Detailed Project Report (DPR) on Potato Chips, French Fries & Flakes

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)