Detailed Project Report on Frozen Food by IQF Technology
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FROZEN FOOD BY IQF TECHNOLOGY
[EIRI/EDPR/1121] J.C. 9768
INTRODUCTION
Individual Quick Freezing (I.Q.F.) is the latest technology available in freezing and with the advent of the same, it is now possible to preserve and store raw fruit and vegetables in the same farm-fresh condition for more than a year, with the color, flavor and texture of produce remaining as good as fresh from the farm.In IQF, each piece is frozen individually using technique of fluidization resulting in freezing of fruit and vegetables only in 10 to 12 minutes which otherwise takes at least 3 to 4 hours or even more in the blast freezer. The important feature of this process is ultra-rapid freezing to very low temperatures (-30°C to - 40°C) designed to halt the activities of the microorganisms that cause decay and deteriorate foodstuffs. This results into better texture and there is no lump/ block formation and the product is free flowing. One does not have to thaw or defrost the whole packet to take out only a portion, and the rest will remain frozen till required again.
Individual Quick Freezing (I.Q.F.) is the latest technology available in freezing and with the advent of the same, it is now possible to preserve and store raw fruit and vegetables in the same farm-fresh condition for more than a year, with the color, flavor and texture of produce remaining as good as fresh from the farm.
Individual Quick freezing (IQF) technology used will be latest and indigenous. It is a freezing method of choice for seasonal products such as fruits and vegetables and over the years it has further developed to cover a broader range of other product such as diced meat, shrimps, pasta and rice etc. IQF is a technology originally developed by Frigoscandia Equipment as a specific solution to block or cluster-freezing of small-sized products, to preserve quality and to give unparalleled convenience to end-users. Quick Freezing is the only process whereby, virtually all the properties of most of the parent food stuffs can preserved.
In IQF, each piece is frozen individually using technique of fluidization resulting in freezing of fruit and vegetables only in 10 to 12 minutes which otherwise takes at least 3 to 4 hours or even more in the blast freezer. This results into better texture and there is no lump/ block formation and the product is free flowing. One does not have to thaw or defrost the whole packet to take out only a portion, and the rest will remain frozen till required again.
COST ESTIMATION
Plant Capacity 24 MT/Day
Land & Building (9000 sq.mt.) Rs. 2.26 Cr
Plant & Machinery Rs. 6.74 Cr
Working Capital for 2 Months Rs. 3.27 Cr
Total Capital Investment Rs. 13.08 Cr
Rate of Return 101%
Break Even Point 29%
CONTENTS
PROJECT AT A GLANCE
CAPACITY OF THE PLANT
UTILITIES
III.MANPOWER REQUIREMENT
PROJECT SCHEDULE
INTRODUCTION
PRODUCT AND ITS APPLICATIONS
MARKET POTENTIAL
FROZEN FOOD CATEGORY TO GROW BY 11 PERCENT
CREATING AWARENESS
CHALLENGES
DARSHAN FOODS, DELHI
AMRIT FOODS, KOLKATA
MOTHER DAIRY FRUIT & VEGETABLE, DELHI/NCR
THE MAJOR MARKET SEGMENTS FOR IQF ARE MARKET OPPORTUNITIES
MARKET SIZE OF FROZEN PROCESSED FOOD INDIA 2004-2009
MARKET SIZE OF FROZEN PROCESSED FOOD INDIA IN 2009-2014
FROZEN FOOD MARKET EXPECTED TO GROW BY ABOUT THREE TIMES BY 2017:
MARKET POTENTIAL OF MANGO PULP OR JUICE
RAW MATERIALS
CRITICAL SUCCESS FACTORS
MANUFACTURING PROCESS & TECHNOLOGY
TECHNOLOGY:
AUXILIARY EQUIPMENT
SOURCES OF PLANT MACHINERY/EQUIPMENTS AND TECHNOLOGY
FREEZING FRUITS AND VEGETABLES
A GENERAL FLOW CHART OF FROZEN FRUITS AND VEGETABLES
FREEZING OF FRUITS
PRODUCTION AND HARVESTING
PRE-PROCESS HANDLING AND OPERATIONS
EFFECT OF INGREDIENTS
PACKAGING
SYRUP PACK
SUGAR PACKS
UNSWEETENED PACKS
TRAY PACKS
FREEZING OF VEGETABLES
FRUIT FREEZING GUIDE
HARVESTING
PRE-PROCESS HANDLING
BLANCHING
PACKAGING
VEGETABLE FREEZING GUIDE
FLOW DIAGRAM OF FREEZING PROCESS FOR FRUIT-BASED PRODUCT
FLOW DIAGRAM OF FREEZING PROCESS OF VEGETABLE-BASED PRODUCT
GENERAL PLANT LAYOUT
EFFLUENT TREATMENT AND DISPOSAL
STANDARDS
TOLERANCE LIMITS FOR INDUSTRIAL EFFLUENT DISCHARGE
WASTE TREATMENT
ANAEROBIC TREATMENT
ANAEROBIC TREATMENT HAS THE ADVANTAGES OF METHANE FERMENTATION IS FAVORED BY A WARM CLIMATE. HOWEVER, ITS MAIN
SECONDARY TREATMENT
TERTIARY TREATMENT
SOLIDS CONCENTRATION
TYPICAL WASTE SOLIDS CHARACTERISTICS
EQUIPMENT REQUIREMENT
EQUIPMENT REQUIREMENTS
MANPOWER
GENERAL
BASIS OF ESTIMATION
ORGANOGRAM OF STAFF
UTILITIES
WATER
WATER QUALITY PARAMETERS FOR PROCESSED WATER:
STEAM
UTILITIES (EQUIPMENTS)
WATER TREATMENT PLANT
REFRIGERATION SYSTEM:
POWER
IMPLEMENTATION SCHEDULE
PROJECT IMPLEMENTATION WILL TAKE A PERIOD OF 12 MONTHS
SPACE REQUIREMENT FOR FROZEN PLANT
DESCRIPTION OF BLOCK DIAGRAM
DETAILS OF PLANT AND MACHINERY
FRUITS & VEGETABLE WASHER
2-TIER INSPECTION CONVEYOR
SORTING, GRADING & CUTTING CONVEYOR (2 TIER)
BUCKET ELEVATOR:
SCREW TYPE BLANCHER:
FOR EXTRACTION OF PULP
DICING/CUBING MACHINE:
MULTIFUNCTION VEGETABLE SLICER/CHOPPER
MULTI-PURPOSE VEGETABLE SLICER:
COOKING KETTLE-STEAM JACKETTED KETTLE
FULLY AUTOMATIC COIL TYPE BOILER (2000 KG)
TECHINICAL DETAILS
ROOT VEGETABLE PEELER/WASHER
PASTEURISATION SYSTEM: SKID MOUNTED JUICE
STERLISATION,CAPACITY 2000 LPH ALONG WITH ACCESSORIES:
DESIGN REQUIREMENT OF PLATE PACK OF JUICE PASTEURISATION
TEMPERATURE PROGRAMME
OPTIONAL
ACCESSORIES OF THE JUICE STERLISATION OFFERED:
HOT WATER GENERATING SYSTEM
PLANT LAYOUT
FROZEN FRUITS AND VEGETABLES PLANT LAYOUT
CODEX STANDARD FOR QUICK FROZEN WHOLE KERNEL
SCOPE
DESCRIPTION
PRODUCT DEFINITION
PROCESS DEFINITION
2.3 HANDLING PRACTICE
3. ESSENTIAL COMPOSITION AND QUALITY FACTORS
OPTIONAL
QUALITY FACTORS
GENERAL REQUIREMENTS
CODEX STANDARD FOR QUICK FROZEN
SCOPE
DESCRIPTION
2.1 PRODUCT DEFINITION
2.2 PROCESS DEFINITION
2.3 HANDLING PRACTICE
2.4 PRESENTATION
2.4.1 TYPES
2.4.2 SIZING
SPECIFICATIONS A FOR
SPECIFICATIONS B FOR
ESSENTIAL COMPOSITION AND QUALITY FACTORS
QUALITY FACTORS
3.2.1 ORGANOLEPTIC AND OTHER CHARACTERISTICS
3.2.2 ANALYTICAL CHARACTERISTICS
DEFINITION OF DEFECTS
TOLERANCES FOR DEFECTS
TOLERANCES FOR SIZES
CODEX STANDARD FOR CANNED MANGOES
DESCRIPTION
PRODUCT DEFINITION
TYPES OF VARIETIES
STYLES
TYPES OF PACK
CODEX STANDARD FOR QUICK FROZEN CARROTS
SCOPE
DESCRIPTION
2.1 PRODUCT DEFINITION
2.2 PROCESS DEFINITION
2.3 HANDLING PRACTICE
2.4 PRESENTATION
2.4.2 STYLES:
2.4.3 OTHER STYLES
2.4.4 TOLERANCES FOR STYLES
2.4.5 SIZING
SPECIFICATION FOR CONICAL CULTIVARS
SPECIFICATION FOR SPHERICAL CULTIVARS
CODEX STANDARD FOR QUICK FROZEN CAULIFLOWER
SCOPE
DESCRIPTION
2.1 PRODUCT DEFINITION
2.2 PROCESS DEFINITION
2.3 HANDLING PRACTICE
2.4 PRESENTATION
2.4.2 OTHER STYLES
2.4.3 SIZING
2.4.4 TOLERANCES FOR SIZES
2.4.4.2 STANDARD SAMPLE SIZE
2.4.5 DEFINITION OF "DEFECTIVE" FOR PRESENTATION
2.4.6 LOT ACCEPTANCE FOR PRESENTATION FACTORS
ESSENTIAL COMPOSITION AND QUALITY FACTORS
3.1 OPTIONAL INGREDIENTS
3.2 QUALITY FACTORS
3.2.1 GENERAL REQUIREMENTS
3.2.2 DEFINITION OF VISUAL DEFECTS
CODEX STANDARD FOR QUICK FROZEN WHOLE KERNEL CORN CODEX STAN 132-1981
SCOPE
DESCRIPTION
2.1 PRODUCT DEFINITION
2.2 PROCESS DEFINITION
2.3 HANDLING PRACTICE
2.4 PRESENTATION
2.4.1 COLOUR
ESSENTIAL COMPOSITION AND QUALITY FACTORS
3.1 OPTIONAL INGREDIENTS
3.2 QUALITY FACTORS
3.2.1 GENERAL REQUIREMENTS
COST OF PLANT AND MACHINERY AND LAB EQUIPMENTS
PEAS PROCESSING LINE 2 MT/HR.
FLAP ELEVATOR
PEA PODDER
WAST COLLECTION CONVEYOR
WASTE ELEVATOR
WASTE DISCHARGE ELEVATOR
GROSS COLLECTION CONVEYOR
GRAIN ELEVATOR
BUCKET ELEVATOR
S.S. ROTARY WASHR
S.S. SCREW TYPE BLANCHER
AFTER COOLER
INSPECTION CONVEYOR
DEQATERING SHAKER
INSTANT QUICK FREEZER 2 MT/HR.
CONVEYOR
CONVEYOR BELT SUPPORT
CONVEYOR DRIVE
DEFROST SYSTEM
CENTRIFUGAL FANS
FREEZERS ENCLOUSERS
VEGETABLES FRUIT CUTTING DICING COMPLETE WITH WORK TABLES
BOILER
PACKING MACHINES
PELLETS
MANGO PROCESSING PLANT
ASEPTIC PACKING
DG SETS 400 KVA*1
KIRLOSKER
SYN PANEL
HT/LT ELECTRICALS
METERING EQUIPMENTS, TESTING COMMISSIONING ETC.
HT CONNECTION CHARGES
HT CABELS & POLES
MIS EQUIPMENTS WAIGHING MACHINES, HSD TANK
TOOLS TESTING DEVICES
PUMPS
WEIGH BRIDGE
TUBE WELL
R.O WATER TREATMENT PLANT
EFFLUENT TREATMENT PLANT
GOODS LIFT
MATERIAL HANDLING EQUIPMENTS
FORK LIFT, CREATS, BINS, TROLLY
B. LIST AND COST OF LAB EQUIPMENTS
COMPLETE PLANT AND EQUIPMENTS SUPPLIERS
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)
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