Coffee / cocoa products
Processing of cocoa beans to: Cocoa mass, Cocoa butter, Cocoa powder
TECH-NFIC-119
Record type
Product / SKU
Product category
Coffee / cocoa products
Popularity
Low Demand
Machinery available at NFIC
Partially
1. Raw materials / commodities
COM-023
Cocoa
NF availability: Availability: High and cluster-based. Source districts: Eluru, West Godavari, East Godavari and Konaseema, generally as an intercrop under coconut. ODOP: No cocoa ODOP in AP. Manufacturing decision: Proceed near the Godavari belt only with access to fermentation and drying. Buying wet beans without controlled post-harvest handling will compromise quality and price.
2. NFIC machines required
NFIC-KUP-U02-01
3 In 1 Polishing Machine (Cleaning & Grading)
Use: Grader
Open machine page →
NFIC-KUP-U03-02
Single Head Pulveriser 7.5 HP — White Powder with Starter
Use: Pulveriser; Nib grinder; Attrition mill etc
Open machine page →
NFIC-KUP-U03-03
Double Drum Roaster Electric
Use: Roaster
Open machine page →
NFIC-KUP-U04-02
Solar Dryer
Use: Tray drier
Open machine page →
NFIC-KUP-U05-02
Destoner — 3 In 1 Blower / Destoner / Grader
Use: De-stoner
Open machine page →
NFIC-KUP-U05-03
Additional Sieves
Use: Sifter
Machine is mapped to this product · no separate public machine page
NFIC-KUP-U07-04
Plastic Tubs
Use: Storage vessels; SS soaking tank etc
Machine is mapped to this product · no separate public machine page
3. How the product is made
?
Receive properly fermented, dried beans; clean and sort.
Validated
Parameters: ICCO cites approximately 7.5% bean moisture for storage; verify lot quality and mould before processing.
?
Roast whole beans or nibs under the selected process.
Validated
?
Separate nibs from shells.
Validated
Parameters: Residual shell and nib recovery.
?
Grind nibs to cocoa liquor/mass.
Validated
Parameters: Particle size, viscosity and temperature; retain this branch as cocoa mass if required.
?
Press cocoa mass to separate butter and cake.
Validated
Parameters: Press temperature/pressure and residual cake fat require equipment-specific settings.
?
Filter and cool the separated butter; pack.
Validated
Parameters: Purity, moisture, oxidation and controlled cooling.
?
Break cake, cool, mill/deagglomerate, classify and condition before packing.
Validated
Parameters: Particle-size grade, fat content and flowability. Alkalisation is optional and needs a separate protocol.
4. Financials and Unit economics
Selling price
₹1,100.00
per pack
Variable cost to make one pack
₹928.42
Money left per pack
₹171.58
Before shared/fixed costs
Minimum production to cover costs
3 batches/month
Whole batches required
At 8 batches/month
₹67,760 profit/month
Money required to start
₹12.76 lakh
1. What will I produce and sell?
Raw material used in one batch (kg)
100.00
Finished product from one batch (kg)
76.00
Packs produced from one batch
76 packs
Selling price per pack
₹1,100.00
Planned production
8 batches/month
Packs available for sale/month
608 packs
Assumption: All saleable production is sold at the indicated selling price.
2. How much does one batch cost?
Variable costs — these increase when you produce more
Main raw material
₹65,000.00
Packaging material
₹1,560.00
Production/helper labour
₹1,800.00
Transport / logistics
₹400.00
Other production costs
₹1,800.00
Total variable cost per batch
₹70,560.00
Sales from one batch
₹83,600.00
76 packs × ₹1,100.00
Variable cost of one batch
₹70,560.00
Money left from one batch
₹13,040.00
Available to pay shared/fixed business costs and thereafter become profit.
Money left per pack
₹171.58
Before shared/fixed costs.
3. NFIC Facility Cost
The fixed/shared cost of using NFIC
NFIC facility charge
₹36,560/month
This includes:
- use of NFIC machinery / shared facility
- electricity, fuel and water
- machine-operator cost
You do not need to separately add electricity or machine-operator cost.
4. Will I make a profit?
Monthly Income Statement
Sales income
₹6,68,800
Main raw material
₹5,20,000
Packaging
₹12,480
Production/helper labour
₹14,400
Transport / logistics
₹3,200
Other variable costs
₹14,400
Total variable costs
₹5,64,480
Money left after variable costs
₹1,04,320
NFIC fixed/shared facility cost
₹36,560
Estimated monthly profit
₹67,760
At 8 batches per month, estimated profit is ₹67,760 per month.
5. How many batches do I need to sell?
Below break-even
2 batches
Sales: ₹1,67,200
Loss: ₹10,480
BREAK-EVEN
3 batches
Sales: ₹2,50,800
Profit: ₹2,560
Above break-even
4 batches
Sales: ₹3,34,400
Profit: ₹15,600
You should produce and sell at least 3 batches per month to cover your costs.
Every additional batch sold after this adds approximately ₹13,040 before any other unforeseen expenses.
6. What happens if I produce more?
1 batches/month
₹23,520 loss
2 batches/month
₹10,480 loss
3 batches/month
₹2,560 profit ← Break-even crossed
4 batches/month
₹15,600 profit
5 batches/month
₹28,640 profit
8 batches/month
₹67,760 profit
11 batches/month
₹1,06,880 profit
More batches sold → the fixed/shared NFIC cost gets spread over more production → monthly profit improves.
7. How much money do I need before starting?
Startup & Working Capital Requirement
Money needed for day-to-day business
₹10,69,200
Other startup requirements
₹2,07,000
Total startup money required
₹12,76,200
Why is ₹10.69 lakh needed for day-to-day business?
Raw material, ingredients, packaging and other expenses have to be paid before all the money from customers comes back.
Working-capital cycle: approximately 51 days
Estimated total money required to start and operate the business
₹12.76 lakh
5. Branding, packaging & labelling
Packaging & labelling guidance
| Pack size | Cocoa mass/butter: 500 g / 1 kg blocks; powder: 200 g / 500 g; B2B: 5 kg / 25 kg. |
|---|---|
| Label copy status | Ready |
Packaging, labelling & compliance guidanceRead one box at a time.
Retail label essentials
- Before printing, check the applicable rules/exemptions for: true food name; ingredients in descending order; additives; prescribed nutrition panel; veg/non-veg symbol; allergen statement; manufacturer/packer/brand-owner details and applicable FSSAI logo/licence number; net quantity; MRP inclusive of taxes and consumer-care details; batch/lot; manufacture/packing date and expiry/use-by as applicable; storage and preparation instructions.
- Check Legal Metrology declarations, type size and unit-sale-price applicability for the final pack.
- Mandatory information must be in English or Hindi; add clear Telugu for rural AP buyers.
Product name, origin & marketing claims
- Put a simple descriptive food name beside the brand, with the actual variant and net quantity prominent.
- Use honest local-origin/FPO statements backed by records.
- Technology titles in column C are not approved marketing claims.
- Do not imply CFTRI or FSSAI endorses the brand.
- A QR recipe/traceability link is optional and cannot replace mandatory on-pack information.
Ingredients, allergens & cross-contact
- Review every ingredient and processing aid/carrier, including compound seasonings and shared machinery.
- Use the prescribed separate allergen statement when applicable; exemptions exist, including where the product itself is the allergen.
- “May contain” follows a genuine cross-contact assessment and is not a substitute for segregation.
- Milk is an allergen even in a vegetarian food; egg changes veg/non-veg status.
- Do not assume millet/buckwheat foods are gluten-free.
- Give the buyer ingredient/allergen/additive specifications and a batch Certificate of Analysis (COA) where relevant.
- Do not use the retail checklist alone for food colours, enzymes, extracts or bulk ingredients.; declare cross-contact allergens only after assessment.
- FSSAI Labelling and Display Regulations, 2020; Version VIII, 09-Sep-2025. Primary regulatory baseline for retail/non-retail labels, allergens and ingredient-specific declarations.
Nutrition & claims
- Nutrition values and claims must match the final recipe, legal calculation/testing basis and serving instructions.
- Check permitted exemptions rather than printing invented values.
Shelf life, storage & after-opening
- Best-before alone is not a universal substitute for expiry/use-by.
- Establish shelf life on the real product/package using safety, sensory and relevant moisture/rancidity/culture tests under intended distribution conditions.
- No expiry duration is supplied in this workbook.
- Print a validated after-opening period where needed, not “consume soon” as the only control.
- Apply current non-retail requirements for identity, quantity, lot/date, manufacturer/packer, applicable FSSAI details, storage and required non-retail identification; supply permitted accompanying documentation for other required information.
FSSAI licence, certifications & marks
- Obtain the applicable FSSAI registration/licence and product-category permissions before food manufacture/sale; it is not a product-quality endorsement.
- Ordinary food rows do not establish a separate mandatory certification merely because they use millet or local produce.
- ISO 22000/HACCP certification, retail barcodes and trademark registration are not universal food-label prerequisites, though a buyer may require them.
- Never display BIS/AGMARK/organic/vegan/+F/other marks without qualifying and obtaining the relevant authorisation where required.
- Special-category rows explicitly need further review.
Regulatory references
- FSSAI Packaging Regulations, 2018; Version V, 02-Apr-2025. Food-contact compliance and Schedule IV indicative package families. Specific pack sizes and sustainability trade-offs in D/E are recommendations, not prescribed by this source.
Other important guidance
- Mass/butter: grease-resistant food-contact liner/wrap in carton, heat-protected transport. Powder: moisture/odour-barrier sealed pouch or lined sack. Separate specifications for each fraction; avoid unnecessary retail tins for B2B.
- Identify cocoa mass/liquor, cocoa butter or cocoa powder correctly; cocoa liquor is not an alcoholic drink.
- Powder: declare alkalisation/additives where relevant.
- Supply a B2B specification/Certificate of Analysis (COA) and follow these B2B/non-retail requirements: B2B is not unlabelled.