Industry Overview
Dehydrated onions are increasingly used because they retain culinary quality and palatability while reducing storage space, transport costs, packaging requirements, and losses during the glut season. They are widely used as condiments, including in overseas markets, and are produced in forms such as flakes, chopped, minced, granules, and powder.
Dehydrated onions have been produced since the nineteenth century and were supplied to British naval expeditions in the mid-nineteenth century. Production increased during subsequent wars, particularly for armed forces and civilian consumption. Although demand declined because early products compared unfavourably with fresh onions after rehydration, processing techniques improved considerably after World War II, particularly from the late nineteen fifties. Growing demand for convenience foods subsequently supported renewed use of dehydrated onions.
Modern dehydration methods include variations of air drying that use relatively low temperatures and vapour pressure differentials, helping reduce crust formation and minimize effects on flavour, texture, colour, and vitamin content. Successful operation also depends on a reliable supply of suitable onion varieties. Contract cultivation is commonly used to ensure continuity, quality, maturity, delivery schedules, and pricing. Specialization in one or two onion types can improve processing efficiency by reducing frequent equipment cleaning and setting changes.
Cost Estimation
| Particulars | Value |
|---|---|
| Plant Capacity | 2 MT/Day |
| Land & Building (1200 sq.mt.) | Rs. 1.65 Cr |
| Plant & Machinery | Rs. 1.25 Cr |
| Working Capital for 2 Months | Rs. 97.79 Lac |
| Total Capital Investment | Rs. 3.94 Cr |
| Rate of Return | 22% |
Content Index
- INTRODUCTION
- PROPERTIES
- COMPOSITION OF ONION
- ONION (ALLIUM CEPA)
- DEHYDRATION
- USES OF DEHYDRATED ONIONS
- DEHYDRATED WHITE ONION FLAKES
- DEHYDRATED WHITE ONION CHOPPED
- DEHYDRATED WHITE ONION MINCED
- DEHYDRATED WHITE ONION POWDER
- B.I.S. SPECIFICATION
- SPECIFICATION OF DEHYDRATED ONION
- COMPOSITION & VARIETY OF ONION
- COMPOSITION OF ONION
- DEHYDRATED ONION
- ONION VARIETIES SUITABLE FOR DEHYDRATION
- FORMS AND APPLICATION OF DEHYDRATION ONION
- FORMS OF DEHYDRATED ONION
- ONION FLAKES/KIBBLED (10MM – 30MM)
- ONION CHOPPED (SIZE 3.0 - 5.0MM)
- ONION MINCED (SIZE 1.0 - 3.0MM)
- ONION GRANULES (SIZE 0.1 - 0.5MM & 0.5 TO 1.0MM)
- ONION POWDER
- ONION SCENARIO IN INDIA
- PRODUCTION OF ONION
- CURRENT STATUS OF SOWING OF ONION
- OVERVIEW OF GLOBAL ONION MARKET
- SOUTH AFRICA EXPECTS DEFICITS
- US POSITIVE MOOD AHEAD OF THE SEASON
- AUSTRALIA EXPORT POTENTIAL DUE TO OVERSUPPLY
- EGYPT HIGH PRICES, REDUCED EXPORTS
- SPAIN EXPECTS HUGE SHORTAGE OF LARGE ONIONS
- GREECE FOCUS SHIFTS TO THE DOMESTIC MARKET
- ISRAEL
- ITALY WHITE ONION PRICES GOING UP
- THE NETHERLANDS SMALL PRODUCER, BUT WORLDWIDE LEADING EXPORTER
- BELGIUM DIFFICULT MARKET AND FEWER LARGE ONIONS
- PERUVIAN ONIONS BACK IN COLOMBIA
- ARGENTINA CHALLENGING SEASON FOR SANTIAGO DEL ESTERO
- BRAZIL SMALLER ACREAGE IN PIEDADE
- MEXICAN PRODUCTION INCREASING
- BOLIVIAN PRODUCTION ON THE RISE
- MARKET POSITION OF DEHYDRATED ONION
- DETAILED EXPORT DATA OF INDIAN DEHYDRATED ONION
- MARKET POSITION OF DEHYDRATED ONIONS
- THE DIMENSIONS OF CFB BOXES USED BY THE EXPORTERS ARE AS FOLLOWS
- PACKAGING MATERIALS COST
- PLASTIC BAGS (INTERMEDIATE PACK)
- THE DIMENSION OF THE CONTAINERS ARE AS FOLLOWS
- PRODUCTION OF DEHYDRATED ONION IN INDIA
- EXPORT OF DEHYDRATED ONION
- LIST OF EXPORTERS
- MANUFACTURERS/EXPORTERS/SUPPLIERS OF ONION POWDERS
- STEPS IN ONION DEHYDRATION
- RAW MATERIAL ONION
- FEEDING AREA
- PEELING & WASHING
- SLICING
- DRYING FIVE LAYERS DRYER
- GRADING
- TEMPERATURE EQUALIZING
- COLOR SORTING & METAL DETECTION
- WEIGHING & PACKING
- STORAGE & DISPATCH
- MANUFACTURING PROCESS OF ONION DEHYDRATION
- PROCESS FLOW DIAGRAM
- DEHYDRATION METHOD AND DEHYDRATOR
- METHODS
- FLOW SHEET FOR ONION DEHYDRATION
- PACKAGING AND STORAGE TECHNIQUE
- PROCESS FLOW SHEET DIAGRAM FOR ONION POWDER
- DEHYDRATION PRACTICES FOR ONION
- REPORTED VARIETAL STUDIES FOR ONION DEHYDRATION
- SOLAR DRYING
- CONVECTIVE AIR DRYING
- FLUIDIZED BED DRYING
- CHEMICAL COMPOSITION OF ONION, FRESH AND DRIED UNDER VARIOUS TEMPERATURES
- MICROWAVE AND FREEZE DRYING
- INFRA RED DRYING
- VACUUM DRYING
- FREEZE DRYING
- OSMOTIC DEHYDRATION
- MODERN METHODS OF ONION DEHYDRATION
- PROCESSING STEPS
- POWER PRODUCTION AND ENERGY REQUIREMENTS
- GEOTHERMAL APPLICATIONS
- SUPPLIERS OF RAW MATERIALS
- ONIONS
- SUPPLIERS OF PLANT AND MACHINERY (INDIAN)
- DEHYDRATOR EQUIPMENTS
- ONION PEELING MACHINE
- ONION SLICING MACHINE
- CONVEYOR BELT
- SPRAY DRYERS
- AUTOMATIC PACKAGING MACHINES
- BOILERS
- D.G. SETS (DIESEL GENERATOR)
- SUPPLIERS OF PLANT AND MACHINERY (IMPORTED)
- PLANT LAYOUT
Appendix
- 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)
Frequently Asked Questions
Dehydrated onions offer easier storage, handling, transportation, and extended usability compared with fresh onions.
They are lighter and occupy less bulk, reducing storage and transport requirements. They also require less packaging than canned products and do not need refrigerated storage like frozen onions. Once opened, the product can generally be used over time as long as it is kept dry and is not rehydrated. These characteristics make dehydrated onions particularly suitable for food manufacturers, institutional users, condiment applications, and convenience-food products.
Dehydrated onions can be produced in several forms, including flakes, chopped pieces, minced onion, granules, and powder.
The appropriate form depends on the intended application and required particle size. The report specifically covers dehydrated white onion flakes, chopped onion, minced onion, granules, and powder. Different forms can serve different food-processing and seasoning requirements. Processing equipment and grading arrangements are selected according to the desired product form, size specification, moisture control, and packaging requirements.
The principal raw material required is fresh onion of a variety suitable for dehydration.
Raw-material selection is critical because onions grown for the fresh market may not always provide the characteristics required for processing. A dehydration plant needs a consistent supply to maintain efficient operation and product quality. The report highlights contract cultivation as an important approach for securing supplies and managing factors such as acreage, planting periods, varieties, field inspection, maturity at harvesting, delivery schedules, grading, and prices.
Major onion dehydration operations include feeding, peeling and washing, slicing, drying, grading, temperature equalizing, sorting, metal detection, weighing, packing, storage, and dispatch.
The exact sequence and equipment configuration depend on the product form and dehydration method. Drying is the central processing operation, while subsequent grading, colour sorting, and metal detection help control finished-product quality. Proper packaging and storage are also important because dehydrated onions must be protected from moisture after processing to maintain their intended characteristics and shelf stability.
Onion dehydration can use several methods, including convective air drying, fluidized bed drying, solar drying, vacuum drying, freeze drying, microwave drying, infrared drying, and osmotic dehydration.
The report also discusses modern dehydration methods and variations of air drying. Different technologies influence drying time, energy use, colour, flavour, texture, nutrient retention, and final product quality. Selection should therefore consider the required product characteristics, plant scale, available utilities, raw material properties, operating economics, and the intended market.
Contract cultivation helps a dehydration plant secure a consistent supply of suitable onions throughout its processing requirements.
Contracts can establish important production and procurement conditions in advance, including acreage, planting periods, varieties, field inspection, maturity at harvesting, delivery dates, grading, and prices. A dependable supply is particularly important because interruptions can reduce plant utilization and efficiency. The report notes that buying onions from the general fresh market may be impractical when suitable varieties and continuity of supply cannot be assured.
Specializing in one or two onion types can reduce equipment changeovers and support more consistent processing operations.
The report recommends that, ideally, a dehydration factory should handle one type of onion over extended periods. Changing between different vegetables or product requirements can require machinery cleaning and adjustments to grading and cutting settings. Limiting such changes can improve operational continuity and reduce downtime associated with repeated equipment preparation. The appropriate degree of specialization ultimately depends on product demand, raw-material availability, and the plant's intended product range.
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