PROJECT REPORT OF POTATO CHIPS- TINY UNIT

Manufacturing Potato chips - Rural Industry (Tiny Unity)

Chips are the most popular variety of snacks on various occasions. Besides being salty,

spicy or flavored, consumer preference is always for fresh quality. Potato and banana chips

are popular processed food items resulting in substantial value-addition.

Potato Powder is one of the oldest commercially processed vegetable products. It is very widely used in the baking industry all over Europe, USA, far Eastern countries and Middle East, although its growth has not kept pace with other processed products of potato. In India it is used in baking industry and as a thickening agent in the soups.

Chips are the most commonly consumed first generation snack foods. They are used as snack food both in domestic as well as in fast food centres and restaurants as side dish and garnishers. Moreover, the product can be safely stored for upto six months without any change in quality.

Market Opportunities

There exists a very large market for chips and they can be sold at various retail outlets, paan

shops, bus-stands, railway stations, roadside eateries, etc. There also exists institutional

market consisting of clubs and other institutions, school & college canteens, army

establishments, bars & pubs, railway and airlines caterers, etc.

Competition from organised sector is increasing but local and small units have distinct

advantages in terms of less overheads and transportation costs, longer shelf life, quick

access to market and cost.

Technical Details:

The manufacturing process using potato powder is briefly summarized below:

- Potato powder of suitable fineness is mixed with various ingredients,

- This powder is cooked and extruded into sheet.

- Products are sheeted, rotary cut and fried.

- Uniform size shapes are die-cut from extruded sheet where low pressure extrusion provides a variety of shape with consistent density and continuous operation.

- Controlled temperature continuous frying is done to get uniform quality and golden yellow

appearance with consistent Crispy taste.

- Automatic packaging in Nitrogen filled moisture proof boxes or in colorful Multilayer Plastic film Pouches for longer shelf life.

- Packing of Pouches and boxes in Cartons for Marketing.

Another technique used for production of fabricated potato chips is thru using farm fresh potatoes, the process of which is briefly summarized below:

- As per the company norms the potatoes bought from farm are made to pass thru a quality test.

- The potatoes are then passed thru a conveyor where they are de-stoned and then peeled.

- The peeled potatoes are then washed with cold water.

- A slicer then cuts the potatoes into thin slices. The slices are again washed in cold water in order to purge any released starch content.

- The slices are then passed thru a chemical solution in order to augment its colour if required.

- The slices are then fried and salted, and passed through a conveyor belt so as to drain excess oil.The chips are then cooled and sorted.

The figure below shows the whole process in sequence.

Chips: Harvesting => Receiving => Washing => Peeling (manual) => Slicing => Removal of excess water => Frying => Mixing of salt and spices => Cooling => Packaging => Transport => Marketing

It is very well established and simple. It involves visual inspection and sorting of damaged potatoes and bananas and washing them in water. Then they are peeled and trimmed before slicing or cutting them to the required size. Then they are once again washed and dried. They are then fried and either salt or other spices/flavours are mixed homogeneously. After cooling them, they are packed in pouches or plastic bags

Varieties of Potato suitable for chips -

Kufri Chipsona - 1, Kufri Chipsona - 2, Kufri Jyoti and Kufri Chandramukhi.

1 Name of the Product :                                     Potato Chips/Wafers

2 Project Cost :

a Capital Expenditure

Land : Own

Building Shed 500 Sq.ft :                                      Rs. 100000.00

Equipment :                                                         Rs. 150000.00

(Boiler,Steam Jacketted Kettle, Potato Peeling

Machine, Pouch Sealing Machine, Frying Pan)

Total Capital Expenditure                                       Rs. 250000.00

b Working Capital                                                Rs. 88500.00

TOTAL PROJECT COST :                                     Rs. 338500.00

3 Estimated Annual Production of Potato Chips/Wafers :                                         

Potato Chips / Wafers 118 Quintal@ Rs. 3000.00     Rs. 354000.00

4 Raw Material:                                                        Rs. 100000.00

5 Lables and Packing Material :                                Rs. 50000.00

6 Wages (Skilled & Unskilled) :                                 Rs. 42000.00

7 Salaries :                                                             Rs. 60000.00

8 Administrative Expenses :                                     Rs. 20000.00

9 Overheads :                                                         Rs. 30000.00

10 Miscellaneous Expenses :                                   Rs. 5000.00

11 Depreciation :                                                    Rs. 20000.00

12 Insurance :                                                        Rs. 2500.00

13 Working Capital Requirement :

Fixed Cost                                                            Rs. 120000.00

Variable Cost                                                       Rs. 233505.00

Requirement of WC per Cycle                               Rs. 88376.00

Note: Project cost is subject to location and  Production Process.

Name of the Machine Manufacturer:

SSP Limited

Address: l9-DLF Industial Area, Phase-II, l3l4-Mathura Road

Faridabad, Haryana-l2l 003 (INDIA)

Phone : +(9 1 )-( I 29) -227 5441 /227 7 7 30

Fax: +(9 I )- (129)-2s27 7 44 |

Email : info@sspindia.com

Hovert Impex Pvt.Ltd.

3704[E, P-hase IV, G.I.D.C., Vatva,

Ahmedabad - 382 445. India

Phone : 9I-79-5840127,

Bajaj Machinery Pvt. Ltd.

C-582, New Friends Colony

Phone: (9 1- I 1) 217 ll5l, 226 5326

Chhatariya Food Pvt Ltd

Mahuva,BhavNagar Gujarat

Phone: 02844-2238

Archana Machinery Stores,

Guwahati

East End Engineering Company

173/1, Gopalrai Thakur Road,

Kolkata 700035.

Tel. No. 25773416/6324

HANDMADE PAPER PROJECT FOR BANANA FIBRE

HANDMADE PAPER UNIT BASED ON BANANA FIBRE

The Handmade paper Industry has become more popular because of its eco-friendly nature and has a significant impact for growing forest and preserving the greenery. The water and air pollution is also negligible. The export of handmade paper is increased in multiples with the growing awareness in developed and developing countries. In recent years handful number of handmade paper manufacturer become major export oriented units. These units are exporting handmade paper & its products to several countries. The demand of handmade paper is increasing day by day in domestic as well as in international market.

Several varieties of Banana are cultivated in the country. The plants are cut down as soon as fruits are harvested for extraction of fibre. Banana fibre has great potentialities for paper making because of its high alpha-cellulose and low lignin content.

Banana fiber is a multiple celled structure. The lumens are large in relation to the wall thickness.Cross markings are rare and fiber tips pointed and flat, ribbon like individual fiber diameter range from 14 to 50 microns and the length from 0.25 cm to 1.3 cm, showing the large oval to round lumen. Banana fiber is a natural fiber with high strength, which can be blended easily with cotton fiber or other synthetic fibers to produce blended fabric & textiles. It is mainly used by cottage industry in Southern India at present. Banana Fiber also finds use in high quality security/ currency paper, packing cloth for agriculture produce, ships towing ropes, wet drilling cables etc.

Banana fiber is the best natural fiber. It has its own physical and chemical characteristics and many other properties that make it a fine quality fiber.

• Appearance of banana fiber is similar to that of bamboo fiber and ramie fiber, but its fineness and spin ability is better than the two.

• The chemical composition of banana fiber is cellulose, hemicellulose, and lignin.

• It is highly strong fiber.

• It has smaller elongation.

• It has somewhat shiny appearance depending upon the extraction & spinning process.

• It is light weight.

• It has strong moisture absorption quality. It absorbs as well as releases moisture very fast.

• It is bio- degradable and has no negative effect on environment and thus can be categorized as eco-friendly fiber.

• Its average fineness is 2400Nm.

• It can be spun through almost all the methods of spinning including ring spinning, open-end spinning, best fiber spinning, and semi-worsted spinning among others.

Process of Manufacture:

• Banana fiber soaked around 1 day(20-24 hrs) into the water.
• The extracted banana fibre cooked with mild alkali (8% NaOH) around 2 hours and Bleaching done through O2 diglinification+hypochlorite bleaching.
• Cooked  through chemical (.05% EDTA+8% NaOH+2% H2O2)  around 4 hours and washed fibre converted into pulp with help of mechanized beater.
• A sheet of pulp is formed over mould by hand then wet paper sheet couched onto a cloth which acts as a interleaf separating the wet sheets.
• A pile of the wet sheets then pressed and excesses water is removed from the wet sheets.
• The pressed sheets are peeled and separated from the cloth and loft dried on Taosuki 0r natural drying.
• The dried sheets are calendared for smoothness and then cut into a required.

Project Cost (Annually) :

Fixed Cost-

Work shed 1000 Sq ft.                                                            - Rs. 2.0 Lacs

Equipment                                                                              - Rs.  10.0 Lacs                                     

(Fiber Cutter , Paper-making Vats, Rotary Digested, Steam Boiler Non

IBR, Beater (18"x24"), Taoshuki. Paper cutting Machine)

Total Fixed Expenditure                                                            - Rs.  12.0 Lacs                                             

Working Capital                                                                      - Rs.  5.0 Lacs

Total Project Cost                                                                    - Rs. 17.0 Lacs

Total  Production (Handmade Paper)                                        -Rs 30.0 Lacs

Net Profit                                                                                 -Rs 13.0 Lacs                                  

Salary and Wages                                                                    -Rs 7.0 Lacs

Raw Material                                                                              -Rs 20.0 lacs

Labels and Packing & Transportation                                       - Rs.  1.0 Lacs

General & Administrative Expenses                                          -Rs  1.0 Lacs

Variable Cost                                                                            - Rs 29.0 Lacs

Requirement of WC per Cycle                                                   - Rs  5.0 Lacs

Note: Cost varied location and size of project and Variety of banana fiber used.

HANDMADE PAPER MAKING IN INDIA

Handmade Papers Making

The social, intellectual and industrial progress of a modern society is interwoven with the usage of paer and paperboards. The global paper industry is capital intensive and resource based. Paper manufacture is one of the most energy intensive industrial processes. In India, total indigenous production of paper and paper products are 4.1 million tons in 1999-2000 by 380 paper mills. The current per capita consumption of paper in India is 3.8 kg. and is expected to more than double at 7.9 kg paper and paper products will increase at a rate of 5% at every phase of human development.

The hand made paper production is an age-old process in India. At present there are about 3260 units producing Rs 53456 Lacs of paper, board and paper fancy items by providing employment to 40000 persons. The usual paper making process in a mill is highly polluting. The black liquor generated by pulping, bleach and boiler emission are great problem for the paper industry, while hand made paper (HMP) making is based on a clean process with negligible or very litter pollution. Thus HMP industry is a sunrise industry with a remarkable increase of about 150% in annual production.

Handmade paper is a sheet of paper or board produced by hand. If the sheet is formed by

means of a cylinder mould and vat or on a fourdiner table, it cannot be called a handmade

paper even if the subsequent operations are carried out discontinuously. It should,

however, be noted that the Khadi and Village Industry Commission (KVIC) includes

paper and boards made in the cylinder mould machine (CMM) with a definite maximum

deckle width of up to 102 cm. The All India Khadi and Village Industries Board was

established in 1953 and it includes the handmade paper industry in its development

program. The above board later became the Khadi and Village Industries Commission

(KVIC), which further encouraged this industry through financial assistance and

technological assistance such as introducing new equipment, new techniques, developing

new varieties of paper, utilizing locally available diverse raw materials and helping

entrepreneurs in their marketing efforts. The handmade paper units also enjoy several

fiscal concessions and incentives such as central excise duty and sales tax exemptions in

some States (6). Due to the above supporting program of the KVIC the number of

handmade paper units grew from 35 in 1953 to more than 350 In 1993-94. In 1953, the

value of handmade paper production was hardly Rs. 500,000 but it was more in 1993

than Rs. 150 million. The employment potential of the handmade paper industry is large.

It employs 7,500 people of whom 50% are women. The total wage bill amounts to over

Rs. 42.5 million.

Paper Characteristics & Paper products

The range of paper and board products can be classified into types and grades: types relate to the paper or board machine design, and the grades are the function of the end  use of the product and the choice of materials. The types, grades and uses of papers manufacture depending on its fibre characteristics such as strength and optical characteristics, processing methods and type of paper machines and their configuration. The types of paper or board can vary according to end- use. There are four distinct grades of paper and board.

Machine glazed (M.G.) paper and Board

This grade of paper or board is obtained by pressing the moist material firmly against the surface of a drying calender. The moist paper adheres to the cylinder surface until it is dry enough for separation.

Creped papers

The M.G. machine can be used to produce creped paper. This can be done with addition of a scraping blade, which removes the paper from the cylinder before it is dry enough for natural separation. The most important area of paper application are as writing paper, cards, boards etc. (Newsprint, coated printing & writing, un-coated printing & writing, tissue & sanitary, packaging & industries and boards etc.)

Improvement in Handmade Paper Making

For improvement in sheet formation of thinner grades of paper, the use of formation aids

should be taught to the papermakers. The formation aids could be either synthetic

chemicals or preferably vegetative mucilages. The vegetable mucilage controls the fibre

dispersion as well as the drainage rate. Mucilage of Cactus (Opiuntia belloni) has been

tested with good results.

In the present work various locally available plants materials such as the seed of the Ban

Tulsi seed, the wild variety of Bhindi (Ambrettie) etc. are identified and their efficacy on

various fibres is being graded. Ambrettie used with jute and rag fibres have shown very

good results. Similarly, the ban tulsi seed imparts good drainage characteristics. These

aids also improve fibre retention, hence the loss of fibre reduces by up to 50%. Research

is also being carried out on the treatment of the final effluent by water hyacinth and

natural polyelectrolytes. The possibility of reusing treated water is being studied so that

“Zero effluent Mill” status can be achieved.

Handmade Paper Training Institutes:

• Any of KVIC units in the region.
• Kumarappa National Handmade Paper Institute  (KNHPI), Sanganer, Jaipur;
• Jamnalal  Bajaj Central Research Institute (JBCRI) in 1955 in Wardha,  Maharashtra
• Khadi Ashram, Ram Nagar, Karnal, Haryan
• Dr. Vatsala, MCRC, Turanani, Chennai
• Dr. H. Sudershan, VGKK, BR Hills, Chamraj Nagar (Distt.), Karnataka.
• Aurobindo  Ashram, Auroville, Pondicherry.
• Shri AMM Murugappa Chettiar Research Center (MCRC), Chennai

PRODUCTION PROCESS OF HANDMADE PAPER IN INDIA

Handmade Paper Production

Paper is generally defined as a single ply, flat material, varying in density and material content according to end use. Paper is a cellulose material amended with different additives, which form a cohesive sheet with desirable paper qualities. Paper can be made from many different plants, which contain adequate amounts of cellulose fibres. Board is defined as a multiply bound material, which normally has a greater density than the paper. The cellulose, in the strong and durable form of elongated tubular fibres is the basic substance of paper. Paper can be made from many different plants which contain adequate amount of cellulosefibres.

In paper manufacturing the fibrous portion of the plants are reduced to pulp by chemical or biological action followed by mechanical process of grinding. Paper is made by deposition, from a dilute water suspension of pulp, an even layer of cellulose fibre on fine screen that permits the water to drain through but retains the intermingled particles of cellulose. This layer of fibres, removed from the screen and finally pressed and dried, becomes a sheet with cohesive strength and associated properties that we recognize as paper. The characteristic quality of the paper produced depends on the colour, length, diameter, flexibility, strength and other related properties of the fibres used.

Fiber used for Handmade Paper Making:

The principal factors that determine whether a plant shall or shall not be used in manufacture of paper are suitability of fibre, dependability of supply, cost of collection, transportation and preparation and tendency to deteriorate in storage.

Seed hair fibre- cotton, silk-cotton, hemp, jute, flex etc.

Stem fibre - corn, sugarcane, bamboo, straw etc.

Leaf fibre - Aloe fibre, pineapple leaf fibre, palm etc.

Fruit fibre - Coconut

Wood fibre- Spruce, cedar, maple etc.

Waste papers -Shredded currency waste, office records, press cuttings etc.

The principal factors that determine whether a plant shall or shall not be used in manufacture of paper are suitability of fibre, dependability of supply, cost of collection, transportation and preparation and tendency to deteriorate in storage.

Handmade paper production requires low capital investment, can easily set up in rural areas and thus can be used to encourage local entrepreneurship. The industry is environment friendly and non-polluting and units can even specialize in the production of a particular type of handmade paper. These units can be used as a means to create employment opportunities in the rural areas. The production of handmade paper does not require skilled labour and local population especially women can be absorbed in this industry. The difference in cost of production of mill-made paper and handmade paper is marginal.

The process of making handmade paper involves a series of steps that are briefly discussed below.

Sorting and dusting: the raw material that is to be used is manually sorted and foreign material like buttons; plastic, synthetic fibres etc. are removed. To remove dust and dirt the material is shaken vigorously.

Rag Chopping: The sorted and dusted material is chopped into pieces of equal size.

Beating: The raw material is mixed with water and harmless chemicals and beaten in a Hollander beater. This consists of a U-shaped trough, with a drum; on the outer side of this drum are iron blades that cut the raw material to make a pulp out of it. There is a washing drum as well that cleans the pulp and drains the dirty water. The quality of the paper to be made determines the consistency of the pulp.

Sheets of handmade paper can be made in two ways.

Dipping Method: This method is normally used for fine or thin paper. The pulp is diluted with water and put into a masonary trough or vat. The lifting mould (a mesh on a wooden frame) is dipped into the trough, shaken evenly and lifted out with the pulp on it. The consistency of the pulp in the tank should be kept constant all the time.

Lifting Method: This method is used for all paper and especially for card paper. A fixed quantity of pulp is poured evenly onto a mould, which is then clamped between two wooden deckles (frames) and then dipped into a water tank. The mould in then lifted using a lever mechanism that allows the excess water to drain away.

Couching: Once the sheet is formed, the wet paper is transferred onto a cloth like muslin or felt sheet and a stack of interleaved sheets in made.

Pressing: A hydraulic press is used to remove the excess water from the sheets. Pressing reduces the thickness of the paper and the sheets become more compact. This process improves the physical properties of the paper and helps drying.

Drying: Even after the sheets have been pressed, they still contain about 50% to 65% of the moisture. The sheets are hung in the sunlight to dry. Solar dries can speed up the process and the space required for drying. Coloured papers are dried in the shade to prevent the sun from bleaching the colour.

Cleaning and Sizing: Small particles of dirt and other foreign matter are removed manually with a sharp instrument. The cleaned sheets are coated with a layer of starch to improve the quality of the paper and prevent feathering. This process is called sizing. This can be done manually using a brush or by dipping the sheet into a vat containing sizing chemicals.

Calendering: The sheets are then placed between metallic plates and passed through spring-loaded rollers in a calendaring machine. This makes the paper smooth and increases the gloss of the paper.

Cutting: The sheets are cut neatly according the required size using a cutting machine.

Raw Material used in Handmade Paper making:

S.NO.	RAW MATERIAL	PROCESS	CHEMICAL USED	CONDITIONS	AVAILABILITY	REMARKS
1	Rag	Cooking Bleaching	3-4% NaOH, 6-8% Na2CO3 or 15%Ca(OH)2 Hypochlorite+ lime or H2O2+Na2CO3 +Na2SiO3	6-8 hrs. 130-1400C Bath ratio-1:3 2-2.5 hrs	White and new rags, old whites, threads and color rags from cotton textile industry, tailors, denim fabric industry and hosiery market	Soda silicate can be used up to 40%, when NaOH is being used 80% brightness can be achieved Ledger paper, Filter paper, Drawing paper, Bible or Skin Paper
2	Cotton linters	Pressure Cooking	6-8% NaOH	2-4 hrs. Bath ratio-1:3	Cotton mills	Very high tear strength
3	Jute and Kenaf	Pressure Cooking Open Cooking	NaOH+Na2SO3 as 14% Na2O NaOH+Na2SO3 as high as 20% Na2O	4 hrs. 160-1650C 8-10 hrs.	West Bengal, Bihar, Assam	High strength but very low brightness. Shopping bags, cover, tags, folders etc.
4	Kenaf and Mesta	Open Cooking	15% NaOH+ 5-10% H2O2	2hrs. Bath ratio-1:10	Andhra Pradesh, Orissa and Tamil Nadu	High tensile strength and brightness level upto 65% IS0
5	Sun Hemp	Pressure Cooking	NaOH+Na2SO3	-	Uttar Pradesh	Used in tissue and cigarette tissue paper
6	Common Hemp	Pressure Cooking Bleaching	20% NaOH Hypo, chlorination and then hypo	4hrs. 1450C Bath ratio-1:5 -	-	Herbaceous and dioecious plant Produced in India for narcotic as well as medicinal values 80% ISO brightness
7	Sisal	Open Cooking	-	1hrs. Bath ratio-1:8	Orissa, Kerala and Karnataka	Dark in color but impart high porosity and absorption capacity
8	Banana	Soaking Pressure cooking Bleaching Open cooking	Water 8% NaOH O2 diglinification+ hypochlorite bleaching .05% EDTA+8% NaOH+2% H2O2	20 hrs. 2hrs., 1350C Bath ratio-1:6 4hrs. Bath ratio-1:6	Maharashtra, Kerala and Andhra Pradesh	Extremely thin transparent like papers, good quality strong tissues and decorative papers. Banana pulp is superior to Rag pulp
9	Ankhada	Soaking Bleaching	15% Na2CO3 30% Na2CO3 1%hypo	70 hrs., 400C 139 hrs., 400C	Gujrat, Punjab, Bihar and Rajasthan	94% yield and 49% ISO brightness 94% yield and 55% ISO brightness 75% ISO brightness so it is possible to produce TCF pulp
10	Waste paper	Soaking	Mild dose of NaOH and deinking chemicals	12 hrs.	Pulp substitutes and high grade deinking waste	Admix with other high strength pulps

Handmade Paper Training Institutions:

• Any of KVIC units in the region.
• Kumarappa National Handmade Paper Institute  (KNHPI), Sanganer, Jaipur;
• Jamnalal  Bajaj Central Research Institute (JBCRI) in 1955 in Wardha,  Maharashtra
• Khadi Ashram, Ram Nagar, Karnal, Haryan
• Dr. Vatsala, MCRC, Turanani, Chennai
• Dr. H. Sudershan, VGKK, BR Hills, Chamraj Nagar (Distt.), Karnataka.
• Aurobindo  Ashram, Auroville, Pondicherry.
• Shri AMM Murugappa Chettiar Research Center (MCRC), Chennai