Introduction
The term cookies generally prefer a baked product containing a percentage of sugar and fat relative to the flour and a small quantity of water. This general statement on composition separates cookies from bread that contain relatively low level of sugar and fat and intermediate level of water.
The type of cookies is defined not only by their composition but also by their method of production. Cookies containing high amount of fats and sugar. Many types of cookies are manufactured in a baking industry, some of them are mostly preferred the common people. These are like Butter cookie, Almond cookie, bar cookie, Benne cookie, Black & White cookie.
Usage/Application
Cookies are generally used for direct consumption.
Products
Cookies in Plastic Pouches/ bottle/ Jar in 50 gms, 100, 200 and 500 Gms.
Objective
The primary objective of the model report is to facilitate the entrepreneurs in understanding the importance of setting up unit of Fruit & Vegetable Powder. This model report will serve as guidance to the entrepreneurs on starting up such a new project and basic technical knowledge for setting up such a facility.
Critical Success Factors
Generally, the Success of a Cookies Brand depends on several factors including innovative packaging, new flavors, tastes, shapes etc. Also rising health consciousness among consumers through the electronics media is effective in the Indian Consumer market. Simply, we have to offer as many as varieties we can at a cheaper price than an established brand.
Raw Material
Basic Raw material for proposed unit is Wheat Flour, Sugar and Salt etc.
Capacity
The capacity of the project is 4 TPD assuming the working capacity of the machinery is 8 Hrs per day for 300 working days.
Land Area Requirement
Land should be located near to the growing Agri-cluster area easily connected with the Road and Rail. The Project Land should also have easy availability of the water and electricity. The ideal land require for the project is 1.00 Acre
Implementation Schedule
It will take Eighteen (18) months to complete all the formalities before starting the commercial production.
Manufacturing Process
The manufacturing process consists of the following steps:
MIXING
In this process all ingredients like flour, fat, sugar etc., are put together in the right proportion for dough formation. The ingredients are fed into the mixers, where they are mixed properly to prepare the dough. Here the dough temperature and mixing time play an important role in the manufacturing of cookies. Normally mixing time is between 10- 15 min but it usually depends upon floor characteristics. It is performed in two or three stages with different mixing speed.
MOULDING
Mixing is followed by moulding, in which the dough is laminated into sheets and is passed down to gauge rollers and appropriate sheet thickness is achieved for cutting. It is here that cookies are given a variety of shapes and sizes using cutter or moulder. The speed of the moulder or the cutter depends on the variety of the cookie. Use of moulder or cutter depends on the type of the dough where moulder is used for short dough type of cookie and cutters are used for sheet variety or hard dough.
BAKING
It is the third stage in cookies making process, where the moulded cookies are put into the baking oven on required temperatures. There are various baking options with different kinds of ovens available like direct fired, indirect fired and hybrid ovens, which can be used keeping in mind the desired temperatures, the convenience and cost. Various methods of heating like conduction, convection and radiation are used in the ovens. These ovens also have dampers to control moisture inside the oven section. Generally, the ovens are classified as 4 zone, 5 zone or 6 zone ovens where length varies from 40 mtr to 80 mtrs. Cookies are carried on wire mesh band in oven.
COOLING
After baking cookies, they are passed on to cooling conveyors for natural cooling prior to packing. These conveyors are generally 300 - 400 ft. and can be of two or 3 deck type as per space availability. In the conveyors, the temperature is brought down to room temperature. Natural cooling is preferred to force cooling as it maintains the texture quality of cookie.
PACKING
After cooling, the cookies are stacked and fed into packing machine. These cookies can be availed in different packaging materials in different packs like Bottle or Jar Packing, pouch pack or family packs. These packs are then put into secondary packing like cartons for transporting to the retailers..
Financial Aspects
Civil Infrastructure : 1.00 Cr.
Plant & Machinery : 1.00 Cr.
Other Expenses : 1.00 Cr.
Total Project Cost : 3.00 Cr.
Means of Finance
Equity Contribution (30%) : 0.90 Cr.
Bank Finance (70%) : 2.10 Cr.
Total Project Cost : 3.00 Cr.
Estimated Turnover of the project will be around Rs. 15 Crore with Positive IRR of 22%.
Government Incentives
1. Government of India has designed a Pradhan Mantri KisanSampada Yojana, In Which Capital Grant from Rs. 5 to 10 Crore is being provided as per the scheme guidelines.
2. Considering Agro and Food Processing as a priority sector various state government are also providing Incentives like Capital Investment Subsidy, Interest Subsidy, Labour Subsidy, Tax Benefits etc.
Our firm Provides following Services
» Project Management Services
o Pre-feasibility Study of the Project and existing market analysis of the product to be manufactured.
o Conceptualization of the Project and Finalization of Project Components.
o Bankable/Detailed Project Report
o Assistance in Grant/ Subsidy
o Detailed Design and Engineering of the Project
o Technology Sourcing
o Project Management Consultancy
o Supply Chain Management
o Agriculture Advisory Services etc.
» Food Product Development Services
o Suitable & Innovative Packaging as per product characteristics
o Bio-Degradable Packaging
o Development of range of variant of product with suitable packaging as per the requirement of product.
» Food Safety & Quality Licenses
o FSSAI
o APEDA
o Spice Board of India
o DGFT
(For Reference Purpose Only)
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