POTATO CHIPS, FRENCH FRIES & FLAKES
[EIRI/EDPR/3572] J.C.: 1657XL
INTRODUCTION
When American-style potato chips were introduced in Great Britain in the 1920s, to avoid confusion with the established term “chip potatoes” they were called potato crisps or simply crisps. Over time, though, these clearly drawn distinctions became blurred. For instance, British-style batter-fried fillets and fried potatoes have become popular in the United States and Canada, and even on the western side of the Atlantic they’re called “fish and chips.” Similarly, when thin French fries—along with hamburgers and other American fast foods—went global, the word “fries” became the standard term in many English-speaking countries (at least in fast-food outlets). Likewise, as American snack foods were marketed overseas, the term potato chips was adopted throughout the world, even in the United Kingdom—although most people there do still call them “crisps.”
The creators of novel potato-based snacks have introduced some new coinages to the world of chips and crisps. In 1967, General Mills introduced Chipos, said to be tastier, crisper, lighter, and less oily because they were fried much faster than traditional potato chips. Two years later Procter & Gamble introduced Pringles, made from dehydrated and reconstituted potatoes. Pringles are uniform in size and shape, so they can be stacked and packaged in a tube. Chipos didn’t make the cut as a commercial product. Pringles were a tremendous success and are sold all over the world, but apparently the time has not arrived for them to be enshrined in an Oxford dictionary.
Potato is widely consumed as food all over the world. Cooked potatoes, in various forms are offered in restaurants and refreshment stalls and variety of processed potato products are available in the market. Surplus and cull potatoes are used as feed for livestock and also as raw material for the manufacture of starch, ethyl alcohol and a few other industrial products.
Potatoes are consumed not only as a fresh vegetable, but also in a variety of processed forms. Dehydrated potato products have been known for long and are especially valued because they afford convenience for use; they have good storage stability and are relatively any to transport. In recent years, there has been a great spurt in the consumption of processed products, such as potato chips, dehydrated mashed potatoes and frozen potato products.
COST ESTIMATION
Plant Capacity 6 MT/Day
Land & Building (3000 sq.mt) Rs. 3.86 Cr
Plant & Machinery Rs. 5.90 Cr
Working Capital for 1 Month Rs. 1.27 Cr
Total Capital Investment Rs. 11.30 Cr
Rate of Return 67%
Break Even Point 19%
CONTENTS
INTRODUCTION
WHAT IS THE DIFFERENCE BETWEEN CRISPS AND CHIPS?
PACKAGED FROZEN FOODS
THERE ARE ACTUALLY TWO MAIN TYPES OF POTATO FLAKES PRODUCED:
FULL PROCESS FLAKES
LOW LEACH FLAKES
B.I.S SPECIFICATIONS
EFFECTIVENESS AND QUALITY OF FROZEN FOODS
EFFECTIVENESS
QUALITY
DETAILS OF INDIVIDUAL QUICK FREEZING (IQF)
THE MAJOR MARKET SEGMENTS FOR IQF ARE-
MARKET SURVEY
REGIONAL ANALYSIS
KEY PLAYERS
SNACK PRODUCTS MARKET IN QATAR
POTATO SPECIALTY SNACK PRODUCTS TO RETAIN DOMINANCE
RETAIL PACKAGE SEGMENT DOMINATES QATAR AND GCC SNACK PRODUCTS MARKET
OVERVIEW OF INDIAN SNACKS MARKET
MARKET OVERVIEW OF POTATO CHIPS IN INDIA
OVERVIEW OF POTATOES FLAKES
OVERVIEW OF GLOBAL FROZEN POTATO PRODUCTS MARKET
INDIAN POTATO TO GO GLOBAL WITH GAP CERTIFICATIONS
VIMAL OIL TO ENTER SNACK FOOD MARKET
PACKAGING REQUIREMENTS FOR FRIED POTATO CHIPS
PHYSICO-CHEMICAL CHANGES DURING STORAGE
MANUFACTURING PROCESS OF POTATO CHIPS
(1) SORTING, CLEANING & WASHING:
(2) SLICING AND WASHING:
(3) DRYING OF SLICES:
TREATING WITH CHEMICALS:
CHIP FRYING:
BATCH FRYING METHOD:
METHOD OF BATCH PROCESSING:
PACKAGING:
FLOW DIAGRAM
STEPS IN FROZEN FRENCH FRIES
PREWASHING PEELING MACHINE
SORTING CONVEYER
FRENCH FRIES CUTTING MACHINE
IMPURITY REMOVING MACHINE
RINSING MACHINE
BLANCHING
VIBRATING DEWATERING MACHINE
AIR VIBRATING MACHINE
FRYING MACHINE
DEOILING MACHINE
MANUFACTURING PROCESS OF FROZEN FRENCH FRIES
GENERAL MAKING PROCEDURE
KEY POINTS IN BLANCHING PROCESS
FACTORS IN DRYING PROCESS
IMPORTANT TIPS IN FRYING PROCESS
PROCESS FLOW DIAGRAM OF FROZEN FRENCH FRIES
PROCESSING DETAILS OF FROZEN FRENCH FRIES
INDIVIDUAL QUICK FREEZING (IQF)
TECHNOLOGY
PROCESS FLOW DIAGRAM
RECIPE OF FROZEN POTATO PATTY
DIFFERENT METHOD OF MAKING FROZEN POTATO PATTIES
A METHOD OF PREPARING A POTATO PATTY FOR FREEZING AND STORAGE COMPRISING:
THE FROZEN POTATO PATTY PREPARED BY THE BELOW METHOD.
ANOTHER METHOD OF PREPARING A FROZEN POTATO PATTY COMPRISING
MANUFACTURING PROCESS FRENCH FRIES (MCCAIN PROCESS)
PROCESS FOR MANUFACTURING FROZEN FRENCH POTATO SEGMENTS FOR OVEN RECONSTITUTION
MANUFACTURING PROCESS FOR POTATO FLAKES
WASHING & SORTING
PEELING
COOKING
PULPING AND DRUM DRYING OF PULP TO PRODUCE FLAKES
CONTINUOUS PROCESS TO MANUFACTURE POTATO FLAKES
A POTATO FLAKE PRODUCTION LINE
FIRST PHASE OF PRODUCTION
CUTTING, PRE-COOKING AND COOLING
DRYING, SIZING AND PACKING.
PLANT LAYOUT
MANUFACTURERS/EXPORTERS/SUPPLIERS
SUPPLIERS OF PLANT & MACHINERY (IMPORTED)
PACKAGING MACHINERY SUPPLIERS
SUPPLIERS OF RAW MATERIALS
SUPPLIERS OF PLANT AND EQUIPMENTS (INDIAN)
PACKAGING MATERIALS FOR FOOD
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)