Detailed Project Report (DPR) on Dehydrated Vegetables (100% EOU)

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)