Detailed Project Report on Frozen Food by IQF Technology

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 (Area 2 Acre)        Rs. 2.27 Cr.
Plant & Machinery                             Rs. 6.75 Cr.        
W.C. for 2 Months                              Rs. 3.27 Cr.          
Total Capital Investment                  Rs. 13.07 Cr.             
Rate of Return                                   101%  
Break Even Point                               29%

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)