Manual to Automatic Roasted Makhana Machine: Startup Scale-Up Case Study

Due to organised retail and health-conscious consumers, demand for roasted makhana in India is growing rapidly. Most rural companies start with hand roasting to keep expenses low. However, a step rise in demand often brings output, consistency, and profitability to a standstill. This case study shows how moving from a manual to an automatic roasted makhana machine affected expenses, productivity, quality, and earnings.

Manual Roasted Makhana Production: Small-Scale Makhana Processing Basics

Roasted Makhana is made manually using simple earthen pots or cast-iron skillets for roasting dried seeds on high heat. After that, the seeds are popped manually using mallets. It is a good starting option for those who want to test the market.

• Production Capacity: The production capacity per day is 8-10 kg popped makhana, as the processing needs to be done manually. The average size of each production lot is 1-2 kg roasted, processed in 10-15 minutes at temperatures ranging from 250 to 320°C, taking 2-3 days for tempering. This requires the assistance of 4-6 trained labourer’s.
• Low investment requires only simple equipment such as pots and mallets, which facilitates easy startup by beginners with low investment, generating instant revenues of ₹400-₹450 per kg with losses typically remaining between 20-30%.

Hidden Limitations

• Inconsistent roasting:  Uneven heat in manual pans causes imperfect popping, while seconds of delayed malleting lead to burning of seeds.
• Uneven quality: There are substantial losses (loss rate 20-30%) due to sorting and grading by human workers. ​ 
• Labour dependency: Requires skilled labour for hot tasks, resulting in high labour costs, labour injuries, and scalability issues.

How Manual Roasting Holds Back Small-Scale Makhana Growth

The manual processes compel Makhana Enterprises to implement roasting machines within the next 6-12 months, enhancing production capacity by 5-10 times or up to 50-100kg/day.

Key Benefits of Upgrade

• Scale Surge: Semi-automatic roasters are able to process 5-10 kgs in 8-10 minutes, thus enabling over 40 batches in a day with only two operators.
• Cost Reduction: Fuel costs drop by nearly 50%, and labour costs reduce by around 60%, saving approximately ₹10,000 per month; losses fall to about 5%.
• Quality Leap: Consistent 90% perfect pops, FSSAI compliant for hygiene, premium pricing set at ₹550 per kilo.

Also read: Small Makhana Processing Machine | 5× Faster, High Output

The Decision Point: Why the Startup Chose an Automatic Roasted Makhana Machine

The startup shortlisted the Manual to Automatic Roasted Makhana Machine to overcome the limitations faced by the manual process and aim to produce output between 50-100 kg/day, having eliminated the other option, which was manual.

Evaluation Criteria: 

• They had a requirement of 20-30 kg per hour power capacity, which could be met through the availability of power capacity (3-5 HP, single phase) and size (8×10 ft). 
• The ROI of 6-9 months could be anticipated with estimated sales of₹50,000+ per month.

Manual Expansion Rejected: 

• If 8-10 employees are employed, the expenses immediately escalate to ₹40,000 per month with no quality control.
• As a result,​ Inconsistency persists, the variation in fire outcomes raises a 25% rate of rejection, preventing building trust.
• Scalability is restricted to 15 kg/day, and there are unmet wholesale demands. 

Dependence on Semi-Automatic Labour:

• Remains at 3-4 for loading/mallets, restricted to 25kg/day owing to high turnover rate​. Marginal Improvement, 2x production with 30% losses is still applicable. 
• ROI period expanded to 18 months from 90% efficiency in the entire auto industry.

Upgrading to Automatic: Installation & Transition Made Easy

Installation and transition to the automatic roasted makhana machine took only 7-10 days, installing confidence in rural teams at Bihar’s processing hubs.

Setup Timeline

• Makhana making machine installation is done within 2-3 days by technicians, including electric setup and calibration, in order to arrive at a throughput of 20-30 kg/hour. 
• Trial runs entailed, in a period of three days, optimisation of sand temperature 250-320°C and batch timing for optimum popping, reaching 90% perfect pops.
• Basic training on the controls, safety, and cleaning, which was purely commonsensical, was imparted within two days, with simple manuals; no advanced skill is required.

Operational Changes

• Manpower reduced: From 4-6 to 1-2 operators, which reduces costs by 60% and handles 50-100 kg/day.
• Smaller cycle times: 8-10 min batches vs. 15 min manual; this enables 40+ shifts without fatigue.
• Predictable quality: Uniform roasting eliminates variations, reducing rejects to 5% for FSSAI compliance. 
• Rural workers adapted seamlessly due to intuitive PLC panels with minimal tech, many at only an 8th-grade education level of training, and mastered it in hours.

Results After Switching to an Automatic Roasted Makhana Machine

A Manual to Automatic Roasted Makhana Machine enabled it to increase production scale from 8-10 kg/day to 50-100 kg/day.

Production Output

• Before: Only 8-10 kg per day, with only 4-6 batches. 
• After: Peak orders are easily completed at the rate of 50-100 kg per day, without production delays.

Labour and Cost Impact

• Manpower reduced: 4-6 people to 1-2 operators.
• Fuel conservation: 50% through optimal heating of sand, saving ₹5,000/month.
• Per kg control: The cost of production reduced from ₹250 per kg to ₹150 per kg.

Investment Check: Did the Automatic Machine Pay Off?

Conclusion

We are well aware of the fact that the transition from Manual to Automatic Roasted Makhana Machine is no ordinary step. We at Foodsure Machines perform investment maximisation, production augmentation, and quality enhancement for start-ups and FPOs. Your scale-up will be hassle-free and profitable for you.