205065.5 
222562.9 
240962.5 Meat 
3,340.50 
3,697.80 
4,110.20 
4,578.80 
5,089.50 Fish and seafood 
4,585.40 
4,904.40 
5,293.20 
5,740.80 
6,173 Pulses 
15,064.20 
17,422.30 
18,120.40 
19,670.40 
21,130.10 Vegetables 
60,541.60 
63,696.40 
68,695.80 
74,319.20 
80,247.10 Starchy roots 
27,671.20 
29,113.70 
32,155.40 
35,706 
38,990.80 Fruits 
35,687.40 
38,095.30 
40,383.60 
42,333.70 
44,351.60 Nuts 
380.7 
413.2 
491.7 
546.2 
598.7 Eggs 
2,417.60 
2,519.20 
2,800.70 
3,127 
3,487.20 Sugar and sweeteners 
21,771.60 
27,992.50 
32,618.50 
36,540.90 
40,894.50 
0.00 
5,000.00 
10,000.00 
15,000.00 
20,000.00 
25,000.00 
2006 
2007 
2008 
2009 
2010 
Pulses Consumtion in India 
ton/annum
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LENTIL SECTOR 
 Lentils are an important part of the Canadian pulse trade with India. They are consumed in larger amounts in the northern and eastern parts of India, compared to the south where they are generally seen as an inferior pulse. 
 India is one of the largest producers of lentils in the world. However, this has not stopped India from becoming one of the major importers of lentils. Poor productivity in the Indian agricultural sector has encouraged lentil imports from countries such as Canada and Australia. 
 Lentils alone were worth $34 million, or 8% of all agri-food and seafood products Canada exported to India in 2008. They amounted to Canada’s second largest export to India in 2008. 
 Lentil consumption is not uniform by type or region. Large red lentils are preferred by Indian consumers and are used primarily for splitting. 
 Yellow lentils are preferred in southern India where they act as a substitute when tur is priced too high for most consumers. 
 Small red lentils are consumed in lesser amounts, and usually among the Muslim minority. 
 Lentils are generally consumed as part of a side dish such as dhal fry, which are essentially cooked pulses served with fried onions. 
CHICKPEA SECTOR 
 The two main chickpea varieties in India are desi and kabuli chickpeas. 
 Chickpeas are the largest domestically produced and consumed pulse in India. They are also the most important in terms of the role they play in the preparation of traditional Indian cuisine. 
 Canada exported approximately $4.5 million worth of chickpeas to India in 2008. Chickpeas accounted for 1% of Canadian agri-food and seafood trade with India. However, chickpeas were still the fifth most important agri-food and seafood export to I 
 Chickpeas are consumed in a variety of different ways. They can be consumed whole, split and cooked as part of dhal or turned into basan flour which is used in the preparation of Indian snack food. 
 Desi chickpeas are the primary chickpeas used in the production of basan flour. These chickpeas are produced lo-cally in large quantities and earn a higher price on the mar-ket as they are considered of the highest quality. Yellow peas, which Canada exports much of, are considered a low end substitute in the creation of basan flour.
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 Canada exports a small number of desi chickpeas, which are generally considered low quality by Indian importers due to their high moisture content. Indian importers are looking for low moisture desi chickpeas as these are what are favoured by their customers. 
 Kabuli chickpeas are usually consumed whole as part of a meal. These chickpeas are not used as much as desi in the preparation of chickpea flour. They are mainly limited to northern India in terms of consumption; however recent trends indicate they have also been growing in popularity in the southern regions of India.
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Packing 
Grading 
De-husking & Splitting 
Seasoning 
Saoking 
Cleaning
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5. PRODUCTION PROCESS 
1. INTRODUCTION : 
The dhal mill is a process industry to dehull the pulses and split them into two halves or dhal and make it available to the consumer ready for use. 
2. APPLICATION : 
There are various pulses like red gram (thoor); green gram (mung); Black gram (udad); Bengal gram (chana); Masoor etc. and all these need dehulling before being made available in the market. 
3. MARKET : 
Since there is a constant demand in the consumer market, the demand for dhals is always preserve and is on the increase. 
4. BASIS AND PRESUMPTIONS : 
1. Production Capacity : 
The mill will be in operation for three shifts a day. The total raw material input would be 3 tons per shift or 9 tons per day. With refraction losses at 2% hulls at 1% and bran at 1% the recovery will be 14% less than the quantity of input material.
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5. Land and Construction Costs : USD = 45 INR INR USD Land Required 0.5 acre 500,000.00 11,111.11 Cost of Construction/sq.FT. 
750 14,250,000.00 316,666.67 Total Cost of Land and Building 
14,750,000.00 
327,777.78 
45 USD = 45 INR INR 
Land Required 0.5 acre 500,000.00 
Cnstruction Sq. Ft 
i. 
Raw material store 
5000 
ii. 
Finished goods store 
5000 
iii. 
Processing area 
4000 
iv. 
Office space 
1500 
v. 
Panel board room 
500 
vi. 
Gunny bags room 
1000 
vii 
Machinery spares room 
1000 
viii 
Toilet space 
200 
ix 
Miscellaneous space 
800 
Total Constructed area 
19,000.00 Cost of Construction/sq.FT. 750.00 14,250,000.00 Total Cost of Land and Building 14,750,000.00
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6. Costing of machinery and equipment: 
S.No. Description Qty. Landed Price 
A. 
Preparatory Section : 
INR 
USD 
i. 
Dectoner 
1 
200,000.00 4,444.44 
ii. 
Chaff separator 
1 
200,000.00 4,444.44 
iii. 
Elevators and conveyers 
550,000.00 12,222.22 
iv. 
Motors for above machinery 
520,000.00 11,555.56 
B. 
Process Section : 
i. 
Roller machine 
1 
235,000.00 5,222.22 
ii. 
Sieves 
2 
134,770.00 2,994.89 
iii. 
Worm machines 
2 
110,994.00 2,466.53 
iv. 
Bucket elevators 
5 
145,600.00 3,235.56 
v. 
Box fan 
1 
112,540.00 2,500.89 
vi. 
Accessories, Shafts, counter shafts, ball bearings etc. 
239,900.00 5,331.11 
Mud steel platform for machinery 
234,200.00 5,204.44 
vii. 
Motors for above machinery 
130,000.00 2,888.89 
viii. 
20 MPA/C motor 
135,000.00 3,000.00 
ix. 
Tool kit accessories, weighing scales. 
121,500.00 2,700.00 
Total cost of machinery 3,069,504.00 68,211.20
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7. Power requirement : 
The total connected load is 50 HP or 37.5 KW. In addition general lighting will require 7.5 KW, making the total power requirement to 45 KW. 
8. Water requirement : 
2 kilolitres per day or 50 kilolitres per month. 
9. Salaries and wages : Salaries and wages /month INR/annum USD/annum 163,000 12 1,956,000.00 43,466.67
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6. TECHNICAL ASPECTS: 
1. Production process outline : 
The gram is first passed through the sieves of the preparatory section to remove chaff and twigs, followed by the destoner to remove stones. The cleaned gram is then passed through the mill when it is cracked, split into two halves and the hulls separated from the dhal with the help of sieves. The hulls are disposed off to cattle feed manufacturers and the dhal packed in 50 kg gunnies. 
2. Quality specifications : 
The dhal should be free from hulls, stones and other contaminant material. 
3. Production capacity : 
The total raw material input is estimated at 9 tonnes per day or 27000 tonnes per annum. The yield is estimated at 14% less than the raw material input i.e. 23220 tonnes. 
4. Pollution control measures : 
Not necessary as there are no pollutants or effluents. However on dehulling there is a lot of dust which must be trapped and not allowed to penetrate into the surroundings.
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7. FINANCIAL FEASIBILITY 
S.No. 
Description 
Total INR 
Loan INR 
Equity INR 
i. 
Land 
500,000 
350,000 
150,000 
ii. 
Civil Works 
14,250,000 
9,975,000 
4,275,000 
iii. 
Plant machinery 
3,069,504 
2,148,653 
920,851 
iv. 
Cost of power connection 
300,000 
210,000 
90,000 
v. 
Electrification cost 
200,000 
140,000 
60,000 
vi. 
Delivery van 
800,000 
560,000 
240,000 
vii. 
Erection, commissioning 
500,000 
350,000 
150,000 
viii. 
Moulds, fixtures 
300,000 
210,000 
90,000 
ix. 
Office equipment 
300,000 
210,000 
90,000 
x. 
Pre operative expenses 
500,000 
350,000 
150,000 
xi. 
Working capital margin 
14,875,750 
- 
14,875,750 35,595,254 14,503,653 21,091,601
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S.No. 
Description 
Total USD 
Loan USD 
Equity USD 
i. 
Land 
11,111 
7,778 
3,333 
ii. 
Civil Works 
316,667 
221,667 
95,000 
iii. 
Plant machinery 
68,211 
47,748 
20,463 
iv. 
Cost of power connection 
6,667 
4,667 
2,000 
v. 
Electrification cost 
4,444 
3,111 
1,333 
vi. 
Delivery van 
17,778 
12,444 
5,333 
vii. 
Erection, commissioning 
11,111 
7,778 
3,333 
viii. 
Moulds, fixtures 
6,667 
4,667 
2,000 
ix. 
Office equipment 
6,667 
4,667 
2,000 
x. 
Pre operative expenses 
11,111 
7,778 
3,333 
xi. 
Working capital margin 
330,572 
- 
330,572 791,006 322,303 468,702
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10. Salary and Wages 
S.No 
Description 
No. 
Salary/head INR 
Total/Salary INR 
i. 
Production incharge 
1 
25,000.00 
25,000.00 
ii. 
Skilled workers 
6 
7,000.00 
42,000.00 
iii. 
Unskilled workers 
12 
5,000.00 
60,000.00 
iv. 
Vandriver 
1 
8,000.00 
8,000.00 
v. 
Administrative staff 
2 
5,000.00 
10,000.00 
vi. 
Security staff 
4 
3,000.00 
12,000.00 
Total 
26 
157,000.00 
Perquisites @ 15% 
23,550.00 
Grand total salaries and wages 
180,550.00 
S.No 
Description 
No. 
Salary/head USD 
Total/Salary USD 
i. 
Production incharge 
1 
555.56 
555.56 
ii. 
Skilled workers 
6 
155.56 
933.33 
iii. 
Unskilled workers 
12 
111.11 
1,333.33 
iv. 
Vandriver 
1 
177.78 
177.78 
v. 
Administrative staff 
2 
111.11 
222.22 
vi. 
Security staff 
4 
66.67 
266.67 
Total 
26 
3,488.89 
Perquisites @ 15% 
523.33 
Grand total salaries and wages 
4,012.22
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11. Raw Material 
S.No. 
Particulars 
Qty. 
Rate/Unit 
Total value 
Rs. P. 
i. 
Gram 
225,000.00 
45.00 
10,125,000.00 
ii. 
Gunny bags 
4,500.00 
20.00 
90,000.00 
Total raw and packing material 
10,215,000.00 
S.No 
Particulars 
Qty. 
Rate/Unit 
Total value 
USD 
USD 
i. 
Gram 
225,000.00 
1.00 
225,000.00 
ii. 
Gunny bags 
4,500.00 
0.44 
2,000.00 
Total raw and packing material 
227,000.00 
12. Utilities per Month 
S.No 
Particulars Per Month 
Expenditure 
USD 
i 
Power 27000 KW @ Rs. 6.00 per unit 
162,000.00 
3,600.00 
ii 
Steam 
- not required 
iii 
Furnace oil 
- not required 
iv 
Water 50 kilolitres @ Rs. 50 per KL 
2,500.00 
55.56 
Total cost of utilities 
164,500.00 
3,655.56
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13. Other contingent expenses per month 
S.No. Particulars INR USD 
i. Rent for land and building. 0 0 
ii. Postage and stationery 5,000.00 111.11 
iii. Telephones 10,000.00 222.22 
iv. Consumable stores 10,000.00 222.22 
v. Repairs and maintenance 15,000.00 333.33 
vi. Transport charges 25,000.00 555.56 
vii. Loading, unloading charges 15,000.00 333.33 
viii Advertisement and publicity 10,000.00 222.22 
ix Insurance 12,000.00 266.67 
x Sales expenses 35,000.00 777.78 
xi Miscellaneous expenses 15,000.00 333.33 
Total contingent expenses 152,000.00 3,377.78 
14. Total working capital per month 
S.No. Description INR USD 
i. Raw materials 10,125,000.00 225,000.00 
ii. Packing materials 90,000.00 2,000.00 
iii. Finished goods 12,577,500.00 279,500.00 
iv. Debtors 6,000,000.00 133,333.33 
v. Salaries and wages 163,000.00 3,622.22 
vi. Utilities 164,500.00 3,655.56 
vii. Contingencies 152,000.00 3,377.78 
Total working capital 29,272,000.00 650,488.89
Dal Mill – Pulses Processing Unit 
zZia@ 
V e n t u r e A r t 
Page 23 
15. PROFITABILITY OF THE UNIT (ANNUAL COSTS) : 
S.No. Description Cost USD 
i. Raw materials 121,500,000.00 2,700,000.00 
ii. Packing materials 1,080,000.00 24,000.00 
iii. Utilities 1,974,000.00 43,866.67 
iv. Salaries and wages 1,956,000.00 43,466.67 
v. Contingencies 1,824,000.00 40,533.33 
vi. Depreciation on land civil 
works @ 10% 
1,475,000.00 32,777.78 
vii. Depreciation on 
machinery @ 10% 
306,950.40 6,821.12 
viii. Depreciation on office 
equipment @ 20% 
60,000.00 1,333.33 
ix. Depreciation on vehicle 
@ 10% 
80,000.00 1,777.78 
x. Depreciation on moulds, 
fixtures @ 10% 
30,000.00 666.67 
xi. Interest on long term 
loan @ 10% 
1,450,365.28 32,230.34 
xii. Interest on short term 
loan @ 13% 
1,871,512.50 41,589.17 
Total production cost 133,607,828.18 2,969,062.85 
S.No. Finished Product Qty. Rate/ton Total Value 
tons Rupees 
i. Dhal Sale INR/annum 2322 65000 150,930,000.00 
INR Sale Per Month 12,577,500.00 
Dal Sale USD /Annum 2322 1,444.44 3,354,000.00 
USD Sale Per Month 279,500.00
Dal Mill – Pulses Processing Unit 
zZia@ 
V e n t u r e A r t 
Page 24 
16. Profitability Ratios 
USD 384,937.15 
Net Profit per year 
Total turnover 
Net Profit per Year 
Total Investment 
Total fixed cost 
Total fixed cost + Net Profit 
BREAK EVEN POINT 67.27% 
NET PROFIT RATIO 11.48% 
Earnings before Tax 17,322,171.82 
(Turnover – Production cost) 
RATE OF RETURN on Equity 48.16% 
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zia@milestonevision.com 
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Dal Mill - Pulses Processing Unit Brief Feasibility Report

  • 1. Brief Project Report Food Processing Series Dal Mill – Pulses Processing Unit Food prices are going very high and with increasing population this will remain high. This is brief project report for Dal Mill or Pulses Processing Unit. This is bankable project based on the emerging market. Depending upon country and place we can develop detail project report. The currency is Indian Rupee as well as US Dollar. Dr. Zia Ahmed Venture Art http://www.ventureart.biz/ zia@milestonevision.com +96565510448
  • 2. Dal Mill – Pulses Processing Unit zZia@ V e n t u r e A r t Page 1 Contents 1. Food in Global Environment ................................................................................................................. 2 • Global Stock Market Performance in 2010 ....................................................................................... 2 • FAO food price indices ...................................................................................................................... 3 • FOOD PRICES AND INFLATION .......................................................................................................... 3 2. 'INDIA REQUIRES IMPORTING 3.4 MN TON PULSES IN ......................................................................... 4 3. Malawi Farmers Scramble to Produce Pulses for India ........................................................................ 6 4. Market Potential ................................................................................................................................... 7 CONSUMER TRENDS ............................................................................................................................. 8 LENTIL SECTOR .................................................................................................................................... 10 CHICKPEA SECTOR ............................................................................................................................... 10 5. PRODUCTION PROCESS ....................................................................................................................... 13 6. TECHNICAL ASPECTS: .......................................................................................................................... 17 7. FINANCIAL FEASIBILITY........................................................................................................................ 18
  • 3. Dal Mill – Pulses Processing Unit zZia@ V e n t u r e A r t Page 2 1. Food in Global Environment There are riots in many African Countries recently. Especially the riots have significance looking at the strategic importance of these countries to the west, Algeria, Tunisia, Morocco, and Egypt. These are the countries who are staunch supporters of the western powers If we look at the other side of the story why this all is happening. Even though economy is slow, there is enough food for everyone and prices are going UP. According to World Bank “The world economy is moving from a post-crisis bounce-back phase of the recovery to slower but still solid growth this year and next, with developing countries contributing almost half of global growth, says the World Bank’s latest Global Economic Prospects 2011.” The World Bank estimates that global GDP, which expanded by 3.9% in 2010, will slow to 3.3% in 2011, before it reaches 3.6% in 2012. Developing countries are expected to grow 7% in 2010, 6% in 2011 and 6.1% in 2012. They will continue to outstrip growth in high-income countries, which is projected at 2.8% in 2010, 2.4% in 2011 and 2.7% in 2012. • Global Stock Market Performance in 2010 The following are some of the key points from a review of the 2010 performance of equity markets around the world: Stock markets can rise despite low or poor economic growth. The U.S. market was a perfect example of this scenario. While the U.S. economy continued to struggle last year with high unemployment rates, slowing demand, more bank failures and other negative events, corporate profits rose and equities took off ending the year with double-digit returns for the S&P 500. It was a very good year 2010 for many markets with amazing returns. India gave a 16% odd returns in 2010. The MSCI Emerging Markets Index (+16.4%) had done enough earlier in the year to outperform the MSCI World Index (+9.6%) by a wide margin for the year as a whole.
  • 4. Dal Mill – Pulses Processing Unit zZia@ V e n t u r e A r t Page 3 • FAO food price indices The FAO Food Price Index in December slightly surpassed its peak of early summer 2008. The indices of sugar and oils and fats increased the most. In Asia, domestic prices of rice further strengthened in December and are at record levels in several countries. Prices of wheat and wheat flour in importing countries of Asia, Latin America and Africa, remained at high levels. • FOOD PRICES AND INFLATION If all the food in the world were shared out evenly, there would be enough to go around. That has been true for centuries now - if food was scarce, the problem was that it wasn't in the right place. The poor, urban multitudes in these countries (including China and India) spend up to half of their entire income on food, compared with only about 10 per cent in rich countries. When food prices soar, these people quickly find that they simply lack the money to go on feeding themselves and their children properly - and food prices now are at an all-time high. Unfortunately we live in world which does not understand logic and rationales. Only vested interest of Global Powers and Power Brokers and lobbies prevail. No one care how many will die of hunger and poverty.
  • 5. Dal Mill – Pulses Processing Unit zZia@ V e n t u r e A r t Page 4 2. 'INDIA REQUIRES IMPORTING 3.4 MN TON PULSES IN India is the world's largest producer of pulses; but last year the country had to import 1.8 million tons of pulses to meet the growing domestic consumption. During the year 2006-07, India imported 1.8 million tons of various pulses, especially from countries like China, Canada and Australia. For instance, the Kolkata Dock System alone handled over a million tons of pulses imported from these countries. This was a nearly 90 per cent jump over the previous year and over 50 per cent of the country's total import of pulses. Despite being the largest producer of the largest varieties of pulses, the demand for consumption of pulses is just growing. India harvests between 12- 15 million tons of pulses each year but the yield has been pretty much static for the last 30 years averaging between 500-600 lb./ acre. While the green revolution produced a three-fold increase in wheat yields in India, pulses have not received the same level of attention in research. Pulses are grown on dry land during the winter season under less than ideal conditions. All of the pulses in India are harvested by hand but losses due to insects and storage problems can be significant. What makes India such an interesting market is that India is best described as a very price sensitive market? India is the biggest importer and consumer of pulses and India government has initiated various programs to ensure that pulses output by the nation remain robust. In the budget for 2011-12, India Finance Minister had announced a number of measures to strengthen the agricultural sector particularly in the areas of pulses, vegetables and oil palm. The country is an importer of pulses and imported 2.79 tons in 2009-10. Compared to 3.5 million tons of pulses imports by India in 2009-10 crop year, the country is expected to import 3 million tons for the current crop year spanning July-June. This is attributed to the high output of pulses by India, said a report in Business Standard citing traders and importers. India is likely to come up with impressive pulses output figures for 2010-11 season at 17.29 million tons, up by 18%. This is when compared to 14.66 million tons in 2009-10, according to a report in The Times of India. Area under pulses climbed by 12% to 23.05 million hectares in 2010-11. Of the estimated production tur is expected at 3.2 million tons, urad at 1.8 million tons and moong at 1.4 million tons. Government -run trading firms like MMTC would import 0.6 mn tons to .7 mn tons of pulses in 2010-11 up from 0.3mn-- 0.4 mn tons Y-O-Y, said Business Standard quoting H S Mann, chief managing director of MMTC Ltd. The
  • 6. Dal Mill – Pulses Processing Unit zZia@ V e n t u r e A r t Page 5 targeted import figures by MMTC forms almost one-fifth of India’s pulses imports. The rest is imported by private firms. Among imports, yellow pea accounts for half of the total figures and is sourced from Canada, Ukraine and the US. India’s State Trading Corporation, another government trading house, had invited bids for the import of 31,000 tons of pulses for sale in the domestic market, recently. Bidders were supposed to procure 25,000 tonnes of yellow peas and 2,000 tonnes each of desi chick peas (chana), black matpe (urad) and leamon tur (arhar) from Canada, Australia and Myanmar, said a report in The Hindu Business Line. Notwithstanding expected bumper production of pulses during 2011-12, India would require to import 3.40 million ton of the vital food grain item to match the enhanced demand. The production of pulses during 2011-12 as per the Second Advance Estimates released by Union Agriculture minister is estimated to be 16.51 million ton. Planning Commission has estimated that the demand for pulses in the country during the period is 19.11 million ton, Thomas said adding the gap of 3.4 million ton have to be met by imports. Given that the supply and demand mismatch with regard to pulses is likely to exist in the near future, the government has permitted imports of pulses at zero duty up to March 31, 2012 to increase domestic availability and stabilize the prices of pulses, he added.
  • 7. Dal Mill – Pulses Processing Unit zZia@ V e n t u r e A r t Page 6 3. Malawi Farmers Scramble to Produce Pulses for India Farmers in the landlocked southeast African country of Malawi are shifting from their traditional crops to grow pulses to meet the increasing demand in the international market, especially from India. The government in Malawi is encouraging farmers to grow more pulses to meet the demand in India, said Malawi businessman John Jimu Banda, who was here to attend the CII-EXIM Bank India-Africa Business Conclave March 27-29. Apart from attending the meet, Banda intended to buy some equipment, but he is going back to his country with an export order for the supply of pigeon pea or tuar dal. "There is a big demand for pigeon pea in India. I have got orders for supplying 1,000 tonnes of pigeon pea from two parties," he said. Malawi is already exporting about 50,000 tonnes of pulses to India, but there is "good scope for increasing the quantity", according to Banda. "The government is putting emphasis on growing beans for the Indian market. It is telling farmers that there is a good market for the pulses abroad." The Malawi government has sought assistance from India for producing new varieties, and for research and training in growing early-maturing and high-yielding varieties of pulses. The main crop in Malawi, formerly known as Nyasaland, is maize, tea and tobacco, but farmers also grew beans of various kinds. Tobacco, tea and sugarcane provided 70 percent of Malawi's export earnings till the international prices of tobacco crashed. Since then the government has been encouraging growers to shift to other crops such as pulses, paprika, macadamia nuts and fruits. Farmers in Malawi grow soya, pigeon pea, chick pea or garbanzo or chole, green gram (moong), white cow peas (lobiya) and red beans or kidney beans (rajma). The red beans are of two varieties - a small deep-red bean and a larger bean with a red-speckled skin. "The difference is only in the colour, the taste of both is the same," Banda said. The Malawi businessman was looking to buy extractor machinery to make soya milk from soya bean. "I have signed a contract with an engineering company for a machine with the capacity to make 500 litres of soya milk in a day," he said.
  • 8. Dal Mill – Pulses Processing Unit zZia@ V e n t u r e A r t Page 7 4. Market Potential Use of pulses is very common in Indian diet. Apart from the most popular use of making "Dal", they are used in making many food as well as snack preparations. They provide proteins. Many types of pulses are used in the country and pigeon pea is one of them. Pulses are used only after de-husking and splitting. This activity is going on since decades and even today some farmers employ these traditional techniques. But with growing demand, manual operations are taken over by the machines which have increased production as well as recovery. Per capita consumption of pulses in India is still very low and thus there is a need to increase it to ensure adequate intake of nutrients. Pulses are used only after de- husking and splitting. Conventional methods have been replaced by machines and today it has become a regular commercial activity and is the third largest processing industry after wheat and paddy. This note deals with de-husking, cleaning and splitting of pigeon peas. This project can be started in several states as pulses are cultivated in most parts of the country. This note considers Gujarat as a prospective location in view of ever increasing demand.ng While India is the largest producer of pulses in the world, it is also the largest consumer and has been unable to meet its own demand since the 1970s. As a result, many of the trade barriers which were in place prior to the 1970s have been removed to encourage cheap imports of pulse products for general consumption. A large percentage of the Indian population is classified as living in poverty and is, therefore, very price sensitive. Despite lower per capita consumption of pulses over the past 30 years, consumption is still increasing in volume and value. Pulses are still in high demand among Indians as they are a major source of protein and used in many traditional Indian dishes.
  • 9. Dal Mill – Pulses Processing Unit zZia@ V e n t u r e A r t Page 8 CONSUMER TRENDS  Pulse consumption in India differs by region; pulses such as lentils are popular in northern India but are not the pulse of preference in southern India.  Pulses which are popular in all parts of the country include: Desi chickpeas, green peas, yellow peas, and black eye beans.  Pulses which are popular in northern India include: Kabuli chickpeas, lentils, and kidney beans.  Pulses which are more popular in southern India include: pigeonpeas and urd.  Low income, rural Indians tend to prefer horsegram (legumes from the tropics grown mostly under dry-land conditions) and khesari (European native pulse grown in the east of India).  Most pulses in India are either split or used in the production of flour. Generally speaking, only kabuli and green peas are consumed in whole form. Split and whole pulses are usually cooked and served as part of a meal with rice or traditional Indian bread.  Chickpea, urd and mung flours are generally very popular. All are important ingredients used in the preparation of snack foods in India. As snack food is also a fast growing market in India, due to rising incomes, pulse flours will be in higher demand.  Demand for pulses is on the rise due to economic growth in India.  Indian production of pulses is stagnant.  Pulses in India go through a large supply chain which drives up the price for consumers. This is generally due to the large number of intermediaries who take their “cut” of the value of the pulses. It is estimated that each middle-man in the pulse supply chain takes at least 1% commission on their sales.  The primary means of distribution is either through wholesalers or retail stores. Retail stores generally charge significantly higher prices than wholesalers, due to the number of intermediaries, profit-taking by the companies and overhead.  In addition, pulse importers generally buy on credit, something which may be scarce as a result of the economic downturn.
  • 10. Dal Mill – Pulses Processing Unit zZia@ V e n t u r e A r t Page 9 India 2006 2007 2008 2009 2010 Fresh Food 171460.3 187854.8 205065.5 222562.9 240962.5 Meat 3,340.50 3,697.80 4,110.20 4,578.80 5,089.50 Fish and seafood 4,585.40 4,904.40 5,293.20 5,740.80 6,173 Pulses 15,064.20 17,422.30 18,120.40 19,670.40 21,130.10 Vegetables 60,541.60 63,696.40 68,695.80 74,319.20 80,247.10 Starchy roots 27,671.20 29,113.70 32,155.40 35,706 38,990.80 Fruits 35,687.40 38,095.30 40,383.60 42,333.70 44,351.60 Nuts 380.7 413.2 491.7 546.2 598.7 Eggs 2,417.60 2,519.20 2,800.70 3,127 3,487.20 Sugar and sweeteners 21,771.60 27,992.50 32,618.50 36,540.90 40,894.50 0.00 5,000.00 10,000.00 15,000.00 20,000.00 25,000.00 2006 2007 2008 2009 2010 Pulses Consumtion in India ton/annum
  • 11. Dal Mill – Pulses Processing Unit zZia@ V e n t u r e A r t Page 10 LENTIL SECTOR  Lentils are an important part of the Canadian pulse trade with India. They are consumed in larger amounts in the northern and eastern parts of India, compared to the south where they are generally seen as an inferior pulse.  India is one of the largest producers of lentils in the world. However, this has not stopped India from becoming one of the major importers of lentils. Poor productivity in the Indian agricultural sector has encouraged lentil imports from countries such as Canada and Australia.  Lentils alone were worth $34 million, or 8% of all agri-food and seafood products Canada exported to India in 2008. They amounted to Canada’s second largest export to India in 2008.  Lentil consumption is not uniform by type or region. Large red lentils are preferred by Indian consumers and are used primarily for splitting.  Yellow lentils are preferred in southern India where they act as a substitute when tur is priced too high for most consumers.  Small red lentils are consumed in lesser amounts, and usually among the Muslim minority.  Lentils are generally consumed as part of a side dish such as dhal fry, which are essentially cooked pulses served with fried onions. CHICKPEA SECTOR  The two main chickpea varieties in India are desi and kabuli chickpeas.  Chickpeas are the largest domestically produced and consumed pulse in India. They are also the most important in terms of the role they play in the preparation of traditional Indian cuisine.  Canada exported approximately $4.5 million worth of chickpeas to India in 2008. Chickpeas accounted for 1% of Canadian agri-food and seafood trade with India. However, chickpeas were still the fifth most important agri-food and seafood export to I  Chickpeas are consumed in a variety of different ways. They can be consumed whole, split and cooked as part of dhal or turned into basan flour which is used in the preparation of Indian snack food.  Desi chickpeas are the primary chickpeas used in the production of basan flour. These chickpeas are produced lo-cally in large quantities and earn a higher price on the mar-ket as they are considered of the highest quality. Yellow peas, which Canada exports much of, are considered a low end substitute in the creation of basan flour.
  • 12. Dal Mill – Pulses Processing Unit zZia@ V e n t u r e A r t Page 11  Canada exports a small number of desi chickpeas, which are generally considered low quality by Indian importers due to their high moisture content. Indian importers are looking for low moisture desi chickpeas as these are what are favoured by their customers.  Kabuli chickpeas are usually consumed whole as part of a meal. These chickpeas are not used as much as desi in the preparation of chickpea flour. They are mainly limited to northern India in terms of consumption; however recent trends indicate they have also been growing in popularity in the southern regions of India.
  • 13. Dal Mill – Pulses Processing Unit zZia@ V e n t u r e A r t Page 12 Packing Grading De-husking & Splitting Seasoning Saoking Cleaning
  • 14. Dal Mill – Pulses Processing Unit zZia@ V e n t u r e A r t Page 13 5. PRODUCTION PROCESS 1. INTRODUCTION : The dhal mill is a process industry to dehull the pulses and split them into two halves or dhal and make it available to the consumer ready for use. 2. APPLICATION : There are various pulses like red gram (thoor); green gram (mung); Black gram (udad); Bengal gram (chana); Masoor etc. and all these need dehulling before being made available in the market. 3. MARKET : Since there is a constant demand in the consumer market, the demand for dhals is always preserve and is on the increase. 4. BASIS AND PRESUMPTIONS : 1. Production Capacity : The mill will be in operation for three shifts a day. The total raw material input would be 3 tons per shift or 9 tons per day. With refraction losses at 2% hulls at 1% and bran at 1% the recovery will be 14% less than the quantity of input material.
  • 15. Dal Mill – Pulses Processing Unit zZia@ V e n t u r e A r t Page 14 5. Land and Construction Costs : USD = 45 INR INR USD Land Required 0.5 acre 500,000.00 11,111.11 Cost of Construction/sq.FT. 750 14,250,000.00 316,666.67 Total Cost of Land and Building 14,750,000.00 327,777.78 45 USD = 45 INR INR Land Required 0.5 acre 500,000.00 Cnstruction Sq. Ft i. Raw material store 5000 ii. Finished goods store 5000 iii. Processing area 4000 iv. Office space 1500 v. Panel board room 500 vi. Gunny bags room 1000 vii Machinery spares room 1000 viii Toilet space 200 ix Miscellaneous space 800 Total Constructed area 19,000.00 Cost of Construction/sq.FT. 750.00 14,250,000.00 Total Cost of Land and Building 14,750,000.00
  • 16. Dal Mill – Pulses Processing Unit zZia@ V e n t u r e A r t Page 15 6. Costing of machinery and equipment: S.No. Description Qty. Landed Price A. Preparatory Section : INR USD i. Dectoner 1 200,000.00 4,444.44 ii. Chaff separator 1 200,000.00 4,444.44 iii. Elevators and conveyers 550,000.00 12,222.22 iv. Motors for above machinery 520,000.00 11,555.56 B. Process Section : i. Roller machine 1 235,000.00 5,222.22 ii. Sieves 2 134,770.00 2,994.89 iii. Worm machines 2 110,994.00 2,466.53 iv. Bucket elevators 5 145,600.00 3,235.56 v. Box fan 1 112,540.00 2,500.89 vi. Accessories, Shafts, counter shafts, ball bearings etc. 239,900.00 5,331.11 Mud steel platform for machinery 234,200.00 5,204.44 vii. Motors for above machinery 130,000.00 2,888.89 viii. 20 MPA/C motor 135,000.00 3,000.00 ix. Tool kit accessories, weighing scales. 121,500.00 2,700.00 Total cost of machinery 3,069,504.00 68,211.20
  • 17. Dal Mill – Pulses Processing Unit zZia@ V e n t u r e A r t Page 16 7. Power requirement : The total connected load is 50 HP or 37.5 KW. In addition general lighting will require 7.5 KW, making the total power requirement to 45 KW. 8. Water requirement : 2 kilolitres per day or 50 kilolitres per month. 9. Salaries and wages : Salaries and wages /month INR/annum USD/annum 163,000 12 1,956,000.00 43,466.67
  • 18. Dal Mill – Pulses Processing Unit zZia@ V e n t u r e A r t Page 17 6. TECHNICAL ASPECTS: 1. Production process outline : The gram is first passed through the sieves of the preparatory section to remove chaff and twigs, followed by the destoner to remove stones. The cleaned gram is then passed through the mill when it is cracked, split into two halves and the hulls separated from the dhal with the help of sieves. The hulls are disposed off to cattle feed manufacturers and the dhal packed in 50 kg gunnies. 2. Quality specifications : The dhal should be free from hulls, stones and other contaminant material. 3. Production capacity : The total raw material input is estimated at 9 tonnes per day or 27000 tonnes per annum. The yield is estimated at 14% less than the raw material input i.e. 23220 tonnes. 4. Pollution control measures : Not necessary as there are no pollutants or effluents. However on dehulling there is a lot of dust which must be trapped and not allowed to penetrate into the surroundings.
  • 19. Dal Mill – Pulses Processing Unit zZia@ V e n t u r e A r t Page 18 7. FINANCIAL FEASIBILITY S.No. Description Total INR Loan INR Equity INR i. Land 500,000 350,000 150,000 ii. Civil Works 14,250,000 9,975,000 4,275,000 iii. Plant machinery 3,069,504 2,148,653 920,851 iv. Cost of power connection 300,000 210,000 90,000 v. Electrification cost 200,000 140,000 60,000 vi. Delivery van 800,000 560,000 240,000 vii. Erection, commissioning 500,000 350,000 150,000 viii. Moulds, fixtures 300,000 210,000 90,000 ix. Office equipment 300,000 210,000 90,000 x. Pre operative expenses 500,000 350,000 150,000 xi. Working capital margin 14,875,750 - 14,875,750 35,595,254 14,503,653 21,091,601
  • 20. Dal Mill – Pulses Processing Unit zZia@ V e n t u r e A r t Page 19 S.No. Description Total USD Loan USD Equity USD i. Land 11,111 7,778 3,333 ii. Civil Works 316,667 221,667 95,000 iii. Plant machinery 68,211 47,748 20,463 iv. Cost of power connection 6,667 4,667 2,000 v. Electrification cost 4,444 3,111 1,333 vi. Delivery van 17,778 12,444 5,333 vii. Erection, commissioning 11,111 7,778 3,333 viii. Moulds, fixtures 6,667 4,667 2,000 ix. Office equipment 6,667 4,667 2,000 x. Pre operative expenses 11,111 7,778 3,333 xi. Working capital margin 330,572 - 330,572 791,006 322,303 468,702
  • 21. Dal Mill – Pulses Processing Unit zZia@ V e n t u r e A r t Page 20 10. Salary and Wages S.No Description No. Salary/head INR Total/Salary INR i. Production incharge 1 25,000.00 25,000.00 ii. Skilled workers 6 7,000.00 42,000.00 iii. Unskilled workers 12 5,000.00 60,000.00 iv. Vandriver 1 8,000.00 8,000.00 v. Administrative staff 2 5,000.00 10,000.00 vi. Security staff 4 3,000.00 12,000.00 Total 26 157,000.00 Perquisites @ 15% 23,550.00 Grand total salaries and wages 180,550.00 S.No Description No. Salary/head USD Total/Salary USD i. Production incharge 1 555.56 555.56 ii. Skilled workers 6 155.56 933.33 iii. Unskilled workers 12 111.11 1,333.33 iv. Vandriver 1 177.78 177.78 v. Administrative staff 2 111.11 222.22 vi. Security staff 4 66.67 266.67 Total 26 3,488.89 Perquisites @ 15% 523.33 Grand total salaries and wages 4,012.22
  • 22. Dal Mill – Pulses Processing Unit zZia@ V e n t u r e A r t Page 21 11. Raw Material S.No. Particulars Qty. Rate/Unit Total value Rs. P. i. Gram 225,000.00 45.00 10,125,000.00 ii. Gunny bags 4,500.00 20.00 90,000.00 Total raw and packing material 10,215,000.00 S.No Particulars Qty. Rate/Unit Total value USD USD i. Gram 225,000.00 1.00 225,000.00 ii. Gunny bags 4,500.00 0.44 2,000.00 Total raw and packing material 227,000.00 12. Utilities per Month S.No Particulars Per Month Expenditure USD i Power 27000 KW @ Rs. 6.00 per unit 162,000.00 3,600.00 ii Steam - not required iii Furnace oil - not required iv Water 50 kilolitres @ Rs. 50 per KL 2,500.00 55.56 Total cost of utilities 164,500.00 3,655.56
  • 23. Dal Mill – Pulses Processing Unit zZia@ V e n t u r e A r t Page 22 13. Other contingent expenses per month S.No. Particulars INR USD i. Rent for land and building. 0 0 ii. Postage and stationery 5,000.00 111.11 iii. Telephones 10,000.00 222.22 iv. Consumable stores 10,000.00 222.22 v. Repairs and maintenance 15,000.00 333.33 vi. Transport charges 25,000.00 555.56 vii. Loading, unloading charges 15,000.00 333.33 viii Advertisement and publicity 10,000.00 222.22 ix Insurance 12,000.00 266.67 x Sales expenses 35,000.00 777.78 xi Miscellaneous expenses 15,000.00 333.33 Total contingent expenses 152,000.00 3,377.78 14. Total working capital per month S.No. Description INR USD i. Raw materials 10,125,000.00 225,000.00 ii. Packing materials 90,000.00 2,000.00 iii. Finished goods 12,577,500.00 279,500.00 iv. Debtors 6,000,000.00 133,333.33 v. Salaries and wages 163,000.00 3,622.22 vi. Utilities 164,500.00 3,655.56 vii. Contingencies 152,000.00 3,377.78 Total working capital 29,272,000.00 650,488.89
  • 24. Dal Mill – Pulses Processing Unit zZia@ V e n t u r e A r t Page 23 15. PROFITABILITY OF THE UNIT (ANNUAL COSTS) : S.No. Description Cost USD i. Raw materials 121,500,000.00 2,700,000.00 ii. Packing materials 1,080,000.00 24,000.00 iii. Utilities 1,974,000.00 43,866.67 iv. Salaries and wages 1,956,000.00 43,466.67 v. Contingencies 1,824,000.00 40,533.33 vi. Depreciation on land civil works @ 10% 1,475,000.00 32,777.78 vii. Depreciation on machinery @ 10% 306,950.40 6,821.12 viii. Depreciation on office equipment @ 20% 60,000.00 1,333.33 ix. Depreciation on vehicle @ 10% 80,000.00 1,777.78 x. Depreciation on moulds, fixtures @ 10% 30,000.00 666.67 xi. Interest on long term loan @ 10% 1,450,365.28 32,230.34 xii. Interest on short term loan @ 13% 1,871,512.50 41,589.17 Total production cost 133,607,828.18 2,969,062.85 S.No. Finished Product Qty. Rate/ton Total Value tons Rupees i. Dhal Sale INR/annum 2322 65000 150,930,000.00 INR Sale Per Month 12,577,500.00 Dal Sale USD /Annum 2322 1,444.44 3,354,000.00 USD Sale Per Month 279,500.00
  • 25. Dal Mill – Pulses Processing Unit zZia@ V e n t u r e A r t Page 24 16. Profitability Ratios USD 384,937.15 Net Profit per year Total turnover Net Profit per Year Total Investment Total fixed cost Total fixed cost + Net Profit BREAK EVEN POINT 67.27% NET PROFIT RATIO 11.48% Earnings before Tax 17,322,171.82 (Turnover – Production cost) RATE OF RETURN on Equity 48.16% If you are looking to start a project we are just click away zia@milestonevision.com For Detailed Project Report Feasibility Report As per your needs based on your place and location