APPLE CHIPS PROCESSING PLANT (MULTI FRUIT & VEGETABLES)
[EIRI/EDPR/4317] J.C. 2499XL
INTRODUCTION
India is known as the second largest fruits and vegetables producer in the world followed by China. India accounts for about 15 per cent of the world’s vegetable production. In the production of many fruits and vegetables, India is either first or second. However, fruits and vegetables being perishable in nature, get wasted to the tune of 20-30 per cent in the whole supply chain due to poor post harvest management. On the other hand, only 2 per cent of fruits and vegetables are processed in to value added products and the rest is consumed as fresh. Therefore, processing of fruits and vegetables offers immense scope for wastage minimization and value addition; thus can generate significant income and employment in Indian agrarian economy.
Fruits and vegetables are seasonal as well as perishable in nature. Dehydration of seasonal fruits and vegetables are good bet for long term storage even upto 5 years or beyond if hermitically sealed and can be made available to the consumers during off season. There is immense scope of market for certain popular and high value dehydrated seasonal fruits and vegetables.
It is estimated that 70-80 percent of the Indian apple growers market their produce via organized marketing channels and approximately 85-90 percent of this fruit is consumed fresh - while the rest is exported, processed, or wasted.(source GAIN report of USDA) As per the latest estimates, by Central Institute of Post Harvest Engineering and Technology (CIPHET), Ludhiana. Hardly 2 per cent of perishable horticultural produce is processed to value added products. Hence, there is huge scope for processing of fruits and vegetables. At the same time, there is market glut during harvesting season and farmers are forced to sell their produce at throw away prices. Therefore, food processing industries can help farmers to get sure income for their produce and also avoid market glut.
COST ESTIMATION
Plant Capacity 600 Kg./Day
Land & Building (1000 sq.mt.) Rs. 1.19 Cr
Plant & Machinery Rs. 1.99 Cr
Working Capital for 1 Month Rs. 37.44 Lac
Total Capital Investment Rs. 3.80 Cr
Rate of Return 26%
Break Even Point 61%
CONTENTS
INTRODUCTION
PROPERTIES
COMPOSITION OF THE APPLE FRUIT:
MARKET OVERVIEW
EXECUTIVE SUMMARY:
INDUSTRY PERFORMANCE
KEY EXTERNAL DRIVERS
DOWNSTREAM DEMAND - SUPERMARKET AND GROCERY STORES
EXTERNAL COMPETITION FOR THE GLOBAL FRUIT AND VEGETABLES PROCESSING INDUSTRY
GLOBAL CONSUMER SPENDING
GLOBAL POPULATION
CURRENT PERFORMANCE
TRENDS IN HEALTH CONSCIOUSNESS AND CONVENIENT MEALS
SIZE AND PROFIT
INDIA
EXPORT MARKET DEVELOPMENT FOR THE VALUE ADDED PRODUCTS
POST-HARVEST MANAGEMENT
INDUSTRY OUTLOOK
OPPORTUNITIES AND TRENDS
INDUSTRY DEFINITION
THE MAJOR PRODUCTS AND SERVICES IN THIS INDUSTRY ARE:
INDIA FACTS AND FIGURES
MARKET SIZE IN INDIA
DEMAND DETERMINANTS
LIFESTYLE CHANGES
COMPETITION
PRICE
CHANGES IN REAL DISPOSABLE INCOME
QUALITY
GROCERY WHOLESALERS AND SUPERMARKETS
MARKET SHARE CONCENTRATION
INDUSTRY CONCENTRATION IS LOW.
KEY SUCCESS FACTORS
MARKETING OF DIFFERENTIATED PRODUCTS
ACCESS TO HIGH QUALITY INPUTS
ATTRACTIVE PRODUCT PRESENTATION
ECONOMIES OF SCALE
ABILITY TO PASS ON COST INCREASES
SUPPLY CONTRACTS IN PLACE FOR KEY INPUTS
COST STRUCTURE BENCHMARKS
COMPETITION IS MEDIUM.
APPLE EXPORTS OF INDIA
MARKETING
PROCESSED FRUITS EXPORTS FROM INDIA
GROWTH DRIVERS
GROWING DOMESTIC REQUIREMENTS
EXPORT OPPORTUNITIES
SUPPLY SIDE ADVANTAGES
EMPHASIS ON R&D AND AUTOMATION
TECHNOLOCICAL ASPECTS
DRIED FRUIT MANUFACTURING PROCESS FLOW CHART.
PROCESS FLOW DIAGRAM OF APPLE CHIPS PROCESSING
PROCESS FLOW CHART
QUALITY CONTROL AND STANDARDS
ENVIRONMENT AND SAFETY ASPECTS OF THE PROJECT AND RELATED PRODUCT
MAJOR PLAYERS
AVAILABILITY OF TECHNOLOGY/KNOW HOW
SPECIFICATION OF PACKAGING MATERIAL FOR APPLE CHIPS
AVAILITY OF FRESH FRUITS AND VEGETABLES CHART IN INDIA
PRODUCT APPLICATIONS
NUTRITIONAL VALUE OF DRIED APPLE CHIPS (12 CHIPS)
AVAILABILITY OF RAW MATERIAL IN VICINITY
DOMESTIC SCENARIO
FRUIT PRODUCTION ZONES IN HIMACHAL PRADESH
FOREIGN EQUIPMENT MANUFACTURERS
POTENTIAL USERS OF INTERMEDIATE PRODUCT
OVERVIEW MARKET
PROCESSING
LIST OF MACHINERY & EQUIPMENTS
DRYER:
BUCKET ELEVATOR:
INSPECTION CONVEYOR:
ROTARY WASHER:
BATCH TYPE WASHER:
MULTI FRUIT & VEGETABLE WASHER:
APPLE SLICER:
FRUIT DRYER (CONTINUOUS HOT AIR BELT DRYER):
PLANT PROJECT LOCATION
DOCUMENTS REQUIRED FOR LICENSES
LIST OF DOCUMENTS:
PRINCIPLES OF PLANT LAYOUT
PLANT LOCATION FACTORS
PRIMARY FACTORS
1. RAW-MATERIAL SUPPLY:
2. MARKETS:
3. POWER AND FUEL SUPPLY:
4. WATER SUPPLY:
5. CLIMATE:
SPECIFIC FACTORS
6. TRANSPORTATION:
A. AVAILABILITY OF VARIOUS SERVICES AND PROJECTED RATES
7. WASTE DISPOSAL:
8. LABOR:
9. REGULATORY LAWS:
10. TAXES:
11. SITE CHARACTERISTICS:
12. COMMUNITY FACTORS:
13. VULNERABILITY TO WARTIME ATTACK:
14. FLOOD AND FIRE CONTROL:
EXPLANATION OF TERMS USED IN THE PROJECT REPORT
1. DEPRECIATION:
2. FIXED ASSETS:
3. WORKING CAPITAL:
4. BREAK-EVEN POINT:
5. OTHER FIXED EXPENSES:
6. MARGIN MONEY:
7. TERM LOANS:
8. TOTAL LOAD:
9. LAND AREA/MAN POWER RATIO:
PACKAGING TYPES
MANUFACTURES PROCESSING MACHINES
SOME OTHER INTERNATIONAL SUPPLIERS OF PLANT AND MACHINERY
CONVEYOR BELT
BUCKET ELEVATORS
WEIGHING MACHINES
BAG SEALING MACHINE
D.G. SET
LABORATORY TESTING EQUIPMENTS
EFFLUENT TREATMENT AND DISPOSAL
STANDARDS
TOLERANCE LIMITS FOR INDUSTRIAL EFFLUENT DISCHARGE
WASTE TREATMENT
PRIMARY TREATMENT
SECONDARY TREATMENT
TERTIARY TREATMENT
SOLIDS CONCENTRATION
TYPICAL WASTE SOLIDS CHARACTERISTICS
PHYSICAL METHODS FOR EFFLUENT TREATMENT
MICROBIOLOGICAL APPROACH FOR EFFLUENT TREATMENT
EQUIPMENT REQUIREMENT
EQUIPMENT REQUIREMENTS
MANPOWER
GENERAL
BASIS OF ESTIMATION
UTILITIES
WATER
WATER QUALITY PARAMETERS FOR PROCESSED WATER:
STEAM
UTILITIES (EQUIPMENTS)
WATER TREATMENT PLANT
REFRIGERATION SYSTEM:
POWER
WORKING
TOTAL MANPOWER AND PAYROLL
QUALITY CONTROL
QUALITY CONTROL PROCEDURE/ PARAMETERS
PHYSICAL EXAMINATION
DETERMINATION OF MOISTURE CONTENT
PROCEDURE
CALCULATION
DETERMINATION OF SOLUBLE SOLIDS
PRINCIPLE:-
APPARATUS
DETERMINATION OF ACIDITY
DETERMINATION OF TOTAL ASH
TEST FOR PRESENCE OF MINERAL ACID
DETERMINATION OF REHYDRATION RATIO:
PROCEDURE
CALCULATION
FINAL PRODUCTS PHOTOGRAPHS
SWOL ANALYSIS
STRENGTHS
OPPORTUNITIES
WEAKNESS
LIMITATIONS
ADDRESSES OF RELEVANT GOVERNMENT OFFICES
ADDRESSES OF FINANCIAL INSTITUTIONS
CLEARANCE REQUIRED
ORGANIZATION CHART
PLANT LAYOUT
TURNKEY CONSULTANT
IMPLEMENTATION SCHEDULE
EFFLUENT TREATMENT PLANT
EFFLUENT TREATMENT PLANT OR ETP FOR FOOD INDUSTRY
TREATMENT CHARACTERISTICS:
TREATMENT SCHEME:
DETAILS OF EFFLUENT TREATMENT PLANT
BLOCK DIAGRAM FOR S.T.P BASED ON AEROBIC TECHNOLOGY:
TREATMENT PROCESS DESCRIPTION
(A) PRIMARY TREATMENT:
(I) OIL AND GREASE REMOVAL SYSTEM
(B) SECONDARY TREATMENT:
(I) DISINFECTION
(C) TERTIARY TREATMENT:
(I) BIOLOGICAL TREATMENT (MBBR)
MBBR COMBINES:
(II) DIFFUSED AEREATION SYSTEM
PLANT AND MACHINERY SPECIFICATIONS
STP PROCESS FLOW DIAGRM
DESCRIPTION OF BLOCK DIAGRAM
APPENDIX – A:
01. PLANT ECONOMICS
02. LAND & BUILDING
03. PLANT AND MACHINERY
04. OTHER FIXED ASSESTS
05. FIXED CAPITAL
06. RAW MATERIAL
07. SALARY AND WAGES
08. UTILITIES AND OVERHEADS
09. TOTAL WORKING CAPITAL
10. TOTAL CAPITAL INVESTMENT
11. COST OF PRODUCTION
12. TURN OVER/ANNUM
13. BREAK EVEN POINT
14. RESOURCES FOR FINANCE
15. INSTALMENT PAYABLE IN 5 YEARS
16. DEPRECIATION CHART FOR 5 YEARS
17. PROFIT ANALYSIS FOR 5 YEARS
18. PROJECTED BALANCE SHEET FOR (5 YEARS)