Agro-processing complex (APC), different models of APC, Flowchart of different unit operations, success stories and few APC in Punjab.

1. AGRO-PROCESSING COMPLEX
Presented by:
Ruchika Zalpouri
L-2K19-AE-163-D
PFE-591

2. STATUS OF AGRICULTURE (INDIA)
• Largest producer >>milk, pulses and
jute
• Second largest producer >> rice,
wheat, sugarcane, groundnut,
vegetables, fruit and cotton
• Leading producers >> spices, fish,
poultry, livestock and plantation crops
• Worth $ 2.1 trillion, India is the
world's third largest economy after the
US and China.
• 70 percent of its rural households
• 82 percent of farmers being small and
marginal.
Source: FAO

3. AVERAGE MONTHLY INCOME

4. CROP INDIA PUNJAB
Rice 117.94 12.28
Wheat 107.18 55.17
MAJOR CROP PRODUCTION 2019-2020 (million
MT)
Source: Press information Bureau, Govt of India

5. A set of techno–economic activities, applied to all the produces,
originating from agricultural farm, livestock , aquaculture sources and
forests for their conservation, handling and value-addition to make
them usable as food, feed, fibre, fuel or industrial raw materials.
AGRO-PROCESSING

6. IMPORTANCE OF AGRO-PROCESSING INDUSTRIES
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7. AGRO-BASED TECHNOLOGIES
Mini rice
milling unit
Baby oil
expeller
Wheat mill
Cotton
ginning
machine
Dhal mill
Farm level
cleaning and
drying
facilities
Farm level
fruits and
vegetables
processing
Milk
processing
Feed
processing
mill
By product
utilization

8. Agro-processing complex is an enterprise where the required
facilities for handling, processing and storage of cereals, pulses,
oilseeds and spices.
AGRO-PROCESSING COMPLEX

9. SETTING OF APC
Site selection
Identification of components of agro-industrial model
Feasibility report of the model
Procurement of finance
Installation of Machines/Equipment
Training on operation, repair and maintenance

10. COMPONENTS OF APC MODELS FOR DIFFERENT REGION OF PUNJAB
Main crop: Wheat & rice
Component of APC: Atta chakki
& mini rice mill
Main crop: Wheat & rice
Other crop: oilseed & cotton
Component of APC: Atta chakki
& mini rice mill
Some cases: baby oil expeller &
penja
Main crop: Wheat, oilseed & rice
Other crop: Animal feed, spices
& cotton
Component of APC: Atta chakki,
baby oil expeller & mini rice mill
Some cases: penja, grinder &
feed mill
Main crop: Wheat, oilseed,
pulses, rice & cotton
Component of APC: Atta chakki,
baby oil expeller, mini rice mill,
penja, grinder & dall mill
Main crop: Wheat & cotton
Other crop: oilseed, rice &
pulses
Component of APC: Atta chakki,
baby oil expeller, mini rice mill,
penja, grinder & dall mill
Source: Agro processing booklet, PAU

11. APC MODELS DEPENDING ON CROP PRODUCE
Agro Industrial Model-I Atta chakki, mini rice mill, penja & grinder
Agro Industrial Model-II Atta chakki, baby oil expeller, mini rice mill & grinder
Agro Industrial Model-III Atta chakki, baby oil expeller, mini rice mill, penja & grinder
Agro Industrial Model-IV Baby oil expeller, mini rice mill, grinder & dall mill
Agro Industrial Model-V Atta chakki, baby oil expeller, penja & grinder
Agro Industrial Model-VI Atta chakki, penja & grinder
Agro Industrial Model-VII Baby oil expeller, penja & grinder
Agro Industrial Model-VIII Atta chakki, baby oil expeller, penja & grinder
Agro Industrial Model-XI Atta chakki, baby oil expeller, mini rice mill, penja & grinder

12. MODEL OF AGRO-PROCESSING COMPLEX
Source: Agro processing booklet, PAU

13. APC LAYOUT
Suggested By: Deptt.
of Processing and
Food Engineering

14. FLOW CHART OF ALL UNIT OPERATIONS

15. RICE MILLING
Raw paddy
Cleaning using
the Satake
cleaner
Dehusking
using the
Satake
dehusker
Paddy
separation
Brown rice
Polishing
using
horizontal
cone polisher
Polished/White
rice
Grading
Head rice and
Brokens
Impurities
Husk
Bran

16. PADDY HUSK BRAN RICE HEAD RICE BROKEN
Raw
22 6 72
Seldom exceeds 65 20-30
Parboiled 68 15-20
AVERAGE YIELD OF MINI RICE MILL (%)

17. WHEAT MILLING
Modern Atta
Chakki

18. OIL MILLING
Type of
seed
Feed
section
Crushing
section
Discharge
section
Sunflower 0.63 0.25 0.25
Rapeseed-
mustard
0.50 0.25 0.25
Chamber-bar spacing in expeller (mm)

19. PULSE MILLING

20. RED CHILLI PROCESSING TUMERIC PROCESSING
Raw turmeric
fingers
Washing
Boiling
Drying
Polishing
Grinding
Packaging and
storage

22. FEED PROCESSING
CLEANING GRINDING MIXING
PALLETISATION WEIGHING PACKAGING

23. Components/ Machines Capacity Cost (Rs.)
Mini Rice Mill with two
polishers & elevators
250 Kg/h 3,00,000/-
Baby Oil Expeller with filters
press
100 kg/h of
oilseed
3,50,000/-
Atta chakki (with scourer) 700 kg/h 7,00,000/-
Atta chakki (Rajasthani) 150 kg/h 50,000/-
Masala Grinder 50 kg/h 70,000/-
Pulse clearner and grader 100 kg/h 60,000/-
Cattle feed mill 900 kg h 3,50,000/-
Electric motor with fittings 20-25 hp 1,50,000/-
Total cost on machinery 20,00,000/-
PRESENT COST OF MACHINES REQUIRED FOR APC
Source: Agro processing booklet, PAU
Extra cost of Rs
8,00,000/-
(Construction of
APC shed along
with installation of
machinery)

24. RUNNING CAPACITY AND BREAKDOWN IN COMPONENTS OF AGRO-PROCESSING
COMPLEXES
Machines Percent of rated
capacity
Breakdowns in components
Atta chakki
a) Burr mill
b) Scourer in atta chakki
80-85
80-82
Bearing, stone, housing, hopper
Central shaft, roller, bearing
Mini rice mill
a) Rubber roll sheller
b) Polisher
c) Double polisher
80-85
70-80
70-75
Rubber roll, gears, hopper,
housing
Bearings, central shaft, housing
Bearings, central shaft, housing
Baby oil Expeller 80-85 Chamber bar, screw, gears
Penja 75-80 Gears, shaft, conveyer
Cotton gin 80-85 Saws, conveyer, gears
Masala grinder 80-85 Bearing, hopper, housing
Source: Agro processing booklet, PAU

25. Cost of installing APC (mini rice mill, baby oil expeller, atta
chakki, masala grinder, pulse cleaner and grader, penja and feed
mill) is Rs 25-30 Lakhs
AGRO-PROCESSING COMPLEX
State Govt. provides
subsidy on machinery
to encourage farmer
to set up APC

26. DO & DON’T’S OF APC
Electrical
Transmission
• Electric motor or diesel engine
• Electrical connection
Belt & Pulley
• Flat belt
• Alignment of shaft and pulley
• Strip tension
• Bearing

27. PRECAUTIONS TO BE TAKEN
Electricity supply-off
Switch off machinery
Proper clothing
Maintenance
Proper layout
Fire hazard

28. AGMARK CERTIFICATION
Provides certification of purity, quality and genuninity of food by
Govt. of India
1. Food grains and allied products
2. Fruits and vegetables
3. Spices and condiments
4. Edible nuts
5. Vegetable oils and fats
6. Oils cakes
7. Fibre crops
8. Livestock dairy and poultry products
Commodities graded
under AGMARK

29. PROCEDURE FOR GRADING UNDER AGMARK
1. Application form
2. Inspection Report by concerned
Assistant Marketing Officer
3. Specimen of Trade Brand Label
(TBL) with word AGMARK written on
the top
4. Undertakings for the use of TBL (on
govt stamp paper
5. Medical certificate (regarding fitness
of the main workers
6. Partnership deed or affidavit by the
proprietor on Rs 15/- stamp paper
7. Authority letter (Power of Attorney by
other partners)
8. Bank certificate (about dealing of the firm
with the bank
9. Affidavit (agreement to abide by the Act
1937 and other instructions
10.Mao of building (blue prints showing
machinery rom, spares and packaging
rooms
11.No objection certificate from owner of
premise, if rented.
12.Consent letter from AGMARK laboratory
for testing
Govt fees: Rs 10,000/-

31. Brar Agro Processing
Complex, Lande
Name of the APC and Address:
S. Pritam Singh
Brar Agro Processing Complex,
Lande, Near Bagha Purana, Moga
District:ar of Establishment:
2003
Total investment : 6, 05,000/-
Profit (annual) : 7, 88,350/-
Profit (monthly) : 65,696/-
Source: APC Bulletin, PAU (2015)

32. Total Investment : Rs. 6, 50,000/-
Profit (Annual) : Rs. 6, 70,000/-
Profit (Monthly) : Rs. 55,853/-
APC Vander Jatana, Faridkot
APC Daddahoor, Raikot
Total Investment : Rs. 7, 72,000/-
Profit (Annual) : Rs. 7, 16,840/-
Profit (Monthly) : Rs. 59,737/-

33. FEW APC ESTABLISHED IN PUNAJAB
Sr.
No.
Address of the APC Year of
Establishment
1. Agro Process Industrial Complex,
Chakdana
1986
2. Oil and Rice Mill, Dehlon,
Ludhiana
1986
3. Dhurian Flour Mill, Mullanpur,
Ludhiana
1987
4. S. Dilbagh Singh
Near Bus Stand, Jodhan, Ludhiana
1996
5 S. Ranjeet Singh
Vill. Talwandi Rai, Raikot
2002
6 S. Manjinder Singh Grewal
Village Lalton Kalan, Distt.
Ludhiana
2003
7 Brar Agro Processing Complex
Vill Lande, Near Bagha Purana,
Distt. Moga
2003
Sr.
No.
Address of the APC Year of
Establishment
8 S. Jaspreet Singh
S/o S. Gurbachan Singh
V.P.O.Talwandi Rai, Teh. Jagraon,
Distt. Ludhiana
2005
9 S. Mohan Singh
S/O S. Gurdev Singh, VPO Talwandi
Rai,, Teh. Jagraon, Distt. Ludhiana
2005
10 S. Puran Singh
Vill. Kotha Guru Ka, Tehsil Phul,
Distt. Bathinda
2005
11 S. Apinder Singh
V&PO Nathowal, Teh. Raikot,
Distt.
2005
12 S. Santokh Singh
V&PO Rhode, Near Bagha Purana,
Moga
2006

34. Sr.
No.
Address of the APC Year of
Establishment
13 Kisan Agro Food Industries,
Vill. Vander Jatana, Faridkot
2006
14 Grewal Flour Mill,
VPO Kaonke, Teh. Jagraon, Distt.
Ludhiana
2006
15 S. Manjit Singh
VPO Hans Kalan, Teh. Jagraon,
Distt. Ludhiana
2006
16 KK Agro Processing Complex,
Ayali Khurd,
Distt. Ludhiana
2007
17 Satshiv Flour Mill, VPO Dadha
hoor, Teh. Raikot, Distt. Ludhiana
2007
18 S. Jagmohan Singh
Vill. Kotsukhian, Faridkot
2009
19 Abnashi Singh and Nirmal Singh,
Singh; VPO Mehaduda, Samrala
2010
Till 2020: more than
300 APC’s
Nearly 4-5 plants
are being installed
every year
PUNJAB

35. Thank you