Besan, also known as gram flour. It is a main ingredient in the Indian kitchen and has been seen globally due to its utility and nutritional value. From traditional recipes such as Pakoras and sweets to modern health foods, besan is increasing in popularity.
In today’s food industry, automation plays an important role in ensuring frequent quality, high production, and low labor costs. Investing in a fully automated gram flour plant can bring an uprising in your business by simplifying the production process, maximizing efficiency, and meeting the growing market demand. Partnering with a reliable, fully automatic besan plant manufacturer ensures long-term usefulness and development.
Understanding a fully automated gram flour plant
A fully automated gram flour plant is a modern food processing setup. Designed to convert pulses such as chickpeas with minimal human intervention into high-quality besan (gram flour). Unlike manual or semi-automatic plants, it integrates all stages of production-from cleaning and dehusking to grinding, sieving, and packaging-in a spontaneous, continuous process. It ensures flour quality, reduces wastage, saves labor costs, and increases production efficiency. Investing in a reliable, fully automated gram flour plant at a fully automatic besan plant manufacturer allows businesses to meet the growing demand of the market while maintaining hygiene and operational excellence.
Major components and machinery of a completely automatic gram flour plant
Pulse Cleaning and Sorting Unit: Removes stones, dust, and impurities from raw pulses.
Dehusker / Peeling Machine: Removes the outer husk of chickpeas for fine flour.
Grinder / Pulverizer: Converts pulses into smooth, fine gram flour.
Shifting and Sieving System: Uniform particle ensures size and remove coarse residues.
Packing unit: automatic weight and packaging for retail or wholesale supply.
Conveyor system: Smooth, connects all machines for continuous operation.
Semi-automatic difference between automatic gram flour plants
Labor requirement: semi-automated plants require manual supervision; Fully automated plants require minimal labor.
Production capacity: Fully automated plants provide higher production per hour than a semi-automatic setup.
Consistency: Fully automated plants produce similar flour quality with low waste.
Operational Speed: Continuous production in completely automated plants vs. batch-wise in semi-automatic plants.
Early Investment vs. ROI: The initial cost of completely automated plants is higher, but the rapid ROI is due to efficiency and output.
Economic benefits of owning a fully automated gram flour plant
Investing in a fully automatic gram flour plant provides significant economic benefits that can change your business. From cost savings to high production efficiency, advantages make automation a smart option for both small and large-scale operations.
1. Cost savings
Low labor requirements: Fully automated plants reduce the need for manual labor, reducing salary and training costs. An operator can manage multiple processes simultaneously.
Lower Operational Downtime: Automatic systems run continuously with minimal human intervention, resulting in a delay in production and maintenance blockage compared to a manual setup.
2. Increase in production capacity
Fully automatic besan plants can process large quantities of pulses continuously, promoting daily and weekly outputs.
3. Consistent quality and less waste
The automation ensures uniform particle size, accurate pieces, and clean production, meeting food safety standards to meet.
Low human handling leads to minimum wastage, an increase in efficiency, and maximizes the use of raw materials.
4. Energy efficiency and long-term ROI
Fully automated plants are designed to consume low energy per unit of production, reducing the cost of electricity over time.
Initial investment and operational costs
A careful plan is required to ensure optimal returns to invest in a fully automated besan plant. Understanding the initial cost and running operational expenses is important for a profitable enterprise.
Estimated price limit
The price of a fully automated besan plant usually ranges from 30 lakh to ₹ 70 lakhs, depending on the brand, and it contains machinery.
People with high-capacity plants or advanced automation facilities may exceed this limit but provide rapid ROIs.
Breakdown of costs
Machinery: Include Dehuskar, Grinder, Pulverizer, Shifting System, Packing Unit, and Conveyor Belt. This is 60–70% of the total investment.
Installation and setup: Costs to collect plant, electrical connections, and initial tests. About 10-15% of the total investment.
Raw materials: Pulses like chickpeas for production. The cost depends on quality and market rates.
Maintenance and servicing: Regular lubrication, spare parts, and minor repairs. About 5–10% of the total investment.
Financing options and government subsidy
Many banks provide loans for food processing machinery with attractive interest rates. Government schemes such as Pradhan Mantri Formalization of Micro Food Processing Enterprises (PMFME) provide financial help and subsidies for small and medium enterprises.
Revenue capacity and market opportunities
Being the owner of a fully automated besan plant opens significant revenue streams locally and internationally. The increasing demand for besan in many areas makes it an attractive business opportunity.
1. Demand in retail, FMCG, and catering industries
Retail region: Besan is a staple in homes, which is used in snacks, sweets, and everyday cooking. The packaged gram flour enjoys high shelf demand in supermarkets and grocery stores.
FMCG companies: Food processing companies use besan as a raw material for ready-to-cook mix, snacks, and bakery items, which produces wholesale demand.
Catering and food services: restaurants, hotels, and catering businesses require large amounts of high-quality besan for traditional and modern dishes.
2. Export opportunities
High-quality besan is growing rapidly in demand globally, especially in the Middle East, the USA, and Southeast Asia.
Besan exports can achieve premium prices due to its nutritional value, hygiene standards, and organic options.
A certified fully automatic gram flour plant manufacturer ensures the machinery meets international quality standards, facilitating export compliance.
Major Ideas Before Purchasing
Choosing the right fully automatic besan plant manufacturer is important to ensure long-term efficiency, reliability, and usefulness. A reliable manufacturer not only provides high-quality machinery but also provides technical support, training, and guidance. This helps businesses to achieve continuous production and operating success.
Factors to consider
- Select a plant that meets your current production needs with room for future expansion.
- Ensure that the manufacturer provides timely service, extra parts, and technical support.
- Choose energy-skilled machinery to reduce working costs.
- Opt for plants with a strong warranty and proven durability.
Comparison of Top Manufacturers
When selecting a fully automatic besan plant manufacturer, it is necessary to compare features, pricing, and support. While many manufacturers provide basic machinery, Aysha stands out for engineering works:
- Customizable plant capacity to match business requirements.
- After-sales service, including installation, training, and maintenance.
- Energy-skilled machines are designed for long-term use.
- Competitive pricing with warranty coverage for all major parts.
Partnership with Aysha Engineering works ensures a reliable investment, a combination of advanced technology with professional support to maximize productivity and profitability.
Challenges and How to Reduce Them
The owner of a fully automated besan plant comes with its own set of challenges, but the active plan can help remove businesses run efficiently. Understanding these challenges ensures smooth operation and makes a maximum return on investment.
Common challenges
Early high investment: Completely automated plants require significant upfront capital compared to a manual setup.
Technical skill requirements: The operation demands trained personnel familiar with advanced machinery automation technology.
Maintenance and downtime risk: mechanical issues or neglect may delay production and increase operating costs.
Effective solution
Training Program: Manufacturers such as Aysha Engineering Works provide operators with training to ensure efficient plant handling.
Regular Servicing: Scheduled maintenance, breakdowns, and prolonged machinery reduce life.
Faithful Manufacturer: A reliable, fully participatory partnership with a fully automatic besan manufacturer ensures quality machinery, technical support, and post-sales service, reducing working risks.
Conclusion
Investing in a fully automated besan plant provides important economic benefits, including low labor costs, high production capacity, regular quality, and long-term ROIs. Automation not only eases processes but also gives businesses a competitive edge in the growing market. For entrepreneurs to skill their besan production efficiently and beneficially, it is necessary to partner with a reliable, fully automatic besan manufacturer. Contact Aysha Engineering today to explore customized solutions that meet your production requirements and help you achieve maximum efficiency and profitability.
