Instant Pickle
Production Capacity : 250 tpa
Uploaded on : March 2009
Product and its Applications
Apart from staple foods, people like spicy adjuncts to make the food palatable and relishing. Pickles are good appetizers and digestive agents. There are several varieties of pickles which are consumed throughout the year. In this context, pickle, a spicy preparation, has gained importance in Indian menu. Preparation of pickles is an old art and a variety of these products are made in Indian homes. The basic principle of pickling is curing of fruits and vegetables by salting, acidifying, addition of vinegar and/or oil and spices. Pickle making is a time consuming process. Often the cost of glass bottle & oil works out more than the cost of actual pickle. A new technology has been developed for making instant pickle mix, which can be converted into a palatable pickle at home by simple addition of water and oil. Thus instant pickle is likely to become popular and acceptable due to various reasons e.g. better shelf life, possibility for addition of extra spices at the users end, relatively low cost of production, convenience in handling and reduction in volume of packaging and low transportation cost. Several varieties of dry pickle mix can be developed by using dehydrated mango, lime (lemon), green chillies, tomatoes, carrots, different types of leaves.
Market Potential
Mustard oil is the popular cooking oil in northern, central, eastern and north- eastern region. There exists a large scope to set up a number of small scale mustard expellers for local production of high pungency oil, which fetches a premium price.
Basis and Presumption
- The unit proposes to work at least 300 days per annum on single shift basis.
- The unit can achieve its full capacity utilization during the 2nd year of operation.
- The wages for workers is taken as per prevailing rates in this type of industry.
- Interest rate for total capital investment is calculated @ 12% per annum.
- The entrepreneur is expected to raise 20-25% of the capital as margin money.
- The unit proposes to construct own building.
- Costs of machinery and equipment are based on average prices enquired from machinery manufacturers.
Implementation schedule
Project implementation will take a period of 8 months. Break-up of the activities and relative time for each activity is shown below:
| Scheme preparation and approval | 01 month |
| SSI provisional registration | 1-2 months |
| Sanction of financial supports etc | 2-5 months |
| Installation of machinery and power connection | 6-8 months |
| Trial run and production | 01 month |
Technical aspects
Location
The unit can be set up in oilseed producing regions or near the consumption centres. However, availability of power and road connectivity should be ensured.
Salient Features of Process / Technology
The seeds are cleaned to remove dust, dirt and foreign particles. These are cured to bring the moisture level of 10-12% and passed through oil expeller. The oil cake is conveyed automatically and pressed to achieve maximum oil recovery, which is about 35% depending upon he variety and quality of seed. The oil is filtered and filled into 1 kg Pet bottles or 16 kg tins.
Quality Control and Standards
As per BIS/PFA requirements
Pollution Control
There is no major pollution problem associated with this industry except for disposal of waste which should be managed appropriately. The entrepreneurs are advised to take "No Objection Certificate" from the State Pollution Control Board.
Energy Conservation
The fuel for the steam generation in the boiler is coal or LDO depending upon the type of boiler. Proper care should be taken while utilising the fuel for the steam production. There should be no leakage of steam in the pipe lines and adequate insulation should be provided.
Production Capacity
| Quantity | 300 tpa |
| Installed capacity | 1200 kg/day |
| Optimum capacity utilization | 70% |
| Working days | 300/annum (3 shifts) |
| Manpower | 22 |
| Utilities | |
| Optimum capacity utilization | 70% |
| Motive Power | 8 kW |
| Water | 10 kL/day |
Financial Aspects
Fixed Capital
Land & Building Amount (Rs. lakh)
Particulars |
Amount (Rs. lakh) |
| Land 400 m 2 | 02.10 |
| Built up area 250 m 2 | 12.90 |
| Total cost of land and building | 15.00 |
Machinery and Equipment Amount (Rs. lakh)
Description |
Amount |
|
07.00 |
| Erection & electrification of machinery & equipment @10% cost | 00.70 |
| Office furniture & fixtures | 02.30 |
| Total | 10.00 |
Pre-operative Expenses Amount (Rs. lakh)
| Consultancy fee, project report, deposits with electricity department etc | 01.00 |
Total Fixed Capital Amount (Rs. lakh)
| (9.1.1+9.1.2+9.1.3) | 26.00 |
Recurring expenses per annum
Personnel Amount (Rs. lakh)
Designation |
No. |
Salary Per month |
Amount |
| Factory Manager | 1 | 10,000 | 01.20 |
| Supervisory staff | 2 | 8,000 | 01.92 |
| Office Assistant | 2 | 7,500 | 01.80 |
| Technician | 0 | 6,000 | 00.72 |
| Skilled workers | 3 | 4,000 | 01.44 |
| Unskilled workers | 8 | 3,000 | 02.88 |
| 09.96 | |||
| Perquisites @15 % | 01.24 | ||
| Total | 11.20 |
Raw Material including packaging materials Amount (Rs. lakh)
Particulars |
Qty (t) |
Rate/t (Rs.) |
Amount (Rs. lakh) |
| Mustard seeds | 860 | 23,000 | 197.80 |
| Pet bottles with cap | 3 lakh | 4.80 each | 014.40 |
| Shrink wrapping rolls | LS | LS | 000.48 |
| Labels | 3 lakh | 0.90 each | 002.70 |
| Cartons cap. 24 bottles | 12,500 | 32 each | 004.00 |
| Gunny bags | LS | LS | 001.12 |
| Total | LS | LS | 220.50 |
Utilities Amount (Rs. lakh)
Particulars |
Amount (Rs. lakh) |
| Power 55000 kWH | 02.80 |
| Water 3000 kL | 00.20 |
| Fuel for boiler | 00.80 |
| Total | 03.80 |
Other Contingent Expenses Amount (Rs. lakh)
Particulars |
Amount(Rs. lakh) |
| Repairs and maintenance @10% | 00.77 |
| Consumables, filter cloth & spares | 00.93 |
| Transport & travel | 00.80 |
| Publicity, postage, telephone | 01.00 |
| Insurance @1% | 00.20 |
| Total | 03.70 |
Working Capital Amount (Rs. lakh)
| Recurring expenses for 3 months | 60.00 |
Total Capital Investment Amount (Rs. lakh)
| Fixed capital (Refer 9.1.4) | 26.00 |
| Working capital (Refer 9.3) | 60.00 |
| Total | 86.00 |
Financial Analysis
Cost of Production (per annum) Amount (Rs. lakh)
| Recurring expenses (Refer 9.2.5) | 219.70 |
| Depreciation on building @ 5% | 000.65 |
| Depreciation on machinery @10% | 000.85 |
| Depreciation on furniture @ 20% | 000.48 |
| Interest on Capital Investment @12% | 010.32 |
| Total | 232.00 |
Sale Proceeds (Turnover) per year Amount (Rs. lakh)
Item |
Qty |
Rate (Rs.) |
Amount (Rs.lakh) |
| Mustard Oil in 1 kg bottle | 300 | 18,000 | 216.00 |
| Mustard cake | 540 | 10,000 | 054.00 |
| Total | 270.00 |
Net Profit per year
= Sales – Cost of production |
Net Profit Ratio
Net profit X 100 Sales 38X 100 270 = 14 % |
Rate of Return on Investment
Net profit X 100 Capital Investment 38X 100 86 = 44 % |
Annual Fixed Cost Amount (Rs. lakh)
| All depreciation | 01.98 |
| Interest | 10.32 |
| 40% of salary, wages, utility, contingency | 07.50 |
| Insurance | 00.20 |
| Total | 20.00 |
Break even Point
Annual Fixed Cost X 100 Annual Fixed Cost + Profit 20X 100 = 34.5 % |
Addresses of Machinery and Equipment Suppliers
- Nandy Eng. Works
139, Benaras Road
Howrah-711 106 - Azad Eng. Co.
C-83, B.S.Road Industrial Area,Ghaziabad-201 009 - Guru Tegh Eng. Co.,G.T.Road, Millerganj, Near Fire Brigade
Ludhiana - Punjab Engg. Works, 32, Ram Krishna Samadhi Road
Kolkata – 700 054 - S.P.Engg. Co.
79/9, Latouche Road ,
P.B. No. 218,
Kanpur – 208 001 - Lyallpur Engg. Co.
G.T.Road, P.B. No. 8,
Ghaziabad (U.P.) - Delhi Iron and Steel Co. Pvt. Ltd.
G.T.Road,
Ghaziabad (UP) - Swastik Engg. Works,
198, Panjara Pole Road
Mumbai – 400 004 - Parekh Machine Tools
5, Khetra Das Lane ,
Behind Broadway Hotel
Kolkata-700 012 - Mecpro Heavy Eng Ltd.
610, Somdutt Chambers II
Bhikaji Cama Place ,
New Delhi – 110 066 - Chemical Construction International (P) Ltd.
J-12, Basement, Saket, New Delhi – 110 017 - Japro International (P) Ltd.
Flower Valley Complex
Tower No. T-2, First Floor
Off Eastern Express Highway
Thane (West) – 400 601 - Muez-Hest Process Technologies (P) Ltd.,
231, Blue Road Industrial Estate,
New Cable Corporation, Western Express Highway ,
Borivalli East, Mumbai – 400 066 - Om Sons International,77-A, Industrial Estate,
Ludhiana - 141 003. - Jindal Expeller Industries
58-B, Industrial Estate, Miller Ganj,
Ludhiana-141 003. - Veendeep Oiltek Exports
A-67, MIDC, Taloja,
Navi Mumbai- 410 208. - Troika Processes Private Limited, Mumbai
607, 6th Floor, Embassy Centre, Nariman Point,
Mumbai- 400 021. - Karnataka Iron Works, Mangalore
Balmatta Road ,
Mangalore,
Karnataka- 575 002. - Servotech India Limited, Mumbai
Office No. 8, a Wing, ''b'' Building, Shiv Sagar Apartments Ram Baug,
S. V. Road, Neat Vijay Sales, Borivali [ w ],
Mumbai- 400 092 - Sunman Engineers India , Faridabad
41B, New DLF Industrial Area,
Faridabad - 121 003. - Vinco Industries
47 - b, Industrial Estate,
Ludhiana- 141 003. - Glamptech Agro Process Pvt. Ltd
105, Charisma Centre, 19th Road, Chembur,
Mumbai- 400 071 - Sethia Oil Industries Limited, 2, Exchange Place ,
Kolkata- 700 001 - Aum Consultancy Pvt. Ltd
Odyssey 2nd Floor, Gandhi Nagar, Adayar,
Chennai- 600 020. - Heiza Chem Engineers Private Limited
P-29, Sukanta Sarani,
Kolkata-700 008. - Ritika Projects International, New Delhi
B-365, C R Park,
New Delhi- 110 019
Other Special Features
A careful selection of product mix is necessary based on the local market demand and availability of raw materials. The facilities can also be utilised to manufacture oil from copra, groundnut, sunflower etc. for fuller utilisation of capacity.
Contact for more information
Information Manager
TIMEIS Project
E-mail: timeis@ficci.com
