Confectionary Grade Sesame Seed
Production Capacity : 280t Confectionary Grade Sesame Seeds
Uploaded on : February 2009
Product and its Applications
The major portion of sesame seed produced in the country is used for extraction of oil. Sesame seed is also used in a variety of sweets, confectionery and bakery products. For utilization in the above food products, sesame has to be de hulled to remove the outer fibrous husk cover. This is usually done by soaking the seeds overnight in water, followed by drying and rubbing against a rough surface. The separated hulls are removed by winnowing. The method is laborious, time consuming and suitable for processing small quantities only. An improved wet de hulling process is now available which accomplishes easy removal of the husk. The de hulled seed can be expeller pressed for obtaining good quality oil. The cake is further solvent extracted to recover the residual oil and the protein rich cake is used for protein fortification of various food preparations.
Market Potential
The dehulled sesame has uniform white colour and is ready for use in cookery and confectionery. It is rich in protein (22%) and oil (60%). It has a large demand in comestic as well as export markets particularly for use in the confectionery industry.
Basis and Presumption
- The unit would work for 200 days per annum on single shift basis.
- The unit can achieve its full capacity utilization during the 3rd year of operation.
- The wages for skilled 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
Raw material
The important sesame growing states are Gujarat, Maharashtra, Madhya Pradesh, Orissa, Rajasthan, West Bengal, Karnataka, Tamilnadu, Andhra Pradesh and Uttar Pradesh. As such sesame seed are easily available all over the country.
Process of Manufacture
- Preliminary cleaning and grading: Commercial quality sesame seed is cleaned to remove dust, fines, stones and other foreign matter using vibratory screening equipment, followed by de stoning.
- Contacting with hot lye: The seeds are placed in a boiling solution of sodium hydroxide for a prescribed time. These are thoroughly washed by a stream of water.
- Removal of skin and pigments: Washed seeds are brushed under a current of water to remove the hulls.
- Drying: The dehulled wet seeds are dried in a cross-flow or fluidized bed drier.
Quality Control and Standards
PFA Specifications
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 | 280 tpa |
| Value | Rs. 221.20 lakh |
| Installed capacity | 2 tpa |
| Working days | 200/annum |
| Optimum capacity utilization | 70% |
| Manpower | 19 |
| Utilities | |
| Motive Power | 18 kW |
| Water | 8 kL/day |
Financial Aspects
Fixed Capital
Land & Building
Particulars |
Amount (Rs. lakh) |
| Land 60 m 2 | 01.50 |
| Built up area 150 m 2 | 11.00 |
| Total cost of land and building | 12.50 |
Machinery and Equipment
Description |
Amount |
| Sesame seed pre-cleaning unit, destoner, wire mesh basket, mixing tanks, vibratory screen, pulper and mechanical drier | 18.00 |
| Erection & electrification of machinery & equipment @10% cost | 01.70 |
| Office furniture & fixtures | 01.70 |
| Total | 28.00 |
Pre-operative Expenses Amount (Rs. lakh)
| Consultancy fee, project report, deposits with electricity department etc | 03.00 |
Total Fixed Capital Amount (Rs. lakh)
| (9.1.1+9.1.2+9.1.3) | 37.00 |
Recurring expenses per annum
Personnel
Designation |
No. |
Salary Per month |
Amount |
| Factory Manager | 1 | 12000 | 01.80 |
| Supervisory staff | 2 | 8000 | 01.92 |
| Office Assistant | 2 | 6000 | 01.44 |
| Marketing supervisor | 2 | 5000 | 01.20 |
| Unskilled workers (7 months) | 8 | 2000 | 01.12 |
| Skilled workers (12 months) | 4 | 3000 | 01.44 |
| 08.92 | |||
| Perquisites @15 % | 01.38 | ||
| Total | 19 | 10.30 |
Raw Material including packaging materials
Particulars |
Qty (t) |
Rate/t (Rs.) |
Amount (Rs. lakh) |
| Raw sesame | 315 | 46000 | 150.00 |
| Soda alkali | 12 | 14500 | 01.74 |
| Hydrochloric acid | 3 | 18000 | 00.54 |
| Jute bags | 5600 no | 11 each | 00.62 |
| Miscellaneous | 9.10 | ||
| Total | 163.00 |
Utilities
Particulars |
Amount (Rs. lakh) |
| Power | 3.40 |
| Water | 0.10 |
| Total | 3.50 |
Other Contingent Expenses
Particulars |
Amount(Rs. lakh) |
| Repairs and maintenance@10% | 2.15 |
| Consumables & spares, others | 1.61 |
| Insurance @1% | 0.44 |
| Total | 4.20 |
Total Recurring Expenditure Amount (Rs. lakh)
| (9.2.1+9.2.2+9.2.3+9.2.4) | 181.00 |
Working Capital Amount (Rs. lakh)
| Recurring expenses for one month | 15.00 |
Total Capital Investment Amount (Rs. lakh)
| Fixed capital (Refer 9.1.4) | 37.00 |
| Working capital (Refer 9.3) | 15.00 |
| Total | 52.00 |
Financial Analysis
Cost of Production (per annum) Amount (Rs. lakh)
| Recurring expenses (Refer 9.2.5) | 181.00 |
| Depreciation on building @5% | 000.55 |
| Depreciation on machinery @10% | 001.98 |
| Depreciation on furniture @20% | 000.34 |
| Interest on Capital Investment @12% | 006.23 |
| Total | 190.10 |
Sale Proceeds (Turnover) per year
Item |
Qty |
Rate (Rs.) |
Amount (Rs.lakh) |
| Confectionary grade sesame seeds | 280 | 79000 | 221.20 |
Net Profit per year
= Sales – Cost of production |
Net Profit Ratio
Net profit x 100 Sales 31.10 x 100 221.20 = 14 % |
Rate of Return on Investment
Net profit x 100 Capital Investment 31.10 x 100 52 = 14 % |
Rate of Return on Investment
Net profit x 100 Capital Investment 31.10 x 100 52 = 59.8 % |
Annual Fixed Cost Amount (Rs. Lakh)
| All depreciation | 2.87 |
| Interest | 6.23 |
| 40% of salary, wages, utility, contingency | 09.70 |
| Insurance | 0.44 |
| Total | 16.74 |
Break even Point
Annual Fixed Cost x 100 Annual Fixed Cost + Profit 16.74 x 100 766 = 35% |
Addresses of Machinery and Equipment Suppliers
- Jyothi Industries.
31, Pampa Mahakavi Road
Bangalore – 560 004 - Raylons Metal Works
Kondivita Lane
Andheri, Mumbai - Shanti Engineering Works
Figure of 8 Road
Coonoor – 643 101 - SIDVIN
78, 5th Main, Saraswathipuram
Mysore – 570 009 - M/s Bajaj Maschinen (P) Ltd.
7/20, 7/27, Jailaxmi Industrial Estate, Site IV
Sahibabad Industrial Area
Ghaziabad -201301
Email : bajaj@del3.vsnl.net.in / bajajmachines@vsnl.com
Web: www.bajajmachinen.com - M/s Narangs Corporation
P -25, Connaught Place
New Delhi -110001
Email: narangs@appexmail.com - M/s S.S.P. (P) Ltd.
13, Milestone, Mathura Road,
Faridabad- 121003
Email: sspgroup@del2.vsnl.net.in - M/s Marvel Machines Pvt Ltd.
140, Anna Salai, Saidpet
Chennai - 600015
Email: marvel12@vsnl.com - M/s Sasib (India) Pvt. Ltd.
B -30, Greater Kailash –I,
New Delhi -110048
Email: sasibnd@nde.vsnl.net.in - M/s Gee Gee Foods & Packaging Co. (P) Ltd.
B -188/2, Savitri Nagar,
Malviya Nagar
New Delhi -110017
Email: swantour@satyam.net.in - M/s D.K. Barry & Co. (P) Ltd.
11/35, West Punjabi Bagh,
New Delhi -110026
Email: dheerajbahry@rediffmail.com - M/s M. Son Industries
D -33, Sector 2,
Noida -201301
Email: mson@nda.vsnl.net.in
- M/s SAK Simpex (India)
B -5/ 160 (2 nd Floor), Safdarjung Enclave,
New Delhi – 110029
Email: saksimpex@yahoo.com - M/s Sanjivan Industries
A -13, Karimsheth Indl. Estate,
Wagdevi Nagar, Near Valishali Nagar
Dahisar (E), Mumbai -400068
Email: sanjivanind@roltanet.com - M/s Biotech & Food Systems (P) Ltd.
435 –P, Sector 14,
Gurgaon -122001
Email: dharamwal@yahoo.com - M/s Pharamalab India Pvt. Ltd.
Star Metal Compound,
LBS Marg, Vikroli (W)
Mumbai -400083
Email: mkt@pharmalab.com - M/s Larsen & Toubro Ltd.
L &T House, Ballard Estate,
Mumbai -400001
Web: www.larsontoubro.com - M/s Shiv Engineers
Patel Avenue, Plot No. 165,
Flat No.1, Right Bhusari Colony,
Paud Road, Pune -411038
Email: shivenginerrs@rediffmail.com - M/s Hightek Engineers
702, GIDC, Phase II, Gundiav,
Valsad -396035 (Gujarat)
Email: info@hightekengineers.com - M/s Geeta Food Engineering
Plot No. C-7/1, TTC Indl Area,
Pawane MIDC, Thane –Belapur Road,
Behind Savita Chemical
Navi –Mumbai -400705
Email: geetafoodengg@yahoo.co.in - M/s Bombay Industrial Engineers
13, Crystal Apartments,
Gulmohar Cross Road,
11, JVPD
Mumbai -400049
Email: ijsehgal@bom5.vsnl.net.in
Contact for more information
Information Manager
TIMEIS Project
E-mail: timeis@ficci.com
