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Dal Mill Project PDF
Dal Mill Project PDF
INTRODUCTION
India is the largest producer of pulses around 14.5 million tones annually. Pulses commonly
known as dal in India are an important component of both the vegetarian as well as the nonvegetarian diet in India. Among the North Eastern States, Assam is the largest producer of
pulses.
THE PROJECT
Pulses constitute one of the main sources of protein in the Indian diet. There are different
varieties of pulses namely Chana, Mung, Masur, Urad and Tuvar dal. Of these, Mung and Masur
dal are predominantly consumed in the North Eastern States. The conversion of pulse grains into
dal through the process of milling. Wherein dal is split into smaller sizes rendering it convenient
for cooking. It is one of the important food processing industry usually in the medium and smallscale sector, some quantity is also processed in the rural sector manually producing inferior
quality dal resulting in lesser revenue earning compared to milled dal.
MARKET POTENTIAL
The all India per capita consumption of pulses is about 2.8 kg per year. In the north-eastern
region, consumption of pulses is generally higher especially in States like Assam and Manipur.
Conservatively, taking the national consumption norm of 2.8 kg and considering the total
population of 365 lakhs in the north-eastern region, the demand for pulses is estimated at
1,02,000 tonne per year. There is no organized dal milling activity in the north-eastern region. In
rural areas, sometimes dal milling is carried out in rice hullers. However, generally raw dal is
processed in unit in nearby areas of West Bengal and milled dal re-enters the north-eastern
states. The total production of pulses in north-eastern region is about 85,000 tonne per year,
assuming that 80% of this quantity is available for dal milling, that the new tiny units process 15%
of the available dal, there is scope for over 15 tiny units with annual milling capacity of 700 tonne
of dal to be set up.
SUGGESTED CAPACITY
In assessing the proposed plant capacity due consideration is given to availability of raw material,
market and basic infrastructure like power etc. a typical dal milling until is envisaged to produce
500 MT per annum on the following basis:
Production Capacity
Number of Shifts
Daily production capacity
Capacity utilization
Working days per annum
Annual Production
Loss during dehusking
Net Production
:
:
:
:
:
:
:
:
159 kg/hr.
2
2.53 tonne
70%
300
6%
6%
500 tonne/annum
INFRASTRUCTURE REQUIREMENT
Covered Area
Power requirement
Water
:
:
:
159
State
Tonne/Year
Arunachal Pradesh
Assam
Meghalaya
Nagaland
Tripura
Mizoram
5000
60000
2000
7000
5000
6000
85000/-
Total:
SUGGESTED LOCATION
A dal milling unit should be located in a urban/semi-urban area which has access to raw material,
skilled manpower and market. However, the following tentative suggestion can be taken into
consideration.
Assam
Manipur
Nagaland
Tripura
Sikkim
PRODUCTION PROCESS
The important steps involved in the process are
1.
2.
3.
4.
Cleaning
Milling
Dehusking and cleaning
Weighing and Packing
PROJECT ECONOMICS
TOTAL CAPITAL REQUIREMENTS
A.
Fixed Capital
1.
2.
3.
4.
5.
6.
(Rs. in lakh)
Land
Site Development
Building (working shed 750 Sq.ft.
Raw material godown, finished product
Godown, Office room)
Plant and Machinery
Misc. Fixed Assets
Preliminary/Pre-operative expenses
Own
0.45
4.87
Total (A):
B.
1.84
0.50
0.30
7.96
Norms
1 month
1 week
1 month
1 week
Total (B):
160
Amount
(Rs.in lakh)
9.23
2.87
0.42
2.93
15.45
Term Loan(75%)
Promoters Equity(25%)
MEANS OF FINANCE
Capacity Utilisation
Output (MT)
Annual Revenue
: 70%
: 500 MT/annum
: Rs. 135.00 lakhs
The cost of various types of pulses varies from Rs. 20 to Rs. 30/Kg, so an average cost
of Rs. 27,000 per tonne is taken into consideration. The annual sales revenue for 500 MT
is estimated at Rs. 135 lakhs.
COST OF PRODUCTION
1.
2.
3.
4.
5.
6.
7.
8.
(Rs. in lakh)
110.75
3.34
1.38
0.35
0.70
0.36
2.46
6.75
Rs. 126.09 lakhs
Operating profit
Return on Sales
1 No.
2 Nos.
5 Nos.
The total cost of equipments have been estimated as Rs. 1.84 lakhs
Manager
Skilled Worker
Unskilled workers
Total:
Nos.
1
1
4
Average Salary/
person/month(Rs)
3,500
2,000
1,500
161
Total monthly
Salaries(Rs)
3,500
2,000
6,000
11,500
: 18.65 Hwh
:
6 Kw
24.65 KW
Say 25 KW
= 320 Kwh
= Rs. 1280/= Rs. 3.84 lakhs
PLANT OVERHEADS
Sl. No.
Items
1.
Repair and Maintenance
(a) 1% on cost of civil works
(b) 2% on Plant and M/c.
(c) 1% on Misc. fixed assets
Sub-Total:
2.
Insurance on Plant Assets
2% on building, Plant & M/c. miscellaneous fixed assets
Total:
At 70% capacity utilization = 0.16%
B.
C.
D.
E.
Variable Cost:
Raw Materials and consumables
Utilities
Selling Expenses
Total (A)
110.75
3.34
6.75
120.84
Total (B)
1.38
0.35
0.36
0.70
2.46
5.25
Semi-variable Cost
Wages and Salaries
Repair and Maintenance
Administrative Expenses
Depreciation
Interest
Sales Realisation
Contribution
Break Even Point = B/D x 70%
135.00
14.16
26%
MACHINERY SUPPLIERS
1.
M/s. Archana Machinery Stores
A.T. Road, Guwahati
2.
M/s. DIW Hindustan Industrial Works
Post Box No. 12, Dahanu Road
Dist: Thane (Maharashtra)
162