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J.R. Simplot, founder of his namesake company, who introduced the world to frozen french fries, died

J.R. Simplot, founder of his namesake company, who introduced the world to frozen french fries, died at his home in Boise, Idaho, May 25, at the age of 99. His was an all-American "rags to riches" story of a farm boy who grew up in a log cabin before striking out on his own to create an empire of businesses employing 10,000 people. Simplot was ranked

the 89th richest

American in Forbes magazine's 2007 list

($3.6 billion). He accomplished that, Forbes said, by seizing opportunities

others overlooked,

then perceiving how one success could lead logically to the next.

J.R. Simplot, founder of his namesake company, who introduced the world to frozen french fries, died
J.R. Simplot, founder of his namesake company, who introduced the world to frozen french fries, died
J.R. Simplot, founder of his namesake company, who introduced the world to frozen french fries, died
J.R. Simplot, founder of his namesake company, who introduced the world to frozen french fries, died

seizing opportunities others overlooked

J.R. Simplot, founder of his namesake company, who introduced the world to frozen french fries, died
Project report prepared by::Issam El Baba industrial consultant
Project report prepared by::Issam El Baba industrial consultant
J.R. Simplot, founder of his namesake company, who introduced the world to frozen french fries, died
After Poland — Romania occupies the second place in terms of potato acreage and total production.

After PolandRomania occupies the second

place in terms of potato

acreage and total production.

Situation and Outlook for

Frozen French Fries

After Poland — Romania occupies the second place in terms of potato acreage and total production.
Project report prepared by: Issam El Baba industrial consultant
Project report prepared by: Issam El Baba industrial consultant
After Poland — Romania occupies the second place in terms of potato acreage and total production.
Romanian Potato output

Romanian Potato output

Global potato trade volume

in tuber equivalent,

1986-2005

(million tones)

Fresh

Processed

Romania is one of the few European countries whose potato output is increasing: per-capita consumption has more than doubled since 1990, and

Romanian researchers are studying the potential use of potatoes as a source of

ethanol for fuel .

after PolandRomania occupies the second place in terms of potato acreage

and total production

Project report prepared by: Issam El Baba industrial consultant
Project report prepared by: Issam El Baba industrial consultant

Romania cartof

Romania cartof • Production: 3 705 694 tons • Potato imports : 140 000 tons • Romania cartof • Romania is among the world's top 20 potato producers. It is also one of the few European countries where potato production has actually been increasing - from 2.8 million tones in 1961 to more than 4 million tones in 2007 - while potato consumption per capita has more than doubled since 1990. • The cartof was introduced to Transylvania from Germany in the 1700s. Today it is an important crop for Romania's agriculture and national economy, and for the estimated 2.2 million Romanians who harvest tubers from their own small potato patches each year. • Almost all of Romania's potatoes are marketed for fresh consumption, with just 2 percent being processed. • In 2007, potato imports totaled more than 140 000 tones, while exports amounted to less than 5 000 tones. • Romanian researchers are exploring the potential of the potato as a source of ethanol for fuel - tubers produced in the southern zone of Romania under irrigation have yielded enough starch to produce around 4 000 liters of ethanol per hectare. Project report prepared by::Issam El Baba industrial consultant " id="pdf-obj-3-4" src="pdf-obj-3-4.jpg">

Production:

3 705 694 tons Potato imports:

140 000 tons exports:

less than 5 000 tons just 2 percent being processed.

Romania cartof • Production: 3 705 694 tons • Potato imports : 140 000 tons • Romania cartof • Romania is among the world's top 20 potato producers. It is also one of the few European countries where potato production has actually been increasing - from 2.8 million tones in 1961 to more than 4 million tones in 2007 - while potato consumption per capita has more than doubled since 1990. • The cartof was introduced to Transylvania from Germany in the 1700s. Today it is an important crop for Romania's agriculture and national economy, and for the estimated 2.2 million Romanians who harvest tubers from their own small potato patches each year. • Almost all of Romania's potatoes are marketed for fresh consumption, with just 2 percent being processed. • In 2007, potato imports totaled more than 140 000 tones, while exports amounted to less than 5 000 tones. • Romanian researchers are exploring the potential of the potato as a source of ethanol for fuel - tubers produced in the southern zone of Romania under irrigation have yielded enough starch to produce around 4 000 liters of ethanol per hectare. Project report prepared by::Issam El Baba industrial consultant " id="pdf-obj-3-22" src="pdf-obj-3-22.jpg">

Romanian processor

Romania cartof

Romania is among the world's top 20 potato producers. It is also one of the few European countries where potato production has actually been increasing - from 2.8 million tones in 1961 to more than 4 million tones in 2007 - while potato consumption per capita has more than doubled

since 1990.

The cartof was introduced to Transylvania from Germany in the 1700s. Today it is an important crop for Romania's agriculture and national economy, and for the estimated 2.2 million Romanians who harvest tubers from their own small potato patches each year.

Almost all of Romania's potatoes are marketed for fresh consumption,

with just 2 percent being processed.

In 2007, potato imports totaled more than 140 000 tones, while exports amounted to less than 5 000 tones.

Romanian researchers are exploring the potential of the potato as a

source of ethanol for fuel - tubers produced in the southern zone of Romania under irrigation have yielded enough starch to produce

around 4 000 liters of ethanol per hectare.

Project report prepared by::Issam El Baba industrial consultant
Project report prepared by::Issam El Baba industrial consultant

Potatoes - Did you know ?

Potatoes are originally from South

America and was grown there as long as

8000 years ago

In the high plateau regions of Bolivia and Peru, certain native potato varieties may be preserved for up to 10 years after undergoing a special drying process making them into chuño

In the United States, the world’s fourth- largest producer of potatoes, per capita consumption exceeds 54 kg of potatoes per year steamed, baked, sautéed, fried, mashed, scalloped, stuffed, and raw

Canada specializes in potato processing

to make frozen potato products, especially

frozen French fries that are exported mainly to the United States

In developing countries, only 1-3% of potatoes are processed, while in developed countries this figure can be as high as 60%

Egypt is the leading potato producer on the African continent

Latin America North America Africa

(in millions of tones)

Asia/Oceania Europe Production in 2006

15,624,716,4131,2126,3

Yield per hectare

(in tones)

in 2006

16,4240,6310,9514,3617,19

consumption in

Per capita

2005

(in kilos)

23,6557,9414,1825,8396,15

Project report prepared by: Issam El Baba industrial consultant
Project report prepared by: Issam El Baba industrial consultant

Potatoes - Did you know ?

Romania is one of the few European countries whose potato output is increasing: per-

capita

consumption

has more than doubled since

1990

South Africa has an advanced seed potato industry and a thriving potato processing industry which produces mainly frozen French fries and crisps

In Rwanda, potatoes are one of the staples of food security: consumption is very high (124 kg per capita), making it the country’s second-largest food crop and the second most important source of calories after cassava

China is the world’s leading potato producer (70.3 million tonnes in 2006, which is more than

20 percent of global output). Potatoes are both a food staple and a source of income, particularly for farmers in mountainous areas with less-fertile soils

Potatoes were introduced to India in the late 16th century. While it is not a food staple there, it

is a cash crop that generates significant income. India is now the world’s third largest potato

producer (24 million tonnes in 2006)

In Bangladesh potatoes are a winter crop. In 2006 the potato harvest was 4 million tones 12 times the 1961 harvest making Bangladesh the fifth-largest producer in Asia

During most of the 20th century, Europe led the world in potato output. Asia has since assumed this role, but seven European countries are still among the leading global producers (Russia is ranked second)

Europe has the highest potato consumption in the world (nearly 100 kg per capita per year). Belarus takes the honors with 340 kg per capita nearly one kilo per day

Romania is one of the few European countries whose potato output is increasing: per-capita consumption has more than doubled since 1990, and Romanian researchers are studying the potential use of potatoes as a source of ethanol for fuel

Project report prepared by:Issam El Baba industrial consultant
Project report prepared by:Issam El Baba industrial consultant

Prefeasibility study

Introduction

French Fries on menu,

Prefeasibility study Introduction French Fries on menu , is one of the easiest ways to increase

is one of the

easiest ways to increase sales and profits.

1.1 Introduction

Fast food sector is growing at 25-30 % annually due to rapid growth of fast food chain

both local and international ..

French fries are among the highest saleable potato products. This is the most abundant

processed food item and can be found in many varieties such as lattice cut, wedges, curly,

batter dipped, seasoned, or straight cut including French Fries on menu, is one of the

easiest ways to increase sales and profits for

the companies.

Project report prepared by: Issam El Baba industrial consultant
Project report prepared by: Issam El Baba industrial consultant

Prefeasibility study

1.2 Objective

The primary objective of the model report is to facilitate the entrepreneurs in understanding the importance of setting up unit of Potato

French Fries, technology and financial

parameters of various components for preparation and submission of project proposal to bank for sanction of long term loan.

This model report will serve as guidance to the entrepreneurs on starting up such a new project and basic technical knowledge for

setting up such a facility

Project report prepared by: Issam El Baba industrial consultant
Project report prepared by: Issam El Baba industrial consultant

Raw Material

• •

1.3 Raw Material Availability

The main requirement for manufacturing of potato French fries are the potatoes.

The price of potatoes in Romania was 324.12 $ MT (2006). Production was around 4 million tones. import was 140 000 tons .

Raw Material • • 1.3 Raw Material Availability The main requirement for manufacturing of potato French
Project report prepared by: Issam El Baba industrial consultant
Project report prepared by: Issam El Baba industrial consultant

Market Opportunities

1.4 Market Opportunities

The market of processed potato products is growing at

the rate of 15 to 20% per annum.

The estimates of trade sources and sector studies indicate a market share of about 30% of potato.

The main potato based products are French fries,

wedges, cutlets, chips etc. dehydrated potato products like flakes, granules and powder are also used in larger quantities in preparation of many products as the substitute of fresh potatoes.

Out of above mentioned products, this section of report

will discuss the domestic and international markets for French fries, wedges and potato flakes, as these are the high value products with high growth rate and high

demand in domestic and international market among all.

Project report prepared by: Issam El Baba industrial consultant
Project report prepared by: Issam El Baba industrial consultant

The international market

1.4.1 International market

Total World trade of potato fries is estimated at 2.9 Million MT for 2008/09.

Netherlands Canada, and USA are the major players contributing more than 90%.

During the past 10 years. The quantity and value of

frozen fry exports have consistently increased.

The major French fries and frozen food importing countries are East Asia countries, where the number of quick service restaurant has expanded significantly

In the year 2008-2009, East Asian countries accounted for over 80% of fry exports.

Japan accounted highest imports of fry shipments followed by china, Hong Kong, Mexico and Taiwan and

Republic of Korea.

Project report prepared by: Issam El Baba industrial consultant
Project report prepared by: Issam El Baba industrial consultant

Domestic market

Domestic market • 1.4.2 Domestic market • The frozen French fries market in Romania is in
Domestic market • 1.4.2 Domestic market • The frozen French fries market in Romania is in
Domestic market • 1.4.2 Domestic market • The frozen French fries market in Romania is in

1.4.2 Domestic market

The frozen French fries market in Romania is in a nascent stage but is growing at the rate of about 25% per year.

The percent organized market for frozen French fries in Romania is estimated at over 3500 tons/

annum, mostly contributed by imported French fries.

There are also some Quick service food chains, and individual large restaurants making French fries for captive consumption.

A number of restaurants make fries using fresh

potatoes. These restaurants are apparently making

own French fires due to irregular supplies and high prices of imported fries. With affordable price and regular supplies, which a domestic producer will be in

a position to organize, the volume will certainly

increase as its market is growing tremendously due

to increasing number of QSR Bars Pubs etc.

Project report prepared by: Issam El Baba industrial consultant
Project report prepared by: Issam El Baba industrial consultant

The major end users of

French fries

The major end users of French fries Quick service restaurants These are main buyer of French
The major end users of French fries Quick service restaurants These are main buyer of French
The major end users of French fries Quick service restaurants These are main buyer of French
  • Quick service restaurants

These are main buyer of French fries. Out of the total imported French

fries, major quantity is sold through McDonald chain. The overall share of this segment is estimated around 60% the growth rate in these QSR is about 20-25%.

  • Restaurants and eateries

Apart from QSR’s other restaurants and eateries also have French fries

on the menu and are also served as an accompaniment to other snacks. The share of this segment is estimated at 10% at present but has the highest growth potential because of sheer size of restaurants and eating joints in the country.

  • Bars/ pubs

Significant quantities are used in bar and pubs with the drinks. This is also growing at appreciable rate of 15%. With relaxation in the licensing policy for bare and pubs in most of the states and increasing consumption of beer, the sale in this segment would increase at a fast

rate.

  • Flight Caterers / Luxury Trains

Caterers, both flight and railways, are the another segment among the user of French fries, growing at the rate of 10%.

Project report prepared by: Issam El Baba industrial consultant
Project report prepared by: Issam El Baba industrial consultant

The major end users of French fries

The major end users of French fries Retail sales Frozen French Fries are also sold in
The major end users of French fries Retail sales Frozen French Fries are also sold in
The major end users of French fries Retail sales Frozen French Fries are also sold in

Retail sales

Frozen French Fries are also sold in retail outlets, like frozen vegetables and meat products from the refrigerated outlets. The

present share of this is 5%. With changing retail formats,

Shopping malls and super markets becoming popular giving better visibility to such products hen by increasing sale.

Presently, the 90% need of domestic market is catered by imported frozen fries and remaining is manufactured in country In the year 1999, the imports were approximately 400 tons, which will grow to an

estimated level of over 3000 tons in the coming years. This shows a

rapid upward trend in the consumption of French-Fries in Romania, which is getting boost with the expansion of fast food chains.

The main companies from which French fries, required for domestic market, is being imported are:

Lamb Weston :

1000 MT/Annum

Aviko :

250 MT/Annum

McCain

1200 MT/Annum

McDonalds :

500 MT/Annum (Direct from McCain)

In the country, the institutional sales of fries accounts for more than

90% of the market, as French fries is an important product on the

menu of quick service outlets. 85% of French fries sold are consumed within the premises, while 15% are sold in packed form. The trend, however, is changing towards packed products for consumption at home.

Project report prepared by: Issam El Baba industrial consultant
Project report prepared by: Issam El Baba industrial consultant
Project description • 1.5.1 Support Infrastructure • The major support infrastructure required for establishment of potato

Project description

1.5.1 Support Infrastructure

The major support infrastructure required for establishment of potato processing facility is

establishment of small collection centers in each of the district along with transport vehicles in the season. It is also suggested that the company should go for contract farming of

potato to produce specifically process able

varieties .

Project description • 1.5.1 Support Infrastructure • The major support infrastructure required for establishment of potato
Project report prepared by: Issam El Baba industrial consultant
Project report prepared by: Issam El Baba industrial consultant

Critical Success Factors

Critical Success Factors 1.6 Critical Success Factors  Availability of raw material  Attack of diseases
Critical Success Factors 1.6 Critical Success Factors  Availability of raw material  Attack of diseases

1.6 Critical Success Factors

  • Availability of raw material

  • Attack of diseases like early blight/late blight

  • Modern storage facilities and use of modern technology as sprout inhibitors very important to ensure year round availability.

  • Through aggressive marketing and pricing strategy, bulk market would need to be created.

Critical Success Factors 1.6 Critical Success Factors  Availability of raw material  Attack of diseases
Project report prepared by: Issam El Baba industrial consultant
Project report prepared by: Issam El Baba industrial consultant

Storing the crop

Seasonal Price Analysis

There are fairly consistent

trends

in

seasonal

price

movements for vegetables

in Romania. Only

approximately

25%

of

potatoes are commercially

stored

in

Romania

generating

significant

seasonal

price

increases.

In 2006, prices for potatoes

rose 55%.

 

Ask for

Potato Storage Feasibility Study

 Storing processing potatoes is a specialized art.  Freshly harvested tubers are first cured at
Storing processing potatoes is a specialized art.
Freshly harvested tubers are first cured at 13°C for
several weeks to heal wounds and set the skin
The temperature is then lowered to 8° -10°C for long term
storage. Humidity, ventilation and temperature are
carefully controlled to maintain tuber quality.
Storage temperatures are kept constant and above 7°C to
prevent the accumulation of sugars which result in dark
processed products.
Sprout inhibitors are applied either as a spray in the field
or through the storage ventilation system in the late fall to
stop the tubers from sprouting. Developing sprouts
dehydrate tubers and reduce quality.
Tubers must be stored up to 8 months to ensure a
constant supply of raw product for the plant.
Project report prepared by: Issam El Baba industrial consultant

Processing facilities

1.7 Processing facilities

  • The processing facilities are being recommended on the basis of:

  • Market potential (Domestic as well as exports)

  • Minimum economic size of processing unit

  • Optimum utilization of various processing lines and raw material

  • Keeping in view, international trade of processing potato products and domestic demand, it is suggested that initially facilities

for processing frozen French Fries be setup.

Process Description for French Fries

Process Description for French Fries  1.8 Process Description for French Fries  De-stoning, washing and
Process Description for French Fries  1.8 Process Description for French Fries  De-stoning, washing and
Process Description for French Fries  1.8 Process Description for French Fries  De-stoning, washing and

1.8 Process Description for French Fries De-stoning, washing and peel removal The line is assumed to be fed with raw material (potatoes) in bulk boxes, which are emptied direct in feed hopper. The bulk boxes are tipped in the dosing hopper, which brings the product into the line. The line has an elevator behind the dosing hopper. De-stoning takes place in a flume de-stoner with a stone catching trap. In the trap is a sieve or a drum washer. In the cyclone de-stoner the product comes in spiral water movement, stones and heavy particles will sink against the

current in to the stone collecting chamber. The potatoes are floating over the drum washer.

Process Description for French Fries  1.8 Process Description for French Fries  De-stoning, washing and
Process Description for French Fries  1.8 Process Description for French Fries  De-stoning, washing and
Project report prepared by: Issam El Baba industrial consultant
Project report prepared by: Issam El Baba industrial consultant

Process Description for French Fries

Process Description for French Fries Peeling  From the drum washer, the product is collected in
Process Description for French Fries Peeling  From the drum washer, the product is collected in

Peeling

  • From the drum washer, the product is collected in a screw conveyor to bring the product to the peeler.

  • Peeling is done through steam peeler, in this method the peel loses are less than with abrasive peeling.

  • In steam peeling method, potatoes are brought under pressure by means of steam and by means of steam heat; the outer layer of the product is heated above atmospheric boiling temperature. Then the pressure is released rapidly, so the potato cell moisture starts boiling and rubs the cell wall. The skin will hang loose around the tuber.

  • In the dry brush machine this loose skin is brushed away. The dry removal gives relative dry peel waste, which is directly usable as cattle

feed.

  • To clean the last starch dirt form potatoes, an after washer is used followed by an inspection belt for manual inspection belt fro manual inspection.

Project report prepared by: Issam El Baba industrial consultant
Project report prepared by: Issam El Baba industrial consultant

Cutting sorting and blanching

Cutting sorting and blanching

The product is collected in a dosing screw with an

increased receiving hopper. This hopper has a buffer for at least 10 minutes to cope with fluctuations in the feed or even with small cleaning breaks or coffee breaks of

the inspectors.

The product is brought to the in-feed of the hydro cutting system. For cutting high quality product the demand to the product is that the product should be square and

straight. This can only be achieved by using a hydro

cutting system.

Project report prepared by: Issam El Baba industrial consultant
Project report prepared by: Issam El Baba industrial consultant

Cutting sorting and blanching

In hydro cutting system knives to cut square rectangular product or wedges a pre-heater can be placed to soften the structure of the potato and give the advantage that during cutting less cells will be damaged and less product breakage and oil take-up.

In hydro cutting system the flexible hose will be adapted to the

size of the potatoes to be cut. This leads to improve length specifications.

Cutting sorting and blanching • In hydro cutting system knives to cut square rectangular product or
Project report prepared by: Issam El Baba industrial consultant
Project report prepared by: Issam El Baba industrial consultant

Cutting sorting and blanching

Behind the cutter the thin side-pieces (silvers) and the too short pieces (nubbins) are removed from the product flow by means of a roller silver remover and a vibratory nubbin grader. The sequence of these two machines depends mostly on the combination with the cutting equipment.

Over the silver remover a spray bar for fresh water is mounted

to remove free starch from the product, which has come free by cutting through the potato cells.

The last check of the product is done manually or through

optical sorters.

An inclined belt elevator brings the product to the blancher. The most common actual blanching process is to blanch short in hot water, followed by long time in less hot water.

Project report prepared by: Issam El Baba industrial consultant
Project report prepared by: Issam El Baba industrial consultant

Cutting sorting and blanching

The first blancher has a retention time up to 2 minutes, the water temperature control is able to maintain the water temperature on approx. 90°C.

The product moves directly over to the second blancher, which is calculated for a retention time of 40 minutes and is commonly set on a temperature of approx. 70°C.

The second blancher is one with pump discharge system to bring the product up to the chemical dip flume. The type of blancher is adapted to the amount of product passing that

blancher.

Cutting sorting and blanching • The first blancher has a retention time up to 2 minutes,
Project report prepared by: Issam El Baba industrial consultant
Project report prepared by: Issam El Baba industrial consultant

Drying

Drying

The high quality demands equal color of the stick and prevention of after cooking darkening. To achieve this product should be dipped for 45-60 seconds in hot (80°C) solution.

The product is de-watered as much as possible and divided over the width of the dryer belt.

The dryer has to remove a certain amount of the water from the product to improve crispiness of the stick and shorter frying times. The drying takes place on a two-belt system with as well

as hot upward airflow as a

downward airflow alternating. By a tipping over from one belt to the other belt the equal;

drying is achieved. The maximal weight removal is 20%.

Nevertheless, the product needs time to equilibrate (10

minutes) its internal moisture prior to frying.

Project report prepared by: Issam El Baba industrial consultant
Project report prepared by: Issam El Baba industrial consultant

Frying

Frying

The product of the dryer is collected on a collecting belt or converging in-feed vibrator to bring the product directly into the fryer. The fryer is a pan filled with oil, on the bottom a wire link conveyor is present is present to transport the product. The oil is injected in the bottom over the width of fryer.

The fryer assembly includes an oil circulation system with belt filter for the course of dirt remover, a thermal oil heat exchanger and a circulation pump. To complete the system a

prime oil day tank in included.

The frying tank is set on 45-90 seconds, in oil of 180 °C the moisture content of the end product is fixed on 64%. The fat take up will be approx. 5-6%. Directly behind the fryer a de-

fatting vibrator is placed to remove as much as possible surface fat from the product.

Project report prepared by: Issam El Baba industrial consultant
Project report prepared by: Issam El Baba industrial consultant

Cooling and freezing

Cooling and freezing

The product is taken over from the de-fatting vibrator by the ambient

air cooling tunnel. The belt is moving through a cabinet where outside air is taken in by means of fans and blown through the product and discharged again. The achieves a relatively easy temperature drop from 90°C incoming product temperature till 5°C above ambient air

temperature for the out coming product. The belt of the ambient

cooling tunnel is designed in such a way that the product is directly dropped over to the freezer belt. This drop over point corresponds with the solidification point of the fat. So, if product has stick together, the relatively week bonds are easily broken apart. The retention time in the

ambient air-cooling tunnel is approximately 4 minutes. In the freezer

the product is individually quick-frozen. This means that a high capacity cold airflow is blowing upward through the product, fluidizing the product bed. The first bel part brings the product on the general solidification point of water (-1°C). The second belt of the freezer has a

thicker has a thicker layer of product and the product layer is cooled

down further till -18°C in average a retention time in a freezer is

approximately 9 minutes.

Project report prepared by: Issam El Baba industrial consultant
Project report prepared by: Issam El Baba industrial consultant

Raw Material Specifications

Raw Material Specifications Raw material : Potato 2.880 kg/ hr Average special gravity 1.08 Potato solids

Raw material : Potato

2.880

kg/ hr

Average special gravity

1.08

Potato solids

20.00%

Reducing Sugar

0.25% (acceptable up to 0.38%)

Recovery

0.960

kg/hr of French fries

Project report prepared by: Issam El Baba industrial consultant
Project report prepared by: Issam El Baba industrial consultant

Capacity of Plant

1.10 Capacity of Plant

  • The rated capacity of the Frozen French fries plant is 1920 MT per annum.

  • Calculated on eight hour shifts per day, five

CAPACITY ةقاطلا ةيجاتنلاا
CAPACITY
ةقاطلا
ةيجاتنلاا

days a week, with one line, 10% planned overtime, a machine utilization of 90%, and an

efficiency of 90%,

Project report prepared by: Issam El Baba industrial consultant
Project report prepared by: Issam El Baba industrial consultant

The plant from A to Z

Truck dumping & hydro- unloading Gentle-Flo potato storage Potato pumping bins & debris removal
Truck dumping & hydro-
unloading
Gentle-Flo potato storage
Potato pumping
bins
& debris
removal
Dirt removal,sizing,crate filing
Dirt removal,sizing,crate
filing

Slicer Feeders

Crate dumping, metering, Continuous or batch de-stoning Transfer Conveyors peeling
Crate dumping, metering,
Continuous or batch
de-stoning
Transfer Conveyors
peeling

conveyors

Inspection/trim

Inshida weighters
Inshida weighters
Heat Pollution recovery Controls systems Heat exchangers Singulating Slicer service feed platforms systems Air sweep water
Heat
Pollution
recovery
Controls
systems
Heat exchangers
Singulating
Slicer service
feed platforms
systems
Air sweep water removal
Slice washers and
Oil filtration systems
conditioners
Potato Fryers
Control systems
Freezing tunnel
Project report prepared by: Issam El Baba industrial consultant
Project report prepared by: Issam El Baba industrial consultant

Project component and cost

Major components of the project and their costs are as described in the table hereunder

Particulars

Unit

Qty

Cost/unit

Total

LAND & BUILDING

1.204.600$

Land

SqM

3,100

60.00$

186000$

Land development

land area

SqM

3,100

10$

18.600$

Building

Production Block

 

Raw Material Hall

SqM

  • 200 1250$

 

250.000$

Production Hal

SqM

  • 300 1750$

525.000$

Laboratory

SqM

  • 40 2500$

100.000$

Ultra hygine area

SqM

  • 50 2500$

125.000$

Project report prepared by: Issam El Baba industrial consultant
Project report prepared by: Issam El Baba industrial consultant

Storage area

Particulars

Unit

Qty

Cost/unit

Total

Storage Block

 

2.575.000$

Finished Product

SqM

100

1750$

175000$

Cold Storage

SqM

1,200

2000$

2.400.000$

Project report prepared by: Issam El Baba industrial consultant
Project report prepared by: Issam El Baba industrial consultant

UTILITY AREA & ADMIN BLOCK

Particulars

Unit

Qty

Cost/unit

Total

UTILITY AREA &

 

212.300$

ADMIN BLOCK

Utility area required

SqM

40

450$

18.000$

for boiler,coal or fuel

store etc.

ADMIN BLOCK

ADMIN BLOCK

SqM

100

1750$

175.000$

Contingencies

 

10%

 

19.300$

Project report prepared by: Issam El Baba industrial consultant
Project report prepared by: Issam El Baba industrial consultant

PLANT & MACHINERY

PLANT & 2.227.200$ MACHINERY Automatic French- LHS 1 1.750.000$ 1.750.000$ Fry Production Line Installation cost LHS
PLANT &
2.227.200$
MACHINERY
Automatic French-
LHS
1 1.750.000$
1.750.000$
Fry Production Line
Installation cost
LHS
5%
87.500$
Contingencies
10%
183700
Miscellaneous
206.000$
Fixed Assets
Furniture and Fixture
25.000$
25.000$
Computers & Other
5
2000$
10.000$
Electrical Items
Cars
1
35.000$
35.000$
Trucks
2
55.000$
110.000$
Weigh Bridge
1
8.000$
8.000$
Contingencies
10%
18.000$
Power: connected load
300 HP
Project report prepared by: Issam El Baba industrial consultant

PRE-OPERATIVE EXPENSES

Establishment

 
  • 1 45000$

 

45.000$

Professional

 
  • 1 15000$

 

15.000$

charges

Contingencies

 

10%

 

6.000$

Interest During

 

40.000$

Construction

Security Deposits

 

8.000$

TOTAL

     

108.000$

 

Grand Total

4.327.100$

Project report prepared by: Issam El Baba industrial consultant
Project report prepared by: Issam El Baba industrial consultant

Working Capital Assessment

ITEMS

Year 1

Year 2

Year 3

year4

Stock of raw

260.000$

350.000$

350.000$

350.000$

material and

packaging material

SUNDRY

1.300.000$

1.750.000$

1.750.000$

1.750.000$

DEBTORS

TOTAL

1.560.000$

2.100.000$

2.100.000$

2.100.000$

MARGIN

520.000$

960 000$ ..

960.000$

960.000$

INTEREST ON WC

20.800$

28.000$

28.000$

28.000$

Project report prepared by: Issam El Baba industrial consultant
Project report prepared by: Issam El Baba industrial consultant

Projected profit and loss account

Particulars

Year 1 40%

Year 2

60%

Year 3

90%

Year 4

90%

INCOME

1896000$

2822400$

3.663.000$

4.070.000$

EXPENDITURE

120000$

140.000$

150000$

170.000$

VARIABLE

705600$

1.058.400$

1.587.600$

1.870.000$

FIXED

350.000$

280.000

120.000$

111.000$

GROSS PROFIT

440400$

1.344.000$

1.6054.00

2.019 000$ ..

RETAINED

308.000

944.000$

1.205.400$

1.619.000$

PROFIT

Project report prepared by: Issam El Baba industrial consultant
Project report prepared by: Issam El Baba industrial consultant

Key Indicators

INTERNAL RATE OF RETURN %

25.01

BREAK EVEN POINT %

35.04

PAY BACK PERIOD ( YEARS)

4.02

Project report prepared by: Issam El Baba industrial consultant
Project report prepared by: Issam El Baba industrial consultant

Man Power Requirement

PARTICULARS

NO.

MANAGER-ADMN & OPRN

3

MANAGER-ACCOUNTS & MARKETING

4

EXECUTIVES

2

PRODUCTION

2

ASTT MGR-QUALITY

1

SHIFT SUPERVISOR

2

REF. ENGINEER/SUPERVISOR

2

MAINTENANCE SUPERVISOR

2

WORKERS

6

SKILLED WORKERS

3

TOTAL

26

Some brands

Project report prepared by: Issam El Baba industrial consultant
Project report prepared by: Issam El Baba industrial consultant
Standard Capacities (kg/hr) 750, 1500, 2000 . We provide the right tool for any investor before

Standard Capacities (kg/hr) 750, 1500, 2000.

We provide the right tool for any investor before investing in a new field.

we're able to provide consulting for:

  • Complete turn-key projects

  • Feasibility studies

  • Installation/commissioning and training of personnel

  • Product formulation

  • Project management

  • Set-up of production and quality control

systems

  • Technical assistance

  • Technology & machinery selection

Project report prepared by: Issam El Baba industrial consultant
Project report prepared by: Issam El Baba industrial consultant

Cost deviation

seizing

opportunities

others

overlooked

The actual cost of projects may deviate on change of any of the assumptions.

Project Profile Issam El-Baba your partner in success.

Contact:

COPYRIGHT 2009 ISSAM EL-BABA ALL RIGHTS RESERVED

Project report prepared by: Issam El Baba industrial consultant
Project report prepared by: Issam El Baba industrial consultant
United Nations declaration International Year of the Potato THE GENERAL ASSEMBLY, Noting that the potato is

United Nations declaration

International Year of the Potato

THE GENERAL ASSEMBLY,

Noting that the potato is a staple food in the diet of the world's population, Recalling resolution 4/2005 of the Conference of the Food and Agriculture Organization of the United Nations, adopted on 25 November 2005, Affirming the need to focus world attention on the role that the potato can play in providing food security and eradicating poverty in support of achievement of the internationally agreed development goals, including the Millennium Development Goals, Decides to declare the year 2008 the International Year of the Potato; Invites the Food and Agriculture Organization of the United Nations to facilitate the implementation of the International Year of the Potato, in collaboration with Governments, the United Nations Development Programme, the Consultative Group on International Agricultural

Research centres and other relevant

organizations of the United Nations system, as well as relevant non- governmental organizations. [22 December 2005]

POTATOES ON THE FRONT LINE AGAINST POVERTY

United Nations declaration International Year of the Potato THE GENERAL ASSEMBLY, Noting that the potato is

COPYRIGHT 2009 ISSAM EL-BABA ALL RIGHTS RESERVED

Project report prepared by: Issam El Baba industrial consultant
Project report prepared by: Issam El Baba industrial consultant
COPYRIGHT 2009 ISSAM EL-BABA ALL RIGHTS RESERVED

COPYRIGHT 2009 ISSAM EL-BABA ALL RIGHTS RESERVED