Project Profile

PULSE MILL
Capacity 25000 TPA
Project Profile Pulse Mill (Large)

PULSE MILL
SECTOR: AGRO AND FOOD PROCESSING UNIT CAPACITY (PER ANNUM): 25000 MT
NO. OF WORKING DAYS: 250 DAYS COST OF PLANT AND MACHINERY: RS.680.0 LAC
COST OF PROJECT: RS.1687.58 LAC IRR: 17.03 %

Project Description

In the proposed project, Whole Pulses are processed to produce Split Pulses (commonly
known as Dal), which is also at times De-skinned and Oiled for ease of cooking and better
preservation. Commonly processed Pulses are Chana (Gram), Mung, Massor, Urad and Arhar
(Tur), which are important part of staple diet in all state of India. Proposed project will have
100 TPD capacity in 3 shift operation, and considering average 20 hours working per day, the
proposed plant will have 5 MT per hour processing capacity.

About Product

Pulses splits commonly called ‘dal’ in India are essential components of the diet for both
vegetarians and non-vegetarians. Split Pulses constitute one of the main sources of
protein in Indian staple food. The common varieties are: Chana (Gram), Mung, Masoor,
Urad and Tur (Arhar) dal. Out Of these, Chana (Gram) Masoor and Mung dal are
predominantly consumed in the North, Central and Eastern India regions. Chana, Arhar,
and Mung Dal are consumed in Western and Central India regions, and Urad, Arhar and
Mung dal are mainly consumed in Southern India region.

During Pulse milling process, grains are split into two halves (Split Pulse) and as further
processing Split Pulse’s skin is also removed, which renders it even more suitable
(convenient) for cooking or wet milling.

Product Applications:

Output from this project will be Split pulses (Dal), natural, de-skinned and Oiled in some
case and small quantity of broken pulses will be produced as bye product of Pulse Mill
operation. Split Pulses finds their direct use as staple food in house hold, bulk catering,
restaurants, Mid Day Meal schemes and preparation of various Food Items snacks /
sweets, and staple food items made from them.

Market Potential

The all India per capita consumption of pulses is about 2.8 kg per year. In the North and
Eastern and Central India consumption of pulses is generally higher. In Western and
Southern India consumption of split pulses is comparatively lower, as there is also Wheat
and Rice, along with Green vegetables used as major part of staple diet. Pulses / split
pulses consumption has also been affected due their irregular supply, high import /

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Project Profile Pulse Mill (Large)

processing cost and use of substitute products. Considering national average of 2.8 kg /
year and population of 110.0 Crore, the estimated demand for pulses / split pulses is
approx. 30.8 Lac MT per annum. At conservative estimate also, there is demand of
approx.25.0 Lac MT/p.a, out of which almost 60% is met from domestic crop and 40 % is
met through import of pulses from various countries.

Manufacturing Process

The stones and foreign matter are removed and the pulse is graded in 2-3 different size
grades through sieves. It is soaked in water for 60-90 minutes and heaped for uniform
moisture absorption and dried in the sun for 2-3 days till fully dried. It is fed into mini dal
mill at 90-100 rpm. The split dal falls in the cone chamber from control plate, which is
separated into whole dal, broken and husk through an aspirator. The fractions are packed
separately. The Mini dal mill can mill Bengal gram, Bokla, Kesari, Pea, Soybeans pigeon
pea in a single operation at 100-130 kg per hour. Lentil (masoor) is milled in 2 operations
with output of 100-125 kg/hour. Black gram, green gram and moth beans are milled with
double operation with output of 60-80 kg dal/hour.

The important steps involved in the Manufacturing Process are –

1. Cleaning
2. Milling
3. De-husking and cleaning and applying Oil in some Dal
4 . Weighing and Packing

Quality Control and Standards: As per AGMARK

requirements Raw Material Requirement

As indicated in the Manufacturing process Flow chart, to produce 1 MT of Split pluses

estimated input requirement is of whole Pulse grain is 1.2 MT, and on this basis the
proposed project will have Raw material requirement of 30000 MT per annum.

Estimated Cost of Project and Means of Finance

As per survey conducted by ICAR-a Govt. of India body, average size of pulse mills in last
one decade is 100 to 500 TPD, and hence proposed capacity is justified in terms of Raw
material availability also.

Major Fixed Assets required includes Land, building and plant and machinery for the
proposed 100 TPD Pulse Mill project are as follows:

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Project Profile Pulse Mill (Large)

Sr. Particulars Quanti

No. ty
1 Land Required for 100 TPD Pulse Mill 10000
Sq.mtr

2 Built up Area for Manufacturing and Storage (WIP +RM) + Office+ QC lab 2500
and Workshop / engineering stores/ security cabin etc; Sq.ntr

3 Plant and machineries including cleaning / packing line 2000

Sq.mtr

a) Utilities:

UTILITY Requirement Units

WATER 100 KL per day
ELECTRIC POWER 250 KWh
ETP 20 KL per day

Estimated Cost of Project

(Rs in Lac)
SR. NO. ESTIMATED COST OF PROJECT AMOUNT RS. IN LAC
1 Land and registration charges. 200.01
2 Building and Civil Works 300.00
3 Plant and Machinery 680.02
4 Misc. Fixed Assets 50.00
5 Preliminary and Pre Operative 90.00
6 Provision for Contingencies 80.00
Total Fixed Assets 1400.03
7 Margin Money for working Capital 287.55
Total Cost of Project 1687.58

SR. NO. MEANS OF FINANCE AMOUNT

1 Promoters Contribution 600.00
Unsecured Deposits 104.06
2 Bank Finance (Term Loan ) 933.52
3 MOFPI Subsidy 50.00

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 Project Profile Pulse Mill (Large)

SR. NO. MEANS OF FINANCE AMOUNT

Total 1687.58

Working Capital Estimate for 1st Year

SR. WORKING CAPITAL ESTIMATES IN DAYS AMOUNT RS IN LAC

NO.
1 Raw material 12 540.00

2 Work in Process 3 135.00

3 Finished 6 252.00
Sub Total 21 927.00
4 Debtors (Net of creditor) 5 223.20

5 Net Working Capital 26 1150.20

6 Margin for working Capital @ 25 % 287.55

Project Time Line

Project implementation will take a period of 8 to 10 months. Break-up of the activities

and relative time for each activity is shown below:
 ➢ Scheme preparation and approval : 01 month
 ➢ SSI provisional registration : 01 months
 ➢ Sanction of financial supports etc. : 2-3 months
 ➢ Building construction: 2-3 months
 ➢ Installation of machinery and power connection : 4-7 months
➢ Trial run and production : 01 month

Above time period is indicative, and many activities will be done concurrently and
considering that aspect overall time line of 8 to 10 months is indicated. This will be
critically dependent on availability of required resources for proposed project
implementation.

Conclusions:

Looking to the Techno-economic parameters of the proposed 100 TPD Pulses processing
unit (Dal) Mill, it has good potential in the area where required raw material is available.
Reasonably well estalished technology and indigenious plant and machineries are
available. Technical and managerial manpower is also available for such agro-processing
projects. On the basis of above analysis it can be assumed that suggested project is
Technically feasible and economically viable proposition, for a

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Project Profile Pulse Mill (Large)

potential entrepreneurs in PMFPL project area in general and Mega Food park in
particular.

PLEASE NOTE: This is Model Project Profile; the actual Cost of Project will change depending on the
Land and Building Prices, Actual Quote from the suppliers of the Plant and Machineries etc…