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Economics of 220 TPA Mushroom Project
Dr B Vijay
DMR Solan
The unit has been designed as per the latest technology of
mushroom growing. The following main structures are
proposed.
1. Prewettng area (Lagoon)
2. Composting yard
3. Spawn lab
4. Phase one bunkers
5. Bulk Chamber
6. Cropping rooms
7. Casing pasteurization room
8. Miscellaneous structures: Office, laboratory,
tanks ,etc.
1. Lagoon (prewetting area): 60 x40 ft. saucer shaped
structure with simple cement flooring for dumping and wetting
the ingredients and will not be covered.
2. Composting yard: 40x40x15ft. (Height), concrete flooring,
G.I. roof on RCC pillars. 3’ high wall on two sides. One goody
pit is also provided.
3. Spawn lab: A total built in area of 60' x 25' x 12' (h) should
be good enough to house the entire spawn unit. This area will
be divided into different work areas like boiling/autoclaving
room, inoculation room, incubation room (insulated and with
AC), cold room (heavily insulated with chilling facilities), store,
office, etc.
4. Phase one bunkers (2 nos.): 55x10x10 ft. required for phase one
phase of the composting. Simple structure with walls on three sides,
while front portion is kept open. It has a ventilation duct, which is
served by a small blower (¼ the capacity of the phase-II fan) with a
timer.
5. Bulk Chamber (1 no.): One bulk chamber of 40x10x12ft.
dimensions. Insulated on all the sides with 2” thick thermocole
sheets. Two doors, one towards compost shed and other toward
spawning area. Blower and ducting as per the design enclosed.
Spawning area of 20x20x12 ft of general construction.
6. Cropping rooms: Eight cropping rooms of 48X 21X 15 ft. (h). 4 each
on one side of the gallery of 12ft width. Walls and ceiling of the growing
rooms to be insulated (2” thermocole sheets). Two vents of 15”x15” are to
be provided on the back walls. Provision for light and water supply in
each room. Each room will have one air-handling unit (AHU) above the
door for climate control inside the room, including cooling, heating,
humidifying and for introducing fresh air. AHU’s are connected with
central cooling plant consisting of chiller, compressor, and condenser and
cooling tower.
Bad area: 44 x 13.5x 6 tiers = 3564 sq.ft.
Compost 7.5 kg /ft2 = 26730 kg or say 26.00 tons
(Cultivation proposed in bags and hence more
compost per unit area.)
7. Casing pasteurization room: 20 x 12 x 8 ft.
Insulated, grated floor, steam jets in the plenum along with
centrifugal blower.
8. Office : 200 sq ft. For sitting of the staff and manager.
9. Cold storage: Modular 8x8x8ft fitted with product
cooler.
10. Utilities: One room each of 24x21x12 ft for central
AC unit /chilling station and for packing mushrooms. 3
rooms of 15x12x11ft dimensions for housing generator,
boiler and tools. Total area 1600 sq.ft.
COST OF PROJECT
Rs in lakhs
1: Land and site development 10.00
2 Building 70.92
3 Plant and Machinery 99.20
4 Misc. fixed assets 17.00
5 Contingencies 19.71
6 Margin money for working capital 9.90
-----------------------
Total Rs. 226.73
------------------------
1. Land and site development 2.0 acre of land will
be required for the project. It will be leveled and
developed including boundary wall/barbed wire making
the total cost of Rs. 10.00 lacks. (Annexure –A)
1. Buildings: (Rs.70.92 lakhs
2. Plant and machinery: Cost Rs. 99.20 lakhs
3. Miscellaneous fixed assets: Rs 17.00 lakhs
4. Contingencies: A provision of contingencies at the rate of 10% of
the land, building, machinery and misc. fixed assets, which works
out to be Rs 19.711lakhs.
5. Margin money for working capital: Working capital is 18.50
lakhs and margin money Rs. 9.90 lakhs
PROFITABILITY PROJECTIONS:
ASSUMPTINS FOR PRODUCTION AND PROFITABILITY
8 cropping rooms of 26 tons composting handling capacity
6 crops will be taken as per availability of advanced hybrids, which
give optimum production (18-20kg/100kg compost) in 30 days of one
cropping cycle.
3. Annual production = 26 tons x 8 rooms x6 crops x 0.18 ton = 224
tons
Accepted = 220 tons
Rate of interest on term loan 12 % and on working capital 15%
Depreciation: 5 % on buildings, 10 % on machinery and
miscellaneous fixed assets.
SALES PROJECTIONS
Installed capacity 220 TPA
Sales 220 TPA fresh
a. Sale of fresh mushrooms:
220 tons @ 70,000 /- ton 154 lakhs
LAND AND SITE DEVELOPMENT
Rs. In lakhs
1. Sufficient land available with the promoter
-
2. Land leveling and site development 2.00
3. Gate and boundary wall. 8.00
Total Rs. 10 .00 lakhs
Buildings
ANNEXURE –B
BUILDINGS
SN.
Facility
Area sq.ft.
Unit cost
(RS.)
Total cost
( in lakhs)
1.
Growing rooms
(Inclusive of insulation)
8064
500
40.32
2.
Bulk chamber
(Inclusive of insulation)
400
500
2.00
3.
Spawning area
400
400
1.60
4.
Lagoon
2400
50
1.20
5
Composting Yard
1600
150
2.40
6
Bunkers
1100
200
2.20
7.
Service room
100
400
0.40
8.
Casing soil room
180
500
0.90
9.
Spawn Lab
1500
500
7.50
9
Office
400
500
2.00
10.
Utilities
1600
400
6.40
11.
Misc.like bore well, workers room, canteen, etc.
1000
4000
4.00
Total
70.92
Plant & Machinery
ANNEXURE – C
PLANT AND MACHINERY
Sn.
Particulars
Price
(Lakhs)
1
Central chilling station (75 TR x 2) including 8 AHU’S
Including ducting, piping, and controllers, complete in all respect.
45.0
2.
Boiler 1no. 200 kg steam generation capacity
3.50
3.
Blowers for the tunnels and casing chamber 4 nos.
1.5
4
Tunnel ventilation system
0.5
5
Temp. & Humidity controllers for growing rooms 8 sets
0.80
6
Multi channel thermometers
0.30
7
Steel racks for the 8 growing rooms & gratings for the tunnel
20.0
8
Insulated doors 20 nos.
4.00
9
Front End Loader
9.50
10
Tunnel Filling line
3.00
10
Modular cold room (8x8x8ft)
1.50
11
Paddy straw cutter
0.60
12
Laminar flow system
1.00
13
Autoclaves 2nos.
2.00
14
Boiling Kettles 2nos 40 liters capacity
1.00
15
BOD incubator 12cft
1.00
16
N analyses
0.25
17
PH and conductivity meter
0.25
18
Air conditioners. 2nos
1.00
19
Refrigerator 300 liters capacity
0.50
20
Misc. equipments
2.00
Total
99.20
MISCELLANEOUS FIXED ASSETS
Rs. in lakhs
1. Electric fittings 2.00
2. Furniture’s and fixtures 1.00
3. Sprayers system 2.00
4. Transformer 200HP 4.00
5 DG set 100 KVA 8.00
Total: 17.00
Raw MAterials
ANNEXURE – E
RAW MATERIALS
(For one crop for one cropping room)
Sn.
Materials
Quantity
Rate
Amount
(Rs.)
1.
Wheat& paddy straw
10 tons
3000/ton
30,000
2.
Chicken manure
7 tons
800/ton
5600
5.
Urea
0.15 tons
4500/ ton
675
6.
Gypsum
0.4 tons.
1500/ ton
600
7.
Casing material
4.0 tons
1500/ton
6000
8
Spawn ( prepared self)
0.2 tons
25 000/ton
5000
8.
Polythene bags
2500nos.
2/ bag
5000
15.
Chemicals
Items
--
1000
16
Miscellaneous
Items
--
1000
TOTAL
54875
Total cost of raw materials required for 48 crops (8 rooms x6 crops) = 26.34 lakhs
Total cost of raw materials required for 48 crops (8 rooms x6 crops) = 26.34 lakhs
WAGES AND PERKS
Sn.
Particulars
No.
Monthly
Salary
Total/year
1.
Manager
1
15,000
1.80
2.
Supervisor
1
6000
0.72
7.
Watch Man
1
4000
0.48
9.
Boiler Attendant
1
5000
0.60
10
Electrician
1
5000
0.60
11
Driver
1
5000
0.60
11
Labourers
23
4000
11.00
Total
15.80
ENERGY, FUEL,AND OTHER OVERHEADS (PER MONTH)
Rs. in Lakhs
1. Energy 1.70
2. Fuel 0.25
---------------------
-
Total for one month 2.00
---------------------
Total for 12 months 24.00 lakhs
PRPFITABILITY PROJECTIONS
A. COSTS (Rs in lakhs)
1. Raw materials 26.34
2. Power and fuel 24.00
3. Salary and wages 15.80
4. Interest on term loan
(12 % of 197.12 lakhs) 23.65
5. Interest on working capital
(15 % of 19.71 lakhs) 2.95
6. Depreciation
a. Plant and Machinery (10 % of 99.20 lakhs) 9.92
b. Buildings (5% of 70.92 lakhs) 3.54
c. Misc assets (10 % of 17.00 lakhs) 1.70
Total 107.90
B. SALES Rs, 154.00 lakhs
C. PROFIT = (B – C) = Rs. 46.10 lakhs
Project would be having full-fledged ultramodern spawn
lab. and will be selling additional spawn to the growers.
Minimum profit envisaged is Rs. 5.0 lakhs.
Project would be generating around 1000 tons of spent
compost annually, which is very good manure for field
crops. An additional profit of Rs. 5.0 lakhs is envisaged on
its sale to the growers.
Directorate of Mushroom Research (Indian Council of Agricultural Research)
Chambaghat, Solan – 173213 (HP) INDIA
Phone : 01792-230767, 230451
Fax : 01792-231207
Email: [email protected]
Website : www.nrcmushroom.org
