DEHYDRATED VEGETABLES
[EIRI/EDPR/4378] J.C.: 2570XL
INTRODUCTION
Food drying / Dehydration of food is a method of food preservation that works by removing water from the food, which inhibits the growth of bacteria. Water is traditionally removed through evaporation (air drying, sun drying, smoking or wind drying), although today electric food dehydrators or freeze-drying can be used to speed the drying process and ensure more consistent results. Dehydrated fruits are a good and healthy option to snack on for people who lead a busy life and don’t get proper time for meals. It contains high nutrients and good calories that are required in one’s daily diet. This also increases the shelf life of the fruits and vegetables.
Dehydrated fruits & vegetables are majorly used in ready to eat foods, fruit bars, soup, energy drinks, beauty products, aromatherapy oils, bakeries, organic paints, etc. It can also be sold individually like raisins, dried figs (Anjeer), banana chips dried mangoes, dried oranges, dates, coconut, sun-dried tomatoes, dried potato chips, amchur powder, chili powder, food flavoring etc. It is also used as flavoring by many kinds of manufacturers.
Dehydrated fruits and vegetables are mostly used by space stations, hikers, campers, hotels, restaurants, organic food retail stores, herbal tea manufacturers. It is a life saver in areas that are affected by disasters like earthquakes, flood, etc. as most of dehydrated products do not require any cooking or refrigeration.
According to IBEF (India Brand Equity Foundation), the Indian food and grocery market is the world’s sixth largest, with retail contributing 70 per cent of the sales. The Indian food processing industry accounts for 32 per cent of the country’s total food market, one of the largest industries in India and is ranked fifth in terms of production, consumption, export and expected growth. It contributes around 8.80 and 8.39 per cent of Gross Value Added (GVA) in Manufacturing and Agriculture respectively, 13 per cent of India’s exports and six per cent of total industrial investment. The Indian gourmet food market is currently valued at US$ 1.3 billion and is growing at a Compound Annual Growth Rate (CAGR) of 20 per cent.
In India, Dehydration of fruits and vegetable has a bright prospects over other foods because India has diverse geographical and climatic conditions and produces a wide range of fruits and vegetables throughout the year. Here almost all type of fruits and vegetables are grown all over the country. These fruits and vegetables are valuable foods. They are a rich source of calcium, phosphorus, iron and vitamins.
Dehydrated fruits & vegetables include a no. of articles mainly, fruit juices, dehydrated fruits and vegetables, squashes, cordials, Beverages, jam, jellies, mermalades, chutney, sauces, pickles, vinegar, pectin etc.
Dehydration is at present defined industrially as drying by artificially produced heat under carefully controlled conditions of temperature, humidity, and air flow. The term `dried' is applied to all dried products regardless of the method of drying.
COST ESTIMATION
Plant Capacity 12 MT/Day
Land & Building (6770 sq.mt.) Rs. 7.10 Cr
Plant & Machinery Rs. 15.89 Cr
Working Capital for 0.1 Months Rs. 84.37 Lac
Total Capital Investment Rs. 24.60 Cr
Rate of Return 35%
Break Even Point 55%
CONTENTS
INTRODUCTION
BENEFITS OF DEHYDRATION
USES/APPLICATIONS
BLANCHING TIME FOR VEGETABLES
TYPICAL PERCENTAGE COMPOSITION OF FOODS OF PLANT ORIGIN
OVERVIEW OF VEGETABLES SECTOR IN INDIA
MAJOR STATES
OPPORTUNITIES IN FRUITS & VEGETABLES PROCESSING AT A GLANCE
KEY STATES FOR TOP 5 VEGETABLES IN INDIA
MARKET POSITION OF DEHYDRATED VEGETABLES
THE MAJOR PLAYERS IN THE DEHYDRATED VEGETABLES MARKET
PRESENT STATUS
FUTURE SCOPE
MANUFACTURERS/SUPPLIERS OF VEGETABLE DEHYDRATION
BIS CERTIFICATION MARKING
THE PRODUCT MAY ALSO BE MARKED WITH THE STANDARD MARK.
ECO-MARK
SAMPLING
DIFFERENT DEHYDRATION METHOD/PROCESS
SUN DRYING:
SOLAR DRYING:
ROOM TEMPERATURE DRYING:
FREEZE DRYING:
DRUM DRYING:
SPRAY DRYING:
OSMOTIC DRYING:
TYPES OF DRYING VEGETABLES
NATURAL SUN DRYING
OVEN DRYING
TABLE: POUNDS OF DEHYDRATED FOOD FROM FRESH FRUITS AND VEGETABLES
COMPOSITION OF ONION
MANUFACTURING PROCESS
COMPARISON WITH CANNED FRUITS AND VEGETABLES
FOOD VALUE OF DEHYDRATED FRUITS AND VEGETABLES
PROCESS FLOW
MANUFACTURING PROCESS OF GARLIC DEHYDRATION
PROCESS FLOW
MANUFACTURING PROCESS OF ONION DEHYDRATION
PROCESS FLOW
PREPARING VEGETABLE FOR DEHYDRATION
STEPS FOR STEAM BLANCHING
STEPS FOR WATER BLANCHING (VEGETABLES ONLY):
METHODS OF DEHYDRATION
SUN DRYING:
SOLAR DRYING:
ROOM TEMPERATURE DRYING:
FREEZE DRYING:
DRUM DRYING:
OSMOTIC DRYING:
PROCESS DESCRIPTION
PREDRYING TREATMENTS
DRYING OR DEHYDRATION
POST DEHYDRATION TREATMENTS
TABLE. BLANCHING AND DRYING TIMES FOR SELECTED VEGETABLES
TABLE. BLANCHING AND DRYING TIMES FOR SELECTED FRUITS
WASHING
PEELING
SLICING, DICING AND SHREDDING
BLANCHING
SULFITING
TRAYS
TRAY LOAD
DRYING TEMPERATURES
VACUUM DRYING
MOISTURE CONTENT
ENZYME TESTS
DRYING RATIOS
ONION
GENERAL
PACKING AND STORAGE
GUIDE LINES AND LICENSES FOR DEHYDRATION PLANT
TRADING/DISTRIBUTORSHIP:
RETAIL:
LICENSES REQUIRED:
GST
FDA LICENSE
PRELIMINARY LAYOUT
SUPPLIERS OF PLANT & MACHINERIES
PLANT AND MACHINERY SUPPLIERS OF COLD STORAGE UNIT
ROTARY WASHER
BLANCHING EQUIPMENTS
TRAY DRYER
BOILERS
TUNNEL DRYER
LABORATORY TESTING EQUIPMENT
MATERIAL HANDLING EQUIPMENTS
INSTRUMENTATION & PROCESS CONTROL EQUIPMENTS
ETP PLANTS
SUPPLIERS OF RAW MATERIALS
SUPPLIERS OF VEGETABLES
PRINCIPLES OF PLANT LAYOUT
MAJOR PROVISIONS IN ROAD PLANNING FOR MULTIPURPOSE SERVICE ARE:
ANTICIPATED ENVIRONMENTAL IMPACTS
CONSTRUCTION PHASE
OPERATION PHASE
MITIGATION MEASURES (PROPOSED)
PROPOSED IMPLEMENTATION SCHEDULE
PROJECT FINANCIALS
BASIS & PRESUMPTIONS (FOR PROFITABILITY WORKINGS)
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)