Food plant setup basically is an overall design of a manufacturing unit and includes several stages such as product identification for manufacture, feasibility study, design and economic appraisal, material procurement, installation of plant and commissioning. The design encompasses technical aspects, number of unit operations, market outlook, economic conditions etc. The primary role of a food plant setup consultant is to analyze the specific requirements of clients and develop a customized layout that offers operational efficiency. The first step to follow before establishing a food processing plant is to conduct in-depth market research. Identifying the current market trends in the industry, preferences of consumers and competitors in the field will provide insights into market dynamics. This is followed by developing a business plan. The business structure must be first established – sole proprietorship/partnership/private company etc. and then the business name must be registered with the Registrar of Companies. Choosing an appropriate location for plant construction is a vital step and this decision is dependent upon the proximity of the plant to raw material suppliers, accessibility to stock, distribution of the end product and labor availability.
The regulatory requirements such as obtaining import export code, FSSAI (Food Safety and Standards Authority of India) license for food safety standards, GST registration for tax compliance, trade license for operating legally in the municipality, fire safety certificate and pollution control NOC (no objection certificate) for abiding by the fire safety regulations and meeting environmental laws of emissions, waste and pollution are required before setting up a food manufacturing business. The next step is to craft a business plan that includes enumerating the objectives of company, strategies for the operation and marketing of the enterprise, amount of capital required for the plant establishment, estimation of profit, revenues and cashflows, calculating the cost of labor, production, raw materials and overhead expenses. A written business plan indicating the financial requirements and available funding from investors and other financial institutions must be documented. Securing funding and acquiring licenses will enable the construction of manufacturing plant with provisions made for machinery, packaging material and storage facilities. There are stark differences between the food and non-food processing plants and these stem from their production methods. As the shelf life of foods is minimal and the quality is strongly influenced by several factors like pH, temperature, microbial contamination, water activity etc., product safety is of prime importance. Therefore, food plants are designed to offer high sanitation levels to prevent the possibility of contamination and product deterioration.
Implementing quality control measures is an important in upholding consumer trust. Establishing hazard analysis and critical control points (HACCP) and standard operating procedures (SOPs) for processes will educate the staff on best practices and regulatory changes in the industry. Expanding business internationally will provide access to a larger consumer base, drive innovation and enable market diversification. It is therefore necessary to develop a marketing plan for product advertisements through online platforms, social media, and engaging in trade shows. Adhering to these steps and seeking assistance from a food consultant will help in overcoming the challenges related to a plant setup and achieving business goals.
