WHEAT ROLLER FLOUR MILL

1.

Introduction
The roller flour mill is a process industry to mill wheat and provide the

endosperm as various fractions viz: maida, sooji, and atta. The skin or bran is
separated from the endosperm and sold as cattle feed.
2.

Market
Since wheat is a staple food among all segments of the population, there

is a constant demand in the consumer market for wheat products and the
demand for these is always on the increase.
3.

Packaging
Maida, Sooji and Atta are packed in 90 kg gunnies. For the retail

commercial market, 500 grams and 1 kilogram packaging are adopted.

4.

Production capacity

The plant will be in operation for three shifts a day.

The plant will operate to a capacity of processing 500 kgs per hour or 10
metric tonnes per day.

The recovery of finished products will be equivalent to the raw material input.

The output of various fractions is termed as extraction percentages. A typical

extraction comprises 60% refined flour or maida; 10% semolina or sooji; 7%
resultant meal or atta and 13% bran.

5.

Sales revenue
The sales revenue will be entirely dependent on the procurement price of raw
material used for milling and the extraction percentages of various fractions.

6.

Production process outline.

The milling of wheat is basically divided into two sections viz:- cleaning

section and the milling section. The milling section comprises the chaff remover;
destoner; scourer; washing machine; intensive dampner; and cockle separator.
In the cleaning section, wheat is cleaned thoroughly before milling. Wheat is first
passed through sieves to remove chaff and stalks. From the chaff separator it
passes through a scouring machine wherein adhering dirt and mud and a part of

the skin are removed. From the scourer, the wheat passes through the destoner
and stones are completely separated from the grain. The grains are then fed into
the washing machine where dust, husk, and mud balls are removed. The
washed wheat is sent through a dampened to raise the moisture content of the
grain and then for conditioning. After conditioning for 36 hours, it is drawn for
milling. The grain passes through a series of milling rolls comprising the break
rolls, scratch rolls, and the polish rolls, purifiers, and plan sifters to get the
desired fractions at the required percentages.
7.

Quality specifications

The different product shall conform to the following specifications:

Atta:- Moisture -13.5% maximum; Ash - 2% maximum; Acid insoluble ash 0.18% maximum; Gluten - 6% minimum; Alcoholic acidity - 0.18%
maximum; Rodent excreta and human hair - absent.

Maida:- Moisture -13.5% maximum; Ash - 1% maximum; Acid insoluble ash

- 0.10% maximum; Gluten - 7.5% minimum; Alcoholic acidity - 0.12%
maximum; Rodent excreta and human hair - absent.

Sooji:- Moisture -13.5% maximum; Ash - 1% maximum; Acid insoluble ash

- 0.15% maximum; Gluten - 6.0% minimum; Alcoholic acidity - 0.18%
maximum; Rodent excreta and human hair - absent.

8.

Pollution control measures

Not necessary as there are no pollutants or effluents.

9.

Energy conservation measures

Common measures will do.

10.

Land and construction cost for the proposed unit

Land 0.5 acres - Rs.1.0 lakhs.
Processing area is 7000 square feet as detailed below.

Sl
Description
1
Raw material store
2
Finished goods store
3
Processing section
4
Office space
5
Gunny bag store room
6
Machinery spares store room
7
Panel board room
8
Laboratory
9
Toilets
10
Security office
11
Miscellaneous space
12
Total
Construction cost Rs. 800 per square foot
Total cost of civil works Rs. 56.00 lakhs.
Total cost of land and civil works is Rs.57.00 lakhs.
11.

Costing of machinery and equipment

Preparatory section

a) Chaff separator
b) Scourer
c) Destoner
d) Washing machine
e) Intensive dampners
f) Elevators and conveyers
g) Motors for above machines

Process section

h) Roller machine
i) Purifiers
j) Plansifters
k) Pneumatic elevation system with pipings
l) Bran finisher
m) Entoleter

Sq. feet
1000
1000
3000
500
150
400
200
200
200
150
200
7000

n) Motor and accessories

o) Tool kit, weighing scales and accessories.

Total cost of machinery - Rs. 33 lakhs

Testing equipment

p) Testing equipment comprising hot air oven, ashing oven, kjeldhal

apparatus, soxhlet apparatus, centrifuge, vortex stirrer, pH meter, precision
weighing scales, glassware and chemicals.
q) Cost of testing equipment - Rs. 1.00 lakh.
Total cost of processing and testing equipment inclusive of taxes and
duties - Rs. 34.0 lakhs.
12.
Sl
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20

Project cost
Description
Land
Civil works
Plant machinery
Laboratory equipment
Transport vehicle
Pollution control equipment
Energy conservation equipment
Cost of power connection
Cost of electrification
Erection and commissioning
Cost of machinery spares
Cost of office equipment
Deposits if any
Company formation expenses
Gestation period expenses
Sales tax registration expenses
Initial advertisement and publicity
Contingencies
Working capital margin money
Total

Rs. lakhs
1.000
56.000
33.000
1.000
7.500
0.000
0.000
1.000
1.000
3.300
0.500
1.000
0.000
0.100
1.500
0.100
5.000
0.250
10.610
122.860

13.

Working capital requirements per month

a.

Salaries and wages

Sl

Description

1
2

Production Manager
Production supervisor cum
chemist
Skilled workers
Unskilled workers
Loadmen
Administrative staff
Sales coordinator
Driver
Security staff
Total

3
4
5
6
7
8
9
10
b.
Sl
1
2
c.
Sl
1

No of
persons
1
2

Total
salary /
month
(Rs. lakhs)
0.150
0.200

3
6
2
2
1
1
3
21

0.180
0.180
0.120
0.200
0.100
0.060
0.120
1.310

Raw material requirement per month

Qty
Rate / kg
Description
(kgs)
(Rs)
Wheat
250,000
13.00
Total raw material

250,000

Value
(Rs. lakhs)
32.50
32.50

Packaging material requirement per month

Rate / unit
Description
Qty
Rs)
Gunny bags
2800 nos
16

Total
Total raw + packaging material = Rs. 32.948 lakhs

d.
Sl
1
2
3
4

Utilities per month

Description
Power 13500 kwh @ Rs. 6.00 per unit
Water
Boiler fuel
Total utilities

Value
(Rs. lakhs)
0.448
0.448

Rs. lakhs
0.810
0.050
0.000
0.860

e.
Sl
1
2
3
4
5
6
7
8
9
10
11
12
13

f.
Sl
1
2
3
4
5
14.
Sl
1
2
3
4

Contingent expenses per month

Description
Rent for processing shed
Postage and stationery
Telephones, fax etc.
Consumable stores
Repairs and maintenance
Local transports, loading and unloading
Advertisement and publicity @ 1% of sales
Insurance
Sales expenses @ 1% of sales
Miscellaneous expenses @ 1% of sales
Trade incentives @ 1% of sales
Taxes @ 4%
Total contingent expenses

Rs. lakhs
0.000
0.010
0.050
0.020
0.325
0.150
0.424
0.018
0.424
0.424
0.424
1.696
3.965

Total working capital requirement per month

Description
Rs. lakhs
Salaries and wages
1.310
Raw material and packaging material
32.948
Utilities
0.860
Contingent expenses
3.965
Total
39.083
Means of finance
Description
Total Project Cost
Equity
Debt
Working capital margin money

Rs. lakhs
122.860
40.953
81.907
10.610

15.
Sl
1
2
3
4
5
6
7
8
9
16.

Financial analysis
Description
Total recurring cost per year
Depreciation on land and building
Depreciation on machinery and vehicle
Depreciation on furnaces
Depreciation on moulds and fixtures
Depreciation on office equipment
Interest on long term loan @ 12%
Interest on short term borrowings@ 12%
Total cost of production

Rs. lakhs
468.996
5.700
4.450
0.000
0.020
0.100
9.829
3.504
492.599

Turnover per year

Sl

Item

Qty
MT

Rate/kg
(Rs)

Maida

1800

18

324.00

Sooji

300

22

66.00

Atta

510

22

112.20

Bran

390

23.40

Total

3000

17.
Sl
1
2
3
4
5

Viability analysis
Description
Net profit before income tax (Rs. lakhs)
Net profit ratio
Internal rate of return
Break even percentage
Debt service coverage ratio

Total
Rs. lakhs

525.60

Value
33.001
6.4%
16.6%
68%
1.863

Machinery suppliers for Wheat Roller Flour Mill

1. Abhay and Abhay Private Limited, B - 84 - 1; Okhla Industrial Estate - II; New
Delhi.110020.; Tel: 011 - 32103978; Fax: 011 - 29396539
2. Buhler India Limited, KIADB Industrial Area, Attibele 562107, Bangalore
District, Karnataka.; Tel: 080-27820000; Fax: 080-27820001
3. Sidvin Machineries Private Limited, 10, 3rd Stage, Industrial Suburb, Mysore,
570008, Karnataka.; Tel: 08212-2485822, 2483228 ; Fax: 0821 - 2489564