Detailed Project Report (DPR) on freeze drying plant

FREEZE DRYING PLANT (3 TONS/DAY)

[CODE NO.4132] 

According to the Food and Agriculture Organization of the United Nations, nearly 33% of all food produced globally for human consumption each year—around 1.3 billion tonnes—is either lost or wasted. The economic impact of this loss is substantial, estimated at approximately US$ 685 billion per annum in industrialized nations and about US$ 310 billion in developing countries. Among all food categories, fruits and vegetables, along with roots and tubers, experience the highest levels of wastage.

Global quantitative food losses and waste per year are roughly 30% for cereals, 40-50% for root crops, fruits and vegetables, 20% for oil seeds, meat and dairy plus 35% for fish.

Every year, consumers in rich countries waste almost as much food (222 million tonnes) as the entire net food production of sub-Saharan Africa (230 million tonnes). Per capita waste by consumers is between 95-115 kg a year in Europe and North America, while consumers in sub- Saharan Africa, south and south-eastern Asia, each throw away only 6-11 kg a year.

In recent years there has been increased demand and objective necessity of building a plant for freeze-dried foods in Bulgaria. Lyophilized foods can replace traditional preservation, but without the use of preservatives.  The method has the following advantages:

• Fully preserved taste, nutritional, organoleptic properties and vitamins, without any harmful preservatives and additives. The dry-heat procedure retains only 50-60% of the original nutritional properties;

• Saving the form and color of freeze-dried products, unlike drying with hot air;

• Durability of storage under ambient conditions (room temperature) 5-15 years (residual humidity up to 2-5%). No need for storage in freezers and refrigerators and related costs during this long period;

• Rapid rehydration, unlike drying with hot air;

• Packaging in hermetic quality three-layer packaging materials with aluminum intermediate layer - vacuum packing and non-oxidative environment of protective gas - nitrogen or argon.

• Saves weight and volume of the metal cans and glass jars, and up to 90% of weight of the food itself.

Fruits are most often to be freeze-dried (strawberries, wild strawberries, apples, pears, melons, apricots, peaches, kiwi, watermelon, blueberries, wild blueberries, cherries, grapes, raspberries and blackberries, sliced lemons and oranges, fruit mix); vegetables (original,

Freeze Drying Project Profile for 3 Ton/Day 

• INTRODUCTION
  
• THE HISTORY AND MARKET
• EQUIPMENT MANUFACTURERS 
• COPACKERS COMPANIES
• COMMERCIAL APPLICATIONS IN FOOD PROCESSING
• POTENTIAL USERS OF FREEZE-DRIED FOODS
• PRODUCTS, RAW MATERIALS AND PRODUCTION TECHNOLOGY
• PROCESS DESCRIPTION
• OVERVIEW ON THE FREEZE-DRIED FOODS MARKET
• COMMERCIAL FREEZE DRYER /MACHINES
• LIST OF MACHINERY & EQUIPMENTS
• PLANT LOCATION: COUNTRY
• DOCUMENTS REQUIRED FOR LICENSES 
• PRINCIPLES OF PLANT LAYOUT
• PLANT LOCATION FACTORS
• EXPLANATION OF TERMS USED IN THE PROJECT REPORT
• FREEZE DRIED FOOD PRODUCTS
• PACKAGING TYPES
• MANUFACTURES OF FREEZE DRIED FOODS
• SUPPLIERS OF PLANT AND MACHINERY
• EFFLUENT TREATMENT AND DISPOSAL
• MANPOWER
• UTILITIES
• QUALITY CONTROL OF FREEZE DRIED FOODS
• FINAL PRODUCTS PHOTOGRAPHS
• SWOL ANALYSIS
• ORGANIZATION CHART
• PLANT LATOUT
• TURNKEY CONSULTANT
• IMPLEMENTATION SCHEDULE

APPENDIX – A:

• 01. PLANT ECONOMICS
• 02. LAND & BUILDING
• 03. PLANT AND MACHINERY
• 04. OTHER FIXED ASSETS
• 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)