Bread Factory Set up Idea

Introduction
Bakery Industry is one of the fastest growing segments of food processing industry in our
country. Bread, an important bakery product of mass consumption, has become an important
nutritional food item in cities and towns. It has also played a vital role in popularizing wheat
in traditionally non-wheat consuming areas of the country.

Product
Bread is a fast and convenient food based on wheat. There are many varieties of bread
depending upon the local demand like whole flour bread, brown bread, bread fortified with
vitamins & minerals, milk bread and bread for diabetic patients. It can be produced in
different sizes and shapes.

Market
Bread is mainly consumed in metres & mini-metros, major towns and areas of industrial
townships. Due to fast life and increase in standard of living the demand for breads is
growing very fast, particularly with more and more women going out for work. Our per
capita consumption of Bakery products is minimum in the world i.e. 1.27 kg against 50-70 kg
in advanced countries. This leaves for substantial scope for bakery industry
Standards and Specifications

Suggested Capacity
The minimum economic capacity of a unit manufacturing breads is 36 lakh loaves of 400
gms each per annum based on a single shift operation of 300 days working schedule in a year.

Land and Building

The unit may require about 1,000 sq.m. land with a covered area of about 600 sq.m. for
setting up this project. Although in the cost of the project below it is proposed to purchase
land and construct building, the unit should preferably acquire the land and building on rental
basis.

Manufacturing Process
In Bangladesh straight dough method is used for making yeast-raised bread. All the
ingredients are mixed together before fermentation. A typical mix of ingredients for bread
consists of:
1. Flour
100.00kg.
2. Water
64.00kg.
3. Sugar
4.00 kg.
4. Salt
2.00kg.
5. Shortening or ghee
4.00 kg.
6. Compressed yeast
1.20kg.
7. Skimmed milk powder
4.00 kg.
Mineral yeast food or dough

conditioner

0.35 kg.

A loaf of 400 gms requires about 270-275 gms flour and corresponding amounts of other
ingredients. First yeast suspension in a portion of water and sugar is made. Sugar, salt and
yeast food are mixed with water. Flour mixed with milk powder is mixed into it. After short
mixing yeast suspension is added. Shortening is added any time after the flour has been
wetted and the dough has been formed. Mixing is continued until the mass becomes smooth
and elastic and does not stick to the bowl. Mixing takes about 20-30 minutes, overmixing
should be avoided.
The dough is then allowed to ferment, at about 27C and 78 per cent relative humidity, to
the desired extent. The dough is divided into uniform pieces of the desired weight (450 gms}.
The dough pieces are rounded using a machine (rounder). The rounded dough is allowed to
rest before being formed for panning. This time is called intermediate proofing (8-15
minutes), during this time dough recovers from being divided and rounded. The dough pieces
are moulded (or shaped) so that they may form loaf of the desired shape.
The pieces are put in greased pans. The pans are put in proof box at about 37C and 88
percent relative humidity to get the right extent of final proof. This usually takes about 60-70
minutes. The pans are next placed in an oven and heated to 205-230UC. The baking time
depends on the size and shape of the loaf and its sugar content. When the crust of the bread
assumes a brown colour the pan is taken out from the oven. The baked loaves are brushed
with butter to give glaze and prevent cracking of the crust. The loaves are allowed to cool and
sliced on a slicing machine and wrapped in a waxed printed paper
which is then heat sealed.

Raw Materials
The annual requirement of main raw materials for the manufacture of 36 lakh loaves of bread
(400 gm each) per annum at 100% capacity utilisation is estimated as follows:
1. Wheat flour
695.00 M.T.
2. Sugar
28.00 M.T.
3. Salt
14.00 M.T.
4. Vegetable oil
28.00 M.T.
5. Yeast
7.56 M.T.
Mineral yeast dough conditioner, vitamins,
other chemicals, waxed paper, etc as reqd

Utilities
The unit may require a total connected load of about 30 KVA and a maximum demand load
of about 25 KVA. Its annual requirement of water is estimated at about 12,000 KL.

Plant and Machinery

The main items of equipment and machinery
required for setting up this project are as follows:
1.Auto Flour sifters
2.Dough kneaders, capacity 100 kg
3.Hand dividers, capacity 400 gm (500-800 loaves per hour)
4.Moulding machine

5.Electric ovens, cap. 1 ton/day

6.Bread slicing cum sealing machines, cap. 400-500 loaves/hr.
7.Platform type weighing scale, 0-100 kg cap.
8.Counter scales, cap. 0-2 kg.
9.Other miscellaneous equipment e.g. vessels, trays, pans, work tables, cooling racks,
laboratory equipment, etc

Personnel
The unit may provide employment to about 33 persons including factory workers and staff
for factory supervision, administration and sales, and watch and ward, etc.
Estimated Cost of the Project
The cost of a 24657.53 loaves per annum capacity bread making project is estimated at
Rs. as follows:
1. Land and site development
2. Buildings
3. Plant and machinery
4. Technical know-how and engg. fees
5. Misc. fixed assets
Preliminary and preoperative
expenses
7. Margin money for working capaital
8. Contingencies
TOTAL

$ 6849.30
$ 32876.71
$47945.20
$4109.58
$6849.30
$4109.58
$10958.90
$5479.45
$119178.08

Suggested Means of Financing

1. Long term loans from financial
institutions
2. State cash subsidy
3. Promoters capital
TOTAL

$79452.49
$15068.49
$ 24657.53
$119178.08

Subsidy is taken as 15% of the Fixed Capital Investment, however it varies from state to
state, ranging from 10% to 25% depending upon the category of identified backward area.