PROCESSED CHEESE MANUFACTURING PLANT

[EIRI/EDPR/3898] J.C.: 2016

INTRODUCTION

Process cheese is a dairy product which differs from natural cheese in the fact that
process cheese is not made directly from milk. However, the main ingredient of process
cheese is natural cheese. Process cheese is produced by blending natural cheese of
different ages and degrees of maturity in the presence of emulsifying salts and other
dairy and nondairy ingredients
gredients followed by heating and continuous mixing to form a
homogeneous product with an extended shelf life.

Some examples of processed cheese are: ‘cheese’ from a tube, spreadable cheese
spreads, ‘La vache quite rit’, cheese strings etc.

Processed Cheese means the product obtained by grinding, mixing, melting and
emulsifying one or more varieties of cheeses with the aid of heat and emulsifying agents
and may contain cream, butter, butter oil and other milk products. It may also contain
non-dairy
dairy ingredients not exceeding one sixth of the weight of the total solids of the final
product on dry matter basis.

Processed Cheese Spread means the product obtained by grinding, mixing, melting and
emulsifying one or more varieties of cheese with emulsifying
emulsifying agents with the aid of heat
and may contain cream, butter oil and other dairy products. It may also contain natural
carbohydrate sweetening agents and other non- non dairy ingredients not exceeding one
sixth of the weight of total solids of the final
final product on dry weight basis.

Standard

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 CONTENTS
INTRODUCTION
STANDARD
PLANT LOCATION
LOCATION AND GEOGRAPHICAL AREA
CLIMATE
HISTORY OF CHEESE
TYPES OF CHEESE
TYPES OF PROCESSED CHEESE
GRATED PROCESSED CHEESE
PROCESSED CHEESE CUBES
PROCESSED CHEESE STICKS
PROCESSED CHEESE STRIPS
CUT THE CHEESE BLOCK INTO THIN OR THICK STRIPS AS PER THE RECIPE
REQUIREMENT
SLICED PROCESSED CHEESE
MANUFACTURING PROCESS OF NATURAL CHEESE
THE GENERAL PROCESSING STEPS FOR CHEDDAR CHEESE ARE USED FOR
ILLUSTRATION
GENERAL CHEESE PROCESSING STEPS
1. STANDARDIZE MILK
2. PASTEURIZE/HEAT TREAT MILK
3. COOL MILK
4. INOCULATE WITH STARTER & NON-STARTER BACTERIA AND RIPEN
5. ADD RENNET AND FORM CURD
6. CUT CURD AND HEAT
7. DRAIN WHEY
8. TEXTURE CURD
9. DRY SALT OR BRINE
10. FORM CHEESE INTO BLOCKS
11. STORE AND AGE
12. PACKAGE
COMPOSITION
PROCESS CHEESE COMPOSITION CONTROL-1
PROCESS CHEESE COMPOSITION CONTROL-2
MANUFACTURING PROCESS OF PROCESSED CHEESE
THE MANUFACTURE OF PCPS INVOLVES THE FOLLOWING MAJOR STEPS:
TRIMMING AND GRINDING
THE RIND MAY BE REMOVED BY KNIVES. ANOTHER METHOD IS TO SOFTEN THE
RIND BY TEMPERING.
PROCESSING
COOKING TECHNIQUE
PACKAGING
STORAGE OF PACKAGE PROCESSED CHEESE

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ADVANTAGE
RAW MATERIAL DETAILS
INGREDIENTS
BACTERIAL CULTURES
PROCESSED CHEESE
INGREDIENTS USED OTHER THAN CHEESE IN PASTEURIZED PROCESSED CHEESE
STANDARDS OF IDENTITY FOR PASTEURIZED PROCESS CHEESE AND PRODUCTS
PASTEURIZED PROCESS CHEESE
PASTEURIZED PROCESS CHEESE FOOD
PASTEURIZED PROCESS CHEESE SPREAD
MARKET SURVEY
CHEESE MARKET IN INDIA
BREAKUP BY TYPE:
BREAKUP BY FORMAT:
BREAKUP BY APPLICATION:
BREAKUP BY RETAIL/INSTITUTIONAL:
REGIONAL INSIGHTS:
COMPETITIVE LANDSCAPE:
MAJOR COMPANIES
THE CHEESE ARCADE
THE OUTLOOK
GROWING FAST FOOD CULTURE INFLUENCING THE PROCESSED CHEESE MARKET
POSITIVELY.
GLOBAL PROCESSED CHEESE MARKET: SEGMENTATION
ON THE BASIS OF TYPE, THE GLOBAL PROCESSED CHEESE IS SEGMENTED AS
ON THE BASIS OF END-USE, THE GLOBAL PROCESSED CHEESE MARKET IS
SEGMENTED AS
GLOBAL PROCESSED CHEESE MARKET: KEY PLAYERS
SOME OF THE KEY PLAYERS IN THE GLOBAL PROCESSED CHEESE MARKET ARE
OPPORTUNITIES FOR MARKET PARTICIPANTS IN PROCESSED CHEESE MARKET.
PROCESS FLOW DIAGRAM
NATURAL CHEESE
PROCESSED CHEESE
FSSAI REGISTRATION FOR DAIRY PRODUCT
THERE ARE 4 STEPS INCLUDING FSSAI LICENSE REGISTRATION PROCEDURE THAT
ARE FOLLOWING
SELECTION OF KIND OF BUSINESS
COMMON DOCUMENTS REQUIRED FOR OBTAINING FSSAI REGISTRATION
FSSAI LICENSE REGISTRATION
MACHINERY SUPPLIERS
MAIN PROCESSED CHEESE MACHINE MANUFACTURERS
INDIVIDUAL MACHINE MANUFACTURER:-
GRINDER/EXTRUDER
HYGIENIC CONVEYER
TWIN RIBBON BLENDERS
RAW MATERIAL SUPPLIERS

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CHEDDAR CHEESE
WHEY POWDER
SODIUM PHOSPHATES
GUAR GUM POWDER
CORN SYRUP
PAPRIKA (ARTIFICIAL COLOURS)
POTASSIUM SORBATE
MACHINERY PHOTOGRAPHS
GRINDER/EXTRUDER
HYGIENIC CONVEYER
TWIN RIBBON BLENDERS
FEED SYSTEMS
DIRECT STEAM INJECTION CONTINUOUS COOKING
VACUUM DE-AERATION VESSEL
SURGE HOPPER / CREAMING TANK
PRODUCT PHOTOGRAPHS
RAW MATERIAL PHOTGRAPHS
CHEDDAR CHEESE
WHEY POWDER
SODIUM PHOSPHATES
GUAR GUM POWDER
SODIUM CHLORIDE
CORN SYRUP
PAPRIKA (ARTIFICIAL COLOURS)
POTASSIUM SORBATE

APPENDIX – A:
01. PLANT ECONOMICS
02. LAND & BUILDING
03. PLANT AND MACHINERY
04. OTHER FIXED ASSESTS
05. FIXED CAPITAL
06. RAW MATERIAL
07. SALARY AND WAGES
08. UTILITIES AND OVERHEADS
09. TOTAL WORKING CAPITAL
10. TOTAL CAPITAL INVESTMENT
11. COST OF PRODUCTION
12. TURN OVER/ANNUM
13. BREAK EVEN POINT
14. RESOURCES FOR FINANCE
15. INSTALMENT PAYABLE IN 5 YEARS
16. DEPRECIATION CHART FOR 5 YEARS
17. PROFIT ANALYSIS FOR 5 YEARS
18. PROJECTED BALANCE SHEET FOR (5 YEARS)

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 COST ESTIMATION

Plant Capacity 12 MT/Day

Land & Building (5000 sq.mt.) Rs. 4.61 Cr
Plant & Machinery Rs. 3.05 Cr
Working Capital for 1 Month Rs. 10.64 Cr
Total Capital Investment Rs. 19.22 Cr
Rate of Return 84%
Break Even Point 22%

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