Professional Documents
Culture Documents
Introduction
The changing food habits and increased export has boosted the demand side
of bottled fruit juice both in the domestic market, institutional market
(hotels, hospitals, airlines and defence).
There is a growing demand for orange, pineapple and apple juice both in the
domestic and international market. The demand of high aromatic passion
fruit juice in the European and American market is also very encouraging.
Mizoram has good existing production of passion fruit.
Process
The farm arrived fruit are first washed than sorted for inspection. From
inspection conveyor the fruit is passed on to fruit mill for crushing and than
to hydraulic press for juice extraction.
Extracted juice is than filtered though press filter and again sent to
centrifuge for clarification.
The clarified fruit juice is concentrated in evaporation plant.
The concentrated juice is sterilized in plate heat exchanger by heating.
The sterilized juice in the hot condition is aseptically packed in aseptic bags
by aseptic bags by aseptic filling packing machine.
Plant capacity – About 2500 kg per day fruit juice concentrate of orange
and passion fruit.
Plant equipment- Infeed fruit conveyor, fruit washer, fruit mill, screw pre
heater, hydraulic press, pulper, press filter, sugar syrup preparation kettle,
aerator, tubular/ plate sterilized/ pasteurizer, jacketed storage tank and filling
machine.
Land requirement – About 400 m2 developed land will be required
Building and civil work - About 1500 m2 floor space is sufficient for
running the plant conveniently.
Power requirement - Total connected load of about 300 KW will be
required.
Water requirement – About 40 KL of fresh water will be required every
working day.
Employment - About 75 persons
Raw material – About 7-8 MT orange or passion fruit every day.
Turn over – Rs. 180.00 lakhs p.a.
Estimated Project Cost (with out cost of procuring land)
Particulars Rs. Lakhs
Land development cost 4.00
Building 60.00
Infrastructure 15.00
Plant and Machinery 75.00
Other Assets 9.00
Technical fees 4.50
Preliminary Pre-operative expenses 8.36
Margin Money 9.00
Contingency 5.14
Total Project Cost (approx) 190.00
FRUIT PROCESSING
MARKET POTENTIALITY : -
At present 15 Micro unit are producing Jam, Jelly Pickles and marketed
locally. Most of the units are in home scale and without F.P.O. quality
standard. The consumption of Jam, Jelly and Pickles are increasing due to
urbanization of families.
The consumption of Jam & Jelly and pickles is around 5 kg. & 2.0 kg.
Annually considering an average family size of 6 numbers in urban
household area.
Fruit processing industries in NER is not fully organized most of the units
are Home scale unit without FPO quality specification due to which they
have to sale their product locally. By over coming these constrains, a few
good units in semi-urban area or in town area with infrastructure facilities
for processing fruit and few micro half processing fruits home scale units
may come-up as a sub-sectors to support to these units and to utilize
available resources during season times. This type of half process unit will
come with a minimum investment of Rs. 10,000/- to Rs. 20,000/- and they
may earn Rs. 1,500/- to Rs. 4,000/- depend on their value addition materials.
PRODUCTION TARGET :-
Installed Capacity : 300 Kg. per day and 60 MT per year in single shift
Utilized Capacity : 66 MT per annum
Product Mix : 45:60:5
Jam : 14.4 MT
Jelly : 16.2 MT
Squash : 21.6 MT
Pickles : 1.8 MT
Jam – The fruit are placed in a slam jalleted shallow kettle and the stem is
turned on the product generally cooked to a temperature of 65 )C to 0C to 78
0C as determined by the preserve thermometer. A small quantity of water is
also added before boiling the mixture to facilitate pulping. Requisite amount
of pectin is added at this stage. The product together with an almost quantity
of citric acid to a temperature of 2200C to 2220C determined by a preserver’s
thermometer. The product is cooled before packing.
Jellies and Squashes : The washed and peeled traits are fed into hopper of
a juice extractor and the juice is filtered. The juice containing sufficient
pectin and the dry sugar are boiled in the stream- jacketed kettle until a
satisfactory Jelly is obtained. Necessary preservative are added towards the
end of boiling process. The extracted and clean juice are sent into a stainless
steel blending tank, where juice is mixed with sugar syrup and other
ingredients like citric acid, essence of orange/ Lemon/ pineapple, water
preservative etc.
Pickles : The washed, peeled and sliced fruit are kept in 2 percent common
slat solution for 24 hours. Then the fruits are kept in a 4 percent common
slate solution for 24 hours. The process is repeated for another two days. On
the fifth days the fruit are shows that the fruits are cured than they are
washed thoroughly in clean hot water. The products kept in vinegar of 5%
acetic acid solution and spice is added to it. Apart from this procedure a
number of local producers are also available which may also be followed.
FEASIBLE LOCATION :-
The site should be surrounded by available raw materials as well as skilled
manpower.
SKILL REQUIRED : -
At least to 2 weeks training is required for necessary skill. This skill can be
acquired through locally available institute or from Govt. Agricultural
Development offices. The quality maintenance is very important and it
should be according to FPO norms of Food products Meter act.
QUALITY CONTROL & STANDARDS : The BIS specification is
IS : 4936 – 1968 : Fruits squash
IS : 3881 – 1966 : Tomato juice
PLANT AND MACHINERIES :
Plant Building : 300 Sq. Feet. : As per F.P.O norms prescribe ministry of
food processing :-
(i) Baby boiler 1
(ii) Screw type juice extractor 1
(iii) Jacketed Kettle of 50 liter capacity 2
(iv) Tomato baby pulpier 1
(v) Cooling tank 2
(vi) Juice stores tank 2
(vii)Juice store tank 1
(viii) Stainless steel knives 20 Pcs.
(ix) Pilfer proof cup sealing machine 1
(x) Platform weighting scale 1
(xi) Water arrangement with filtration and filtrate 1
(1000 capacity tank)
(xii) Stainless steel posts 5
(xiii) Syrup Mudding tank 1
(xiv) Gas Burner (Commercial) 2
Ractracto meter 0.50% 1
40% - 85% 1
Utilities :-
Power : 235 Kw
Water : 2000 Kiloliter
Steam : 40 Tones
Coal or Gas : 8 tones (120 cylinder per annum)
Capital Cost :-
Land Development : 30,000.00
Shed of 300 sq.Ft@300/- sq.ft. : 90,000.00
Preliminary & per operative : 30,000.00
Installation : 10,000.00
Plant office Furniture : 15,000.00
Plant & Machinery : 1,70,000.00
Total : 3,45,000.00
(a) Consumption of Raw Materials :
(b) Manpower :
(c) Utilities :
i) LPG Gas Cylinder 7 250/- 2,52,000.00
(d) Overhead :
i) Printing & Stationary 1,000.00
ii) Advertisement (Banner & Leaflet) 2,400.00
iii) Internal travels 6,000.00
iv) Power 6,000.00
v) Insurance 2,400.00
Total 17,800.00
TOTAL INVESTMENT
Abstract of guidelines regarding grant of fruit products order licence for the
manufacture of products. It is informed that there are five categories of
licence under fruit products order-1955, depending upon the annual
production in metric tones. The details of the different categories are given
below :-
The entrepreneur is also required to make provision for free flowing tap
water in the manufacturing area. Water shall be got analysed chemically and
bacteriologically for its for its profitability by a recognized laboratory, it
should be ensured that the water sample for analysis is drawn by a
representative of the laboratory or local health inspector and mention to this
affect is made in water analysis report.
The total investment approved so far exceeds Rs. 4309 crores (US$ 1.19
billion), out of which foreign investment is Rs. 788 crores (US $ 218.8
million).
This sector is regulated by the Fruit Products Order, 1955 (FPO), issued
under the Essential Commodities Act. The Ministry of Food Processing
Industries administers this order. The order lays down product specifications
and quality control requirements on production-hygiene, relabeling and
marketing of processed fruit product.
All processing units are required to obtain a license under this order.
Periodic inspection of units is also carried out. In addition, consignments of
fruit products intended for export are subject to pre-shipment inspection
under the FPO. Many F&VP industries are eligible for automatic approval of
foreign technology agreement and up to 51% foreign equity participation.
These include : tomatoes, mushrooms, fruit, fruit-peel, fruit jellies,
marmalades, fruit juices, etc.
Market
The present industry is fragmented by different operation sizes as follows :
• Home Scale 44%
• Cottage Scale 17%
• Small Scale 16%
• Relabeller 14%
• Large Scale 9%
It is very difficult to estimate the actual and potential market size of this
product category. However, there is a latent demand of around 10 crores
litters of natural fruit juice which is much more than current consumption/
supply level of around 3 crores litters, both organized and unorganized
sectors taken together.
Fresh and processed fruits have been identified as a thrust area for export
too. In view of the above, it appears that there is a good scope for the
proposed fruit processing industry in Manipur.
The world fruit juice market has become much more competitive in
recent years and in most developed countries, there is a plentiful supply
of fruit juice concentrate. The market for reconstituted orange, apple and
pineapple juice in particular has become very competitive.
Major fruit processors therefore with to produce fruit juices, which are of
such a high quality that the product can be readily differentiated from
cheaper counterparts. To meet this demand, there is a growing trend
toward the production of “not-from-concentrate” (NFC) juices since
these are perceived to be of better quality than reconstituted juices.
In the US, production of NFC orange juice has grown to 30% of the total
production within five years and, despite the high cost of transportation,
this trend is being repeated in Europe. Similarly new opportunities are
arising for NFC juice containing cells and fibre processed from wide
range of freshly squeezed and cellular fruit juices.
These temperate area fruit are processed using similar process equipment,
but each has particular characteristics, which affect the exact method of
extraction and thermal treatment. Most of these fruits contain pectin, which
needs to be removed in order to produce a clear and product.
Nectars are obtained by the addition of water and sugar to fruit juice, fruit
juice concentrate, fruit puree or a mixture of these. Fruits suitable for nectar
production includes :
• Apricot
• Peach
• Pear
• Mango
• Guava
• Apple
• Citrus juices
Process
• The farm arrived fruit are first washed than sorted for inspection.
From inspection conveyor the fruit is passed on to fruit mill for
crushing and than to hydraulic press for juice extraction.
• Extracted juice is than filtered through press filter and again sent to
centrifuge for clarification.
• The clarified fruit juice is concentrated in evaporation plant.
• The concentrated juice is sterilized in plate heat exchanger by
heating.
• The sterilized juice in the hot condition is aseptically packed in
aseptic bags by aseptic filling packing machine.
Proposed capacity
The proposed multi fruit juicing unit will have a finished production
capacity of about 1,500 MT juice per annum as follows :
Raw Material
The raw material and other material requirement for manufacturing
pineapple, orange and passion fruit juice for the projected production mix
and quantity will be as follows :
Item RM Annual value Quantity Annual value
Quantity @ of RM (Rs. In (MT) 2nd of RM (Rs.
70% (1050 Lakhs) year In Lakhs)
MT) onwards
@ 80%
(1200
MT)
Pineapple 3139.50 55.88 3588.00 63.86
Orange 571.67 28.58 653.33 32.67
Passion fruit 513.33 23.10 586.67 26.40
Total Quantity
Sugar required per MT 157.50 24.41 180.00 27.90
finished product
Preservatives & Additives - 2.63 - 3.00
@ Rs. 250/MT finished
product
Packing materials @ Rs. - 52.50 - 60.00
5000/-
Fuel for generating steam 48.30 9.66 51.84 10.37
as well as for DG set
Total 4430.30 196.76 5059.84 224.20
Land requirement : 4 acres of land
Power requirement
Total connected load of about 250 KW will be required. Due to present short
supply of power a DG set back up of 150 KVA is also envisaged.
Water requirement
About 75 KL of water will be required every working day.
Employment
93 persons of different category as per following table
Sl. Type On roll Salary/ Total Annua
No. wages per rupees per l cost
month month Rs. In
Lakhs
1. Managerial (Senior) 2 18,000.00 36,000.00 4.32
2. Sr. Engineer 3 12,000.00 36,000.00 4.32
3. Engineers 3 10,000.00 30,000.00 3.6
4. Technical supervisor 4 6,000.00 24,000.00 2.88
5. Non-Technical 9 4,000.00 36,000.00
supervisor
6. Clerical staff 2 3,500.00 7,000.00 0.84
7. Skilled worker 10 3,500.00 35,000.00 4.2
8. Semiskilled worker 30 3,000.00 90,000.00 10.8
9. Unskilled worker 30 2,000.00 60,000.00 7.2
Total 345,000.00 42.48
(Rs. In Lakhs)
Description of Investment Total Cost
Preliminary expenses 2.60
Land and Land Development 4.90
Drains, Roads & Walls 19.60
Civil Structural 49.30
Main processing plant and equipment 697.60
Auxiliaries 22.00
Utilities 77.10
Pollution control equipment 26.30
Other assets 8.20
Electrical 29.10
Eng. & pre operative expenses 135.40
Margin for working capital 32.90
Total Capital cost 1105.00
Break-even Point
Break-even point of the project is determined in the 2nd year at 80% of
installed capacity. The break-even point of the projection is at 35% of
installed capacity in the 2nd year of operation when plant optimizes its
production at 1200 TPY.
Pay Back Period
The entire capital investment excluding margin for working capital will be
paid back within 5 years and 1 months of operation.
Supplier of equipment
SSP Limited
Contact Person : Mr. Tapas Chatarjee
Address : 19 DLF Industrial Area, Phase-II, 13/4, Mathura Road,
Faridabad, Haryana-121003 (INDIA)
Phone : +(91)(129) 2275441/ 2277730
Fax : +(91) (129) 25277441
E-mail : info@sspindia.com
M/s Albertson International, USA
M/s Bardo Citrus Products, USA
M/s In Industries Alimenticias, Brazil
M/s Citrosuco Paulista, Brazil
M/s Alfa Leval, Sweden/ India
Introduction
The consumption of the products like mixed fruits jam and orange jam/
marmalade is gaining popularity day by day owing to the growing change in
the food habits and increased consumption of bread and other convenient
snack foods.
As regards fruit squash, it finds wide consumption as fruit drink. India is, by
and large, a tropical country where the habit of taking soft drinks is pretty
high.
Investment scenario
Since withdrawal of excise duty on fruit and vegetable products there has
been significant rise in the growth of the industry. The sector has registered
a production growth of 13% overall, exports have been increasing
continuously and are put at US$ 250.5 million.
The total investment approved so far exceeds Rs. 4309 crores (US $ 1.19
billion), out of which foreign investment is Rs. 788 crores (US $ 218.8
million).
This sector is regulated by the Fruit Products Order, 1955 (FPO), issued
under the Essential Commodities Act. The Ministry of Food Processing
Industries administers this order. The order lays down product specifications
and quality control requirements on production-hygiene, a labeling and
marketing of processed fruit product.
All processing units are required to obtain a licence under this order.
Periodic inspections of units are also carried out. In addition, consignments
of fruit products intended for export are subject to pre-shipment inspection
under the FPO. Many F&VP industries are eligible for automatic approval of
foreign technology agreement and up to 51% foreign equity participation.
These include; tomatoes, mushrooms, fruit, nuts, fruit-peel, fruit jellies,
marmalades, fruit juices, etc.
Technology- The proposed manufacturing activity does not call for import of
technology. However, CFTRI, Mysore may be contacted for technical know-
how.
Process
Squash
The fruits (orange & others like passion/ peach/ berry) are carefully sorted/
selected according to quality. The fruits are then washed with sprayed water
to remove unwanted elements. After washing, the fruits are again inspected.
The oranges are peeled. The peeled oranges are put to juice extractor for
extraction of juice. Juice is collected in stainless steel tanks and fed into
strainer where suspended coarse materials are removed. The juice is then
centrifuged in stainless steel centrifuge. The juice is diluted to required
concentration to which sugar and citric acid are added. Necessary flavours,
permitted colour and preservative are also added to it to form squash which
is subsequently filled in glass bottles, sealed, labeled and packed in cartons
for dispatch.
Jam/ Marmalade
The pulp produced after extraction of juice is boiled along with sugar and
citric acid at a controlled temperature. Upon boiling required permitted
colours, flavours and preservatives are added. It is then cooled to required
temperature and forms a jelly like consistency. The jam thus obtained is
filled in bottles, sealed, labeled and packed in cartons for dispatch.
Tomato Sauce
Fully ripe selected tomatoes are washed at first and then sliced. It is heated
and passed through pulper to produce pulp followed by sieving. The liquid
pulp is boiled/ cooked with various ingredients (ground spice, garlic, onion
etc. as per formulation) followed by addition of sugar, salt, acetic acid/
vinegar, chemicals etc. Sodium Benzoate is generally added before the
product is filled into washed bottles, sealed, labeled and packed in cartons
for dispatch.
Proposed capacity
The unit will operate on two-shift basis per day for 250 days per annum. The
unit will have the flexibility to process nearly 500 Kgs. each of Orange and
mix fruit per shift, depending on the availability. The profile is based on
processing of orange for 00 days, mixed fruits for 25 days and Tomato for 60
days.
Sugar citric acid, preservatives, colours, chemicals, salts, spices etc. are also
required for production of the said items. The products will be packed in
glass bottles/jars and finally in cartons. All these fruits are available within
the State, NER and other parts of the country and may be procured from
different producing centers in different seasons. The average cost of fruits
has been taken considering the seasonal fluctuation in price. All other
consumable items can easily be procured from the local dealers/ open
market.
The details of raw material requirement is given below :
Power requirement
Total connected load of about 30 KW will be required. Due to present short
supply of power of DG set back up to 30 KVA is also envisaged.
Water requirement
About 0 KL of water will be required every working day.
Employment
20 persons of different category as per following table
(Rs. In Lakhs)
Supplier of equipment
SSP Limited
Mather & Platt (India) Ltd., Mumbai
Pasteur Engineering Co. Ltd., Kolkatta
Process Machinery and Equipment Pvt. Ltd., Kolkatta
Batliboi & Co. Ltd., Kolkatta
PEC Boilers (P) Ltd., Kolkatta