AUTOMATIC INSTANT NOODLES PLANT

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Instant noodles with flavoring powder in a separate packet were launched in response to people’s strong demand for better quality and taste, and the product line was highly acclaimed. The forerunner of Japan Convenience Foods Industry Association was founded in 1964 when the entrants rapidly increased and competition among them became excessively fierce in this growing market. The association strove to maintain the product quality by applying Japan Agricultural Standard (JAS) and started to display the date of manufacture to be more consumer-friendly. Since then, increasingly many different flavors of instant noodles had been put into the market, and their product quality, as represented by non-fried noodles, had been improved.

Spreading first to Asia and then to Americas and Europe, instant noodles have become accepted globally. Especially with the rise of income level in developing countries in the 1990s, the consumption increased rapidly there. Annual global demand for instant noodles was estimated approximately 15 billion servings in 1990, and the demand grew to 50 billion servings in 2001 and exceeded 100 billion servings mark in 2012. The rapid growth was attributed to the universality of the five principles Momofuku Ando had set forth in developing the food, namely affordability, convenience, safety and hygiene, long shelf life, and palatability. Besides, it was pointed that the versatility of instant noodles enabled themselves to fuse with ingredients in local cooking and traditional flavors. Moreover, going ahead of rising health-consciousness, many manufacturers launched instant noodles with various healthy recipes: noodles with dietary fiber and collagen, low-calorie noodles, and low-sodium noodles, etc.

CLASSIFICATION OF NOODLES

There is no systematic classification or nomenclature for Asian noodles; wide differences exist between countries. There is a need to standardize noodle nomenclature using a universal classification system. Classification below is based on the current state of the knowledge.

Based on Raw Material:

Noodles can be made from wheat flour alone or in combination with buckwheat flour. Wheat flour noodles include Chinese and Japanese type noodles. There are many varieties in each noodle type, representing different formulation, processing and noodle quality characteristics. Noodles containing buckwheat are also called soba, meaning buckwheat noodle. These noodles are typically light brown or gray in color with a unique taste and flavor

Based on Salt Used:

Based on the absence or presence of alkaline salt in the formula, noodles can be classified as white (containing salt) noodles or yellow (containing alkaline salt) noodles.

Based on Size:

According to the width of the noodle strands, Japanese noodles are classified into four types. Since the smaller size noodles usually soften faster in hot water than the larger size, so-men and hiya-mughi noodles are usually served cool in the summer, and udon and hira-men are often eaten hot in the cool seasons.

Based on Processing:

The simplest way to classify noodles based on processing is handmade versus machine-made noodles. Noodle processing operations include mixing raw materials, dough sheeting, compounding, sheeting /rolling and slitting. This series of processes remains constant among countries for all noodle types. Noodle strands are further processed to produce different kinds of noodles, and this can be a means of classification

Fresh- Noodle strands coming out of slitting rolls are cut into certain lengths for packaging without any further processing

Dried- Fresh noodle stands are dried by sunlight or in a controlled chamber. Noodle shelf life is dramatically extended, but fragile noodles may have handling problems.

Boiled- Fresh noodle strands are either parboiled (90% complete cooking) or fully cooked. Boiled noodles are re-cooked for another 1-2 minutes before serving.

Steamed- Fresh alkaline noodle strands are steamed in a steamer and softened with water through rinsing or steeping.

Description

INTRODUCTION
CLASSIFICATION OF NOODLES
BASED ON RAW MATERIAL:
BASED ON SALT USED:
BASED ON SIZE:
BASED ON PROCESSING:
MARKET OVERVIEW OF INSTANT NOODLE
CUP/BOWL NOODLES REGISTERS THE HIGHEST GROWTH RATE
COMPETITIVE LANDSCAPE
MAJOR PLAYERS
MARKET POTENTIAL OF INSTANT NOODLE
NATIONAL SCENARIO
FACTORS AFFECTING NOODLE MARKET DRIVERS
FORMULATION OF TASTE MAKER SPICE
RECIPE NO. 1
FORMULATIONS OF NOODLES
FORMULATION OF MILLED BASED INSTANT NOODLES
RANKING THE BEST INSTANT RAMEN OF 2020
THE BEST IN FLAVOR, TEXTURE, AND BOLDNESS: SHIN RAMEN
THE BEST IN LUXURY AND MILD FLAVOR: PRIMA TASTE SINGAPORE LAKSA LA MIAN
BEST IN BALANCED FLAVOR AND COMFORT: MAMA NOODLES
BEST TRADITIONAL: SAPPORO ICHIBAN RAMEN
SEQUENCES IN NOODLE MANUFACTURE
DRY MIXING
DOUGH FORMATION
EXTRUSION
PRE-DRYING
DRYING
TECHNICAL PROCESS FLOW CHART
THE MAIN PROCESSES ARE:
THE SPECIFIC PROCESS IS AS FOLLOWS:
1. MIXING
2. COMPOUND
3. CALENDERING
4. CUTTING
5. STEAMING
6. CUT OFF AND INPUTS
7. FRYING
8. COOLING
9. PACKING
PRCESSING DETAILS OF NOODLE
1. PRODUCTION RATE:
2. COOKING TEMPERATURE:
3. COOLING TEMPERATURE:
4. MOISTURE CONTENT:
5. MIXING SPEED:
6. MIXING TIME:
7. CUTTER SPEED:
8. COOKING TIME:
NOODLES PROCESSING
STEP BY STEP PROCESS
KNEAD AND MIX:
CREATING NOODLE BELT:
ROLLING:
SLITTER:
STEAMER:
DIPPING BATH:
FEEDER:
DE-WATERING + FRYING PROCESS:
COOLER:
CHECK WEIGHT AND DETECT METAL:
TASTE MAKER ADDING:
PACKING:
THERE ARE TWO KINDS OF STORAGES:
1. DRY STORAGE ROOMS: (FOR DRY INGREDIENTS)
NOODLES SHELF LIFE
PRESERVATION METHODS
QUALITY PARAMETER:
1. APPEARANCE:
2. TASTE:
3. NUTRITIONAL CONTENT:
4. SHELF LIFE:
5. PACKAGING:
IMPROVERS AND PRESERVATIVES:
FLOW CHART FOR NOODLES PROCESSING
FOOD SAFETY REGULATION AND STANDARD OF NOODLE
STANDARD
PROCESSING OF NOODLES
1. TEMPERATURE:
2. MOISTURE:
3. OXYGEN:
4. LIGHT:
FOOD SAFETY
SANITARY AND HYGIENIC REQUIREMENTS FOR FOOD MANUFACTURER/PROCESSOR/HANDLER
LABELING STANDARDS
LEADING INSTANT NOODLES COMPANIES IN THE WORLD
INDOFOOD
NISSIN FOODS HOLDINGS CO. LTD.
NESTLÉ S.A.
UNI-PRESIDENT ENTERPRISES CORP.
TOYO SUISAN KAISHA LTD.
TINGYI (CAYMAN ISLANDS) HOLDING CORP.
AJINOMOTO CO. INC.
CAMPBELL SOUP COMPANY
ITC LIMITED
THE UNILEVER GROUP
PLANT LOCATION FACTORS
PRIMARY FACTORS
1. RAW-MATERIAL SUPPLY:
2. MARKETS:
3. POWER AND FUEL SUPPLY:
4. WATER SUPPLY:
5. CLIMATE:
SPECIFIC FACTORS
6. TRANSPORTATION:
A. AVAILABILITY OF VARIOUS SERVICES AND PROJECTED RATES
7. WASTE DISPOSAL:
8. LABOR:
9. REGULATORY LAWS:
10. TAXES:
11. SITE CHARACTERISTICS:
12. COMMUNITY FACTORS:
13. VULNERABILITY TO WARTIME ATTACK:
14. FLOOD AND FIRE CONTROL:
EXPLANATION OF TERMS USED IN THE PROJECT REPORT
1. DEPRECIATION:
2. FIXED ASSETS:
3. WORKING CAPITAL:
4. BREAK-EVEN POINT:
5. OTHER FIXED EXPENSES:
6. MARGIN MONEY:
7. TOTAL LOAD:
8. LAND AREA/MAN POWER RATIO:
PROJECT IMPLEMENTATION SCHEDULES
INTRODUCTION
PROJECT HANDLING
PROJECT SCHEDULING
PROJECT CONSTRUCTION SCHEDULE
TIME SCHEDULE
RAW MATERIAL SUPPLIERS
SUPPLIERS OF STARCH
ADDRESSES OF PLANT AND MACHINERIES SUPPLIERS
PLANT AND MACHINERY SUPPLIERS [IMPORTED]
MACHINERY PHOTOGRAPHS
FLOUR AIR TRANSPORT EQUIPMENT
VIBRATING SCREEN
ALKALI LIQUID MIXER
FLOUR MIXER
FEEDER MACHINE
COMPOUND ROLLING MACHINE
CONTINUOUS ROLLING MACHINE
THREE LAYERS COOKING MACHINE
CUTTING & DIVIDING MACHINE
FRYING MACHINE
COOLING MACHINE
DISTRIBUTARY AND TRANSPORT MACHINE
PACKING CONVEYOR
CONTROL CABINET

APPENDIX – A:

01. PLANT ECONOMICS
02. LAND & BUILDING
03. PLANT AND MACHINERY
04. OTHER FIXED ASSESTS
05. FIXED CAPITAL
06. RAW MATERIAL
07. SALARY AND WAGES
08. UTILITIES AND OVERHEADS
09. TOTAL WORKING CAPITAL
10. TOTAL CAPITAL INVESTMENT
11. COST OF PRODUCTION
12. TURN OVER/ANNUM
13. BREAK EVEN POINT
14. RESOURCES FOR FINANCE
15. INSTALMENT PAYABLE IN 5 YEARS
16. DEPRECIATION CHART FOR 5 YEARS
17. PROFIT ANALYSIS FOR 5 YEARS
18. PROJECTED BALANCE SHEET FOR (5 YEARS)

Additional information

Plant Capacity

1500 Kg./Day

Land & Building

(1000 sq.mt.)

Plant & Machinery

US$ 125714

Rate of Return

31%

Break Even Point

71%