ACKNOWLEDGEMENT

AVCOE , SANGAMNER
DEPARTMENT OF MECHANICAL ENGINEERING
I would like to express my deepest gratitude to Prof. V.D. Wakchaure
sir, for their unwavering support and guidance throughout my academic
journey.

I am also profoundly thankful to prof. V.M. Mhaske sir and prof.

Y.R.GUNJAL sir, for their guidance and support.

Furthermore, I extend my sincere appreciation to NAVCHAITNYA

AGRO. works for providing me with the opportunity to intern with their
esteemed organization.
I am grateful for the exposure to real-world challenges, the chance to
apply classroom knowledge in a practical setting, and the supportive
environment that fostered my development.

Lastly, I would like to thank all the individuals who directly or

indirectly contributed to my growth during this internship. Your support
has been instrumental in shaping my professional identity and preparing
me for future endeavors.

Thank you all for your valuable contributions and support.

INTERNSHIP REPORT

NAME: NAVALE YASHNT RAMDAS. TE-A,

ROLL NO.- 3165
GUIDANCE
PROF. V.M. MHASKE SIR.
V.D. WAKCHAURE SIR
PROF. Y.R.GUNJAL SIR
 ABSTRACT

ABOUT :

Navchaitanya agro processing industry is situated in Sangamner

MIDC. They mainly manufacture the flour and distributes in
various districts in maharatra.the goal of the company is provide
chemical free food to word.

INTERNSHP OUTCOMES:

I got hands-on experience in the

field of manufacturing industry . I worked with highly skilled
professionals ,they mentored me throughout the internship. I
exposed to various projects . worked on practical skills such as
machining, quality control etc. Got chance to directly work on
project.

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MARKET POTENTIAL:

In 2019, the global demand for wheat flour reached a consumption volume of 391 million tons,
with steady growth during 2014-2019. Wheat flour is currently one of the most common food
ingredients used in the world. It provides health benefits, such as reducing levels of cholesterol,
improving metabolism, managing obesity, and controlling blood sugar levels. Because of the
presence of gluten, a protein that gives strength and elasticity to the dough as well as contributes
to the texture of baked goods, wheat flour is used extensively. The global demand for wheat flour
has been further strengthened by factors such as population growth, growing disposable incomes,

increasing consumption of bakery goods and changing lifestyles.

India's packaged wheat flour market is rising by almost 21% at a whooping CAGR . If the
growth trend stays the same, by the end of the current fiscal year (2020-21) itself, the market
could be likely to hit a new height of Rs 20,000 Cr. The numerous micro- and macroeconomic
variables pave the way for the growth of the market. However, wheat flour, which was still
packed, remained an urban phenomenon, with the urban market occupying more than 90% of
theoverall market. But with the market penetration of the leading players in the market
expanding, the rural market would also see a steady increase in demand for packaged wheat flour
in India.

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 RAW MATERIAL DESCRIPTION:

Wheat grains, or kernels, consist of about 85 percent of the starchy endosperm, or food-storage
portion; about 13 percent of several outer layers that make up the bran; and about 2 percent of
the oily germ, or embryo plant. The aim of the milling process in the manufacture of refined
flour is to distinguish the endosperm from the other kernel parts. Both parts of the kernel are used
in processing whole wheat flour.

Carbohydrate 70%
Protein 9-15%
Fat 2-2.2%
Fiber 2-2.5
Ash 1.8 %
Moisture 9-13%i

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 PROCESS FLOW CHART

 Grain delivery: The grain is supplied by covered trucks and hopper railcars to factories. The
distance travelled by the grain varies tremendously. In several times, the 110-car unit train
has covered hundreds of miles. In other situations, it is shipped in the same county from a
nearby plant. After arriving at the mill, grain stocks will often have gone through a variety of
accumulation processes (farmer, country elevator, terminal elevator, etc.).The number of
conveyances carrying grain can vary based on the time of harvesting and delivery.

 Grain standard: Before wheat grains are unloaded in a factory, the assessment is required
with samples. The grain is tested for moisture, test weight, unsound seeds, and
foreignmaterial. The grains are categorized according to Indian Grain Standards and are also
subject to the ISO trade standards. Product management chemists start experiments to
identify grain and assess end-user values during unloading.

 Cleaning: After inspection, the grain is unloaded directly from the truck into the unloading
container and transferred into large bins or silos through conveyors and bucket lifts. Grain
storing is a science. It is necessary to maintain the correct moisture, heat, and air or mildew,
sprout, or ferment Wheat . The grain can also be fumigated to eradicate insect pests during
transportation. During the process In terms of nutrient level and consistency, barely is stored.

 Cleaning the wheat grains: It can take as many as six steps. The machines that clean the
grain are collectively called the cleaning house.

 Magnetic separator – The grain first passes by a magnet that removes ferrous metal
particles. It will pass through other metal detectors after milling to ensure that no metal
pieces are in the finished product. Magnets are also positioned throughout the milling
process and at the last step prior to load-out.

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  Separator – Vibrating or rotating drum separators remove bits of wood, straw, and
almost anything else too big or too small to be the desired grain.

 Aspirator – Air currents act as a vacuum to remove dust and lighter impurities.

 De-stoner – Using gravity, the machine separates the heavy material from the light to
remove stones that may be the same size as the desired grain.

 Disc separator – The grain passes through a separator that identifies the size of the
kernels even more closely. It rejects anything longer, shorter, more round, more angularor
in any way a different shape.

 Scourer– The scourer eliminates the outer husks, the soil in the kernel crease, and other
minor impurities with vigorous scouring action. Currents of air are dragging up all the
loose stuff.

 Impact Entoleter– The centrifugal force cuts down some unsound kernels or insect eggs
and the aspiration rejects them from the flow of the mill. From the meet, the sound of the
Wheat flows into the grinding bins, large hoppers that regulate the feeding of the Wheat
to the actual milling process.

 Colour Separator – Newer mills may also utilize electronic color separators to simplify
the cleaning process.

 Grinding: The grains of wheat are now ready to be milled into flour.The modern milling
process is a gradual reduction of the wheat grains through the grinding and sifting process.
This science of analysis, blending, grinding, sifting, and blending results in consistent end
product. Wheat kernels are weighed or fed from bins to roller mills, corrugated cylinders
made of chilled steel. The rolls are paired and rotated inward to each other at varying speeds.

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 Passing through the corrugated "first break" rolls, the separation of the bran, endosperm, and
germ begins.
There are about five roller mills or breaks in the system. Again, the aim is to remove the
endosperm from the bran and the germ. To get as much pure endosperm as possible, each
break roll must be set. The "break" rolls, each has successively finer corrugations,
throughthe break rolls. The grist is sent back upstairs to drop through sifters after each trip.
The system reworks the coarse stocks from the sifters and reduces the Wheat particles to
granular “middling” that are as free from bran as possible.

 Sifters- Through pneumatic tubes, the broken particles of Wheat are elevated and then
dropped into huge, vibrating, box-like sifters where they are shaken to separate the larger
from the smaller particles by either a series of bolting cloths or screens.
There may be as many as 27 frames inside the sifter, each covered with either a screen or
nylon or stainless steel, with square holes that get narrower and smaller and the farther down
they go. It is probable that up to six different particle sizes come from a single sifter.

 Blending: From the fibre, the flour is separated and the process is repeated again.

 Testing of the final product: Lab checks are carried out after milling to ensure that the flour
follows the specification and standards. Millers also conduct routine monitoring of indicator
natural organisms. While dry flour does not provide an atmosphere that is conducive to
microbial development, it is important to note that flour is not a ready-to-eat food and is a
minimally processed agricultural ingredient.

 Packaging of Product: The packaging is carried out in a much simple process then milling,
the Wheat flour is fed to holding tank of the packaging machine, which simply seals one end
of continuous packaging first, then it simply fills the packet as per required weight & seals
the other end, generating the required packet.

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 Grain Delivery

Grain Storage

Cleaning

Grinding

Sifters

Finished Product Testing

Packaging & Storage

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BASIS & PRESUMPTIONS

1. Production Capacity of Wheat flour is 100 kg per hr. First year, Capacity has been taken @
60%.

2. Working shift of 8 hours per day has been considered.

3. Raw Material stock is for 10 days and Finished goods Closing Stock has been taken for 15
days.

4. Credit period to Sundry Debtors has been given for 15 days.

5. Credit period by the Sundry Creditors has been provided for 7 days.

6. Depreciation and Income tax has been taken as per the Income tax Act, 1961.

7. Interest on working Capital Loan and Term loan has been taken at 11%.

8. Salary and wages rates are taken as per the Current Market Scenario.

9. Power Consumption has been taken at 15KW.

10. Increase in sales and raw material costing has been taken @ 5% on a yearly basis.

11.Interest on working Capital Loan and Term loan has been taken at 11%.

12.Salary and wages rates are taken as per the Current Market Scenario.

13. Power Consumption has been taken at 15KW.

14.Increase in sales and raw material costing has been taken @ 5% on a yearly basis.

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CAPACITY, UTILIZATION, PRODUCTION & OUTPUT

COMPUTATION OF PRODUCTION OF WHEAT FLOUR

Items to be Manufactured
Wheat Flour

Machine capacity Per hour 100 Kg

Total working Hours 8
Machine capacity Per Day 800 Kg
Working days in a month 25 Days
Working days per annum 300
Machine capacity per annum 240000 Kg
Final Product to be packed in 1 kg Packet
Number of Packets per annum 240000 1 Kg Packet

4.2. PREMISES/INFRASTRUCTURE

The approximate total area required for complete factory setup is 2000-2500 Sq. ft. for
smooth production including storage area. It is expected that the premises will be on rental.

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 4.3. MACHINERY & EQUIPMENTS

1. GRAIN CLEANER

1. The unclean grain first come in first compartment in grain cleaner where unwanted dust is
removed.

2. Then the grain comes in second compartment where unwanted small stones are removed.

3. In third compartment the high pressure air remove unfertilized grain particle.

4. In last compartment the clean grain is forwarded toward storage tank.

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2. STORAGE TANK

1. In storage tank all clean grain is storage .

2. The grain from storage tank is transmitted to flore mill.

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3. GRAIN GRINDER

1. The grain from storage tank is transmitted to grain grinder.

2. The friction generated between the grains and the stones or rollers
causes the grains to be crushed, ground, and pulverized.

3. The result is a coarse powder that gradually transforms into fine flour.
To ensure consistent and uniform grinding, flour mills are equipped
with adjustable settings.

4. Then the perfectly fine flour is transmitted toward the flour strainer.

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4. FLOUR STRAINER

1. The main purpose of flour strainer is to separate raw particle of grain from flour.

2. The flour is enter in flour cleaner where multiple strainer are attached.

3. The grain particle are remove using the strainer.

4. Then the worker puts the flour in bags in wright quantity.

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5. PACKAGING MACHINE

1. The packed flour bags are sealed in packeging machin manualy.

2. The bag of flour are stored in dry storage and deliver according to orders.

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 CONCLUSION
My internship experience at the NAVCHAITANYA AGRO PROCESSING INDUSTRY has been
incredibly enriching and insightful, providing me with a valuable opportunity to immerse myself in
the manufacturing industry and gain practical knowledge and skills that complement my mechanical
engineering education.
Throughout the internship, I had the privilege of working alongside experienced technicians and
marketing experts. From conducting all process every task I undertook contributed to my growth as a
mechanical engineering student and aspiring professional in the manufacturing sector
One of the key takeaways from my internship at NAVCHAITANYA AGRO is the importance of
attention to detail and precision in food manufacturing service operations. Whether it was performing
routine maintenance tasks or diagnosing complex mechanical issues, I learned the significance of
meticulousness and accuracy in ensuring the safety and reliability of manufacturing process.
Additionally, I gained valuable insights into the significance of effective communication and teamwork
in delivering exceptional service experiences to customers.

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Some images of the
industry

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