Whey Powder and Whey Cream

Name of Company: ANATOLIA A.Ş.
Address:AFYON Industrial Zone
Company Activity:WHEY POWDER AND WHEY CREAM
Production Capacity:
(processed): 73000 ton Sweet Whey/Year
(produced):
Area Of The Plant: m2 process area
m2 total area
Operation Time: 365 days/year

THE MAIN PURPOSE OF OUR COMPANY

Gain modern “Whey Powder Manufacturing Plant” to Afyon

Produce non-caking whey powder with high quality

Contribute to Afyon zone economically

Our Quality Statement
Uninterrupted improvement or the managerial system.
Investment in team work and human resources satisfaction.
To produce in line with global food production standards.
Be hygienic always
Be affordable always

Whey is the serum or liquid part of milk that is separated from curd when making cheese. As whey is a secondary product of the cheese making process, whey production is related to the dairy industry.
What is Whey ?

components
Quantity in whey (%)
Water 93,3
Dry solid 6,7
Fat 0,9
Protein 0,9
Lactose 4,4
Ash 0,5
Composition of Whey

Importance of whey ?
Whey has been the most important pollutant source due to its BOD value (40g/lt).

Whey has a high nutritional value, as it contains valuable proteins-vitamins (lactoalbumin and lactoglobulin).

Whey has high economical income for dairy farms.

Protein 16200
Fat 17400
Mineral 11400
Lactose 8600
Amount of nutrients sent to canalization (Tons/Year)

Importance of whey powder?
Whey and whey components are used by the food industry in a wide variety of applications on the basis of their excellent nutritional and functional properties.

As a value-added ingredient in many other food products including meat and fish products, bakery, etc.
Production of Animal feed
Medicine industry (due to its essential amino acid)
Dairy products (for increasing nutrition value and texture)

Moisture max % 3
Protein %7-9
Lactose %76- 83
Ash max % 6
Salt max % 3.5
Fat max % 1
Composition of whey powder

Many small sized dairy-farms(raw material source)

Low labor and energy cost

The easy transportation to other cities

No competition

Incitement???????
WHY WE CHOOSE AFYON ?

Transportation: adequate transportation facilities to transport our final product.

Raw Material: There are many dairy-farms of small capacity and they can not utilize whey because of economical imposibilities

Land: Land is given free by industry and Commercial Chamber of Afyon.

Competition: there is no plant for whey powder manufectuing in the area.

FACTORS/CÄ°TÄ°ES
AFYON
GAZÄ°ANTEP
BURSA

Raw material
45
10
45

Energy source
20
40
40

Transportation
45
20
35

Required Labor Power
30
35
35

The geographical location of land
35
30
35

Competition with other factories
50
35
15

Stimulation:Stimulation
70
20
10

Total

295

190

215
FACTORS THAT AFFECT PLANT SELECTION

Maybi
TekirdaÄŸ
Enka
Konya
Akbel
Konya(EreÄŸli)
Sütaş
Bursa
Ak-süt
Adapazarı(Pamukova)
Some Of Whey Powder Manufactoring Plants In Turkey

Plant Lay Out

Countries
Quantity(ton)
Worthiness($)
Philippines
2,836
3,244,000,00
Syria
2,730
3,123,000,00
Egypt
1,370
1,567,000,00
Kore
1,595
1,824,000,00
Singapore
979
1,120,000,00
Yemen
1,170
1,338,000,00
Pakistan
1,695
1,939,000,00
China
1,450
1,658,000,00
Suudi Arabia
634
725,000,00
iran
160
183,000,00
Ghana
359
410,000,00

Total

14,978

17,131,000,00
Countries which Turkey performed the most exportation to,2007

End Of The Introduction

Presented by Zahide Ü.Altunay

COST ANALYSIS

TOTAL CAPITAL INVESTMENT

Fixed Capital Investment
+
Working Capital Investment __________________________________

Total Capital Investment

21

Processing Equipment
Number
Capasite
Price($)/unit

Clarifier
1
15 ton/h
70000$
Cream separator
1
15ton/h
120000$
Nano filter
1
15ton/h
550000$
Falling film evaporator
Vacuum separator
Vacuum pump
Pre- heating equipment
Pasteurization holding equipment
Condenser
Compressor (MVR)
Cooling towers
Flash cooler
Pumping
Steam machine

1

15ton/h

800000$
Crystallization tanks
4
5ton
320000$
Spray dryer (integrated with fluid bed dryer)
Drying chamber
Hot air system and air distributor
Feed system
Atomizing device
Powder separation system
Fluid bed after drying/cooling
Instrumentation and automation
Pumping
1

1,5 ton/h

5250000$
Packaging machine for whey powder
Packaging machine for whey cream
1
0.75ton/h
0.1 ton/h
200000$
50000$

Total: 7360000 $

50% stumilation=3680000$

PURCHASED AUXILIARY EQUIPMENTS EXPENSES
Auxiliary Equipments
Cost of Equipments($)
Number of systems
Total Cost($)
Electronic scale
25,000
1
25,000
Forklift
18,000
2
36,000
Phone central & Apparatus
2,000
1
2,000
Computer Network system
1,000
10
10,000
Trafo(2000kVA)
15,000
1
15,000
Generator
30000
1
30,000
Repair &care equipment
10,000
1
10,000
Car &small lorry &van
100,000
1
100,000
TOTAL
490,000 $

Autoclave 7000$
Oven 1600$
Ash Oven 2100$
NIR product Analyzer 11000$
Sensitive Scale 3000$
Water Bath x3 1800$
Gerber centrifuge 700$
Desicator x2 1000$
Incubator x2 900$
Moisture Analyzer x2 4000$
Ph Meter 1400$
Glass Materials 1000$
Distilled water device 1500$
Total : 37000$

LABORATORY EQUIPMENTS

CAPITAL INVESTMENT ESTIMATION TYPE
Liquid Process
COST ($)
PURCHASED EQUIPMENT
100
4,207,000
PURCHASED EQUIPMENT INSTALLATION
47
1,977,300
INSTRUMENTATION AND CONTROL
18
757,260
PIPING
66
2,776,620
ELECTRICAL INSTALLATION
11
462,770
BUILDINGS
18
757,260
YARD IMPROVEMENTS
10
420,700
LAND
6
0
SERVICE FACILITIES
70
2,944,900
TOTAL DIRECT COST
346
13,884,170 $
CONSTRUCTION EXPENSE
41
1,724,870
ENGENEERING –SUPERVISION
33
1,388,310
TOTAL DIRECT AND INDIRECT COST
420
16,997,350$
CONTRACTOR’S FEE
5% of(TDIC)
849,867
CONTIGENCIES
10% of(TDIC)
1,699,735
FIXED CAPITAL INVESTMENT
19,546,952
WORKING CAPITAL
15% of TCI
2,549,620
TOTAL CAPITAL INVESTMENT
44,176,478
22,100,000$

PERSONNEL EXPENSES
Number
Name of Duty
#of Person
Salary($/month)
TOTAL($/month)
1
General manager
1
3000
3000
2
Factory Manager
1
2000
2000
3
Personal Manager
1
1750
1750
4
Production Manager
1
1750
1750
5
Sales and Purchasing Manager
1
1750
1750
6
Quality Control Manager
1
1500
1500
7
Mechanical Engineer
1
1500
1500
8
Electrical&Electronical Engineer
1
1500
1500
9
Finance Manager
1
1,500
1,500
10
Production Chief
3
1,000
3,000
11
Quality Cont. Chief
3
1,000
3,000
12
Repair And Maintenance
2
800
1,600
13
Accounters
1
1,000
1,000
14
Laborant
3
600
1,800
15
Secretary
1
500
500
16
Driver
2
500
1,000
17
Security
3
400
1,200
18
Cooker
2
500
1,000
19
Worker
20
400
8,000
TOTAL COST PER MONTH
37,350$
TOTAL COST PER YEAR
450,000$

RAW MATERIAL COST
whey:(12500kg/hour)*(20hour/day)*(365day/year)*(0,02$/kg)=1,825,000$/year

Packaging Material for whey powder: (25kg):
4,891,000(kg/year)*/25 (kg/package)=195,640 package/year
195,640 (package/year)*0.5($/package)=97,820$/year

Packaging Material for whey cream:(17kg):
456,250(kg/year)*/17 (kg/package)=26,838 package/year
26,838 (package/year)*3($/package)=80,514$/year

Total : 2,000,000$

MANUFACTURING COST
Manufacturing cost=direct product cost+fixed charges+plant overhead cost

Direct product cost ($4,460,000 per year)
*Raw material cost=$2,000,000per year
*Operating labor=(20 workers)*($400/worker-month)*12month/year=$96,000/year
(6 chiefs)*($1000/chief-month)*12month/year=$72,000 per year
(3 laborants)*($600/laborant-month)*12month/year=$21,600per year
(3 security)*($400/security-month)*12month/year=$14,400 per year
(2 drivers)*($500/driver-month)*12month/year=$12,000 per year
(2 cooker)*($500/cooke-month)*12month/year=$12,000 per year
Total=$228,000 per year

*Direct supervisory and clerical labor=$22,800 per year (10% of operating labor)
*Maintenance and repairs=$977,500 per year (5% of fixed capital investment)
*Operating supplies=$97,750 per year (0.5% of fixed capital investment)
*Laboratory charges=$18,240 per year (8 % of operating labor)

Utilities and Energy
*Water: 30,000$ /year
*Electricity:550,000$/year (600kW/h)*20h*365 (days/year)*0.125$
*Coal : 763,600$/year
Depreciation

Depreciation=(V-Vs)/n
V:the cost of purchased equipment($4,207,000)
Vs:the salvage value of equipment(%5)
n:service life of equipment(18 year)
Depreciation:($4,207,000-223,000)/18year=
$221,333 per year
Insurance:$70,000 per year
Plant Insurance:200,000$
Fixed charges(491,000$ per year)

Plant overhead cost
Meal: 60,000$
Service:30,000$
Others: 110,000$
total:200,000$
Manufacturing cost=direct product cost+fixed charges+plant overhead cost

Manufacturing cost= $5,151,000 per year

GENERAL EXPENSES($515,000 per year)
Distribution and marketing costs=$309,080 per year (6% of total product cost)
Research and development costs=$206,053 per year (4% of total product cost)

TOTAL PRODUCT COST

TOTAL PRODUCT COST=MANUFACTURING COST+GENERAL EXPENSES

TOTAL PRODUCT COST=5,666,000$/YEAR

BREAK-EVEN POINT ANALYSIS

Total product cost=5,666,000$ per year
Total product=4,891,000kg/year=4,891ton/year (whey powder)
Total product=456,250kg/year=456.25ton/year (whey cream)
Total product cost=5,666,000$/year/5,348,000kg/year=$1.059/kg=$1050/ton
Income= 1500$/ton of whey powder
Income= 8000$/ton of whey cream
Total income=1500$/ton*4,891 ton/year= $7,336,500/year
8000$/ton*456.25 ton/year= $3,650,000/year
Total=$7,336,500+$3,650,000=10,986,000$/year
Gross earning=10,986,000$-5,666,000$=5,320,000$/year
Tax(20% of gross earning)= 5,320,000 $/year*0.2=1,064,000$/year
Net profit=5,320,000 $/year-1,064,000$/year=4,256,000$/year
Fixed charges=491,000$/year

1500 *0,92*X+8000*0,08*X = 1050X +491,000 $/year X=ton/year
X = 506,185 ton/year
Break even point is %9,308(506,185*100/5,438) of total product     Â
=%9.308
If we work 506,185 ton/year capacity,we reach the break-even point

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