Bakery products
Sugar free rusk
TECH-NFIC-135
Record type
Product / SKU
Product category
Bakery products
Popularity
Low Demand
Machinery available at NFIC
Partially
1. Raw materials / commodities
COM-003
Wheat
NF availability: Availability: Low. Source districts: No dependable AP production district identified; small volumes are included with 'other millets and wheat'. ODOP: No wheat ODOP in AP. Manufacturing decision: Do not base an AP-local venture on wheat unless a contracted local cluster is first established; otherwise budget for inter-state grain.
2. NFIC machines required
3. How the product is made
?
Identify the lot; remove stones, insects, mouldy and damaged material. Sieve/aspirate dry ingredients before weighing.
Validated
Parameters: Record lot, incoming moisture and rejection weight; keep food grain separate from treated seed.
?
Blend the specified cereal flours; weigh yeast, salt, fat and other recipe ingredients.
Validated
Parameters: Millet percentage changes water absorption and loaf volume; record the actual blend.
?
Add potable water and mix/knead to a cohesive dough.
Validated
Parameters: Record water addition, final dough temperature and mixing endpoint; flour lot changes may require adjustment.
?
Allow the yeast dough to develop in a controlled fermentation area.
Validated
Parameters: Follow dough expansion and maturity; AP room temperature is not a reproducible process setting.
?
Divide to consistent mass; round, rest and mould into pans or the selected product shape.
Validated
Parameters: Piece mass, handling losses and pan fill.
?
Proof shaped dough before baking.
Validated
Parameters: Proof height and dough resilience; avoid overproofing.
?
Bake using an oven profile matched to loaf mass and recipe.
Validated
?
Depan; cool under hygienic conditions before slicing and packing.
Validated
Parameters: No warm condensation inside packs; clean slicer and limit post-bake handling.
?
Arrange slices in a single layer and rebake/dry to crispness.
Validated
Parameters: Uniform slice thickness and dryer loading; measure final moisture/water activity.
?
Cool in a clean, dry area; weigh, seal and batch-code moisture-barrier food-grade packs.
Validated
Parameters: No condensation; check seal continuity, pack weight and moisture/water activity against the product release specification.
4. Financials and Unit economics
Selling price
₹63.75
per pack
Variable cost to make one pack
₹42.91
Money left per pack
₹20.84
Before shared/fixed costs
Minimum production to cover costs
8 batches/month
Whole batches required
At 12 batches/month
₹28,725 profit/month
Money required to start
₹5.07 lakh
1. What will I produce and sell?
Raw material used in one batch (kg)
40.00
Finished product from one batch (kg)
58.20
Packs produced from one batch
291 packs
Selling price per pack
₹63.75
Planned production
12 batches/month
Packs available for sale/month
3,492 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
₹1,600.00
Other ingredients
₹5,937.50
Packaging material
₹1,500.00
Production/helper labour
₹1,800.00
Transport / logistics
₹450.00
Other production costs
₹1,200.00
Total variable cost per batch
₹12,487.50
Sales from one batch
₹18,551.25
291 packs × ₹63.75
Variable cost of one batch
₹12,487.50
Money left from one batch
₹6,063.75
Available to pay shared/fixed business costs and thereafter become profit.
Money left per pack
₹20.84
Before shared/fixed costs.
3. NFIC Facility Cost
The fixed/shared cost of using NFIC
NFIC facility charge
₹44,040/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
₹2,22,615
Main raw material
₹19,200
Other ingredients
₹71,250
Packaging
₹18,000
Production/helper labour
₹21,600
Transport / logistics
₹5,400
Other variable costs
₹14,400
Total variable costs
₹1,49,850
Money left after variable costs
₹72,765
NFIC fixed/shared facility cost
₹44,040
Estimated monthly profit
₹28,725
At 12 batches per month, estimated profit is ₹28,725 per month.
5. How many batches do I need to sell?
Below break-even
7 batches
Sales: ₹1,29,859
Loss: ₹1,594
BREAK-EVEN
8 batches
Sales: ₹1,48,410
Profit: ₹4,470
Above break-even
9 batches
Sales: ₹1,66,961
Profit: ₹10,534
You should produce and sell at least 8 batches per month to cover your costs.
Every additional batch sold after this adds approximately ₹6,064 before any other unforeseen expenses.
6. What happens if I produce more?
6 batches/month
₹7,658 loss
7 batches/month
₹1,594 loss
8 batches/month
₹4,470 profit ← Break-even crossed
9 batches/month
₹10,534 profit
10 batches/month
₹16,598 profit
12 batches/month
₹28,725 profit
15 batches/month
₹46,916 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
₹2,65,462
Other startup requirements
₹2,42,000
Total startup money required
₹5,07,462
Why is ₹2.65 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 39 days
Estimated total money required to start and operate the business
₹5.07 lakh
5. Branding, packaging & labelling
Packaging & labelling guidance
| Pack size | Retail: 100 g / 200 g; family: 400 g. |
|---|---|
| Label copy status | Ready |
Packaging, labelling & compliance guidanceRead one box at a time.
Recommended packaging
- Heat-sealed moisture/oxygen-barrier flow-wrap or pouch; use a light protective tray only if breakage trials justify it. Metallised laminate is a candidate, not a compulsory material.
Economical / sustainable option
- trial a recyclable PE- or PP-based mono-material pack only if its barrier and seals pass the same shelf-life test; confirm local collection. Plain paper alone is unsuitable.
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.
- 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.
- Protect from moisture after opening.
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
- Name rusk or soup sticks as appropriate.
- Declare wheat/gluten and any milk, soy, egg or nuts present.
- Sugar-free / sweetener claim note: “Sugar-free” requires compliance with the finished-food claim limit, not just replacing sucrose.
- Identify permitted sweeteners and reproduce the exact applicable Schedule II declarations/warnings; sugar-free does not mean carbohydrate-free or safe for every diabetic.
- FSSAI Advertising and Claims Regulations, 2018; Version IV, 14-Dec-2022. Claim principles and conditions; later effective amendments must also be checked.