Detailed Project Report on fruit, onion and garlic dehydration plant

FRUIT, ONION AND GARLIC DEHYDRATION PLANT [3637]

Food drying / Dehydration of food is a method of food preservation that works by removing water from the food, which inhibits the growth of bacteria. Water is traditionally removed through evaporation (air drying, sun drying, smoking or wind drying), although today electric food dehydrators or freeze-drying can be used to speed the drying process and ensure more consistent results. Dehydrated fruits are a good and healthy option to snack on for people who lead a busy life and don’t get proper time for meals. It contains high nutrients and good calories that are required in one’s daily diet. This also increases the shelf life of the fruits and vegetables. Dehydrated fruits & vegetables are majorly used in ready to eat foods, fruit bars, soup, energy drinks, beauty products, aromatherapy oils, bakeries, organic paints, etc. It can also be sold individually like raisins, dried figs (Anjeer), banana chips dried mangoes, dried oranges, dates, coconut, sun-dried tomatoes, dried potato chips, amchur powder, chili powder, food flavoring etc. It is also used as flavoring by many kinds of manufacturers. Dehydrated fruits and vegetables are mostly used by space stations, hikers, campers, hotels, restaurants, organic food retail stores, herbal tea manufacturers. It is a life saver in areas that are affected by disasters like earthquakes, flood, etc. as most of dehydrated products do not require any cooking or refrigeration. According to IBEF (India Brand Equity Foundation), the Indian food and grocery market is the world’s sixth largest, with retail contributing 70 per cent of the sales. The Indian food processing industry accounts for 32 per cent of the country’s total food market, one of the largest industries in India and is ranked fifth in terms of production, consumption, export and expected growth. It contributes around 8.80 and 8.39 per cent of Gross Value Added (GVA) in Manufacturing and Agriculture respectively, 13 per cent of India’s exports and six per cent of total industrial investment. The Indian gourmet food market is currently valued at US$ 1.3 billion and is growing at a Compound Annual Growth Rate (CAGR) of 20 per cent. In India, Dehydration of fruits and vegetable has a bright prospects over  other foods because India has diverse geographical and climatic conditions and produces a wide range of fruits and vegetables throughout the year.  Here almost all type of fruits and vegetables are grown all over the country.  These fruits and vegetables are valuable foods.  They are a rich source of calcium, phosphorus, iron and vitamins. Dehydrated fruits & vegetables include a no. of articles mainly, fruit juices, dehydrated fruits and vegetables, squashes, cordials, Beverages, jam, jellies, mermalades, chutney,  sauces, pickles, vinegar, pectin etc. Dehydration is at present defined industrially as drying by artificially produced heat under carefully controlled conditions of temperature, humidity,  and air flow. The term `dried' is applied to all dried products regardless of the method of drying. Fruits and vegetables are dried to enhance storage stability, minimize packaging requirement and reduce transport weight. Preservation of fruits and vegetables through drying based on sun and solar drying techniques which cause poor quality and product contamination. Energy consumption and quality of dried products are critical parameters in the selection of drying process. An optimum drying system for the preparation of quality dehydrated products is cost effective as it shortens the drying time and cause minimum damage to the product. To reduce the energy utilization and operational cost new dimensions came up in drying techniques. Among the technologies osmotic dehydration, vacuum drying, freeze drying, superheated steam drying, heat pump drying and spray drying have great scope for the production of quality dried products and powders. The keeping quality of a food material is greatly influenced by its water content. Fruits and vegetables containing high percentage of water deteriorate more rapidly than cereals, and root crops.  Preservation of foods by sun drying is perhaps the oldest method known. Fruits like figs, amla, mango banana, coconut etc. and vegetables like tapioca, chillies, peas, turmeric  and  ginger are preserved by sun drying. The use of machinery for drying and the development of the dehydration industry are comparatively recent and like canning dehydration is assuming increasing importance as a process of good preservation.

COST ESTIMATION

Plant Capacity                           1000 Kg/Day  
Land & Building (1000 sq.mt)     Rs. 1.12 Cr
Plant & Machinery                    Rs. 75 Lac
Working Capital for 1 Month    Rs. 68 Lac
Total Capital Investment          Rs. 2.60 Cr
Rate of Return                         26%
Break Even Point                     59%



INTRODUCTION    
BENEFITS OF DEHYDRATION    
USES AND APPLICATIONS    
BLANCHING TIME FOR VEGETABLES    
TYPICAL PERCENTAGE COMPOSITION OF FOODS OF PLANT ORIGIN    
OVERVIEW OF FRUITS & VEGETABLES SECTOR IN INDIA    
MAJOR STATES    
OPPORTUNITIES IN FRUITS & VEGETABLES PROCESSING AT A GLANCE    
EQUIPMENT & TECHNOLOGY SUPPLIERS    
F & V PROCESSORS    
EXPORTS    
KEY STATES FOR TOP 5 FRUITS IN INDIA    
KEY STATES FOR TOP 5 VEGETABLES IN INDIA    
MARKET POSITION OF DEHYDRATED FRUITS & VEGETABLES    
LONG SHELF LIFE TO INFLUENCE CONSUMER PREFERENCES FOR
   DEHYDRATED VEGETABLES MARKET    
FRUIT MARKET IS FORECASTED TO REACH 118M TONNES BY 2025    
INDIAN FRUIT OUTPUT CONTINUES TO INCREASE AGAINST THE BACKGROUND
   OF GROWING AREAS UNDER FRUIT CULTIVATION    
BANANA RANKED FIRST IN INDIAN FRUIT OUTPUT    
THE MARKET SHARE OF IMPORTED FRUITS WAS INSIGNIFICANT    
INDIAN FRUIT IMPORTS INCREASED OVER THE LAST YEARS, MOSTLY DUE
  TO GROWTH OF SUPPLIES FROM CHINA    
THE UAE, THE NETHERLANDS, SAUDI ARABIA, NEPAL AND BANGLADESH
  WERE THE KEY FOREIGN MARKET FOR INDIAN FRUITS    
THE MAJOR PLAYERS IN THE DEHYDRATED FRUITS & VEGETABLES MARKET    
PRESENT STATUS    
FUTURE SCOPE    
EXPORT DATA OF DEHYDRATED VEGETABLES    
PRODUCTION INSTALLED CAPACITY AND CAPACITY UTILITIES
   OF PROCESSED FRUITS & VEGETABLES    
APPERENT CONSUMPTION OF PROCESSED FRUITS & VEGETABLES    
ESTIMATED DEMAND    
MANUFACTURERS/SUPPLIERS OF FRUITS AND VEGETABLE DEHYDRATION    
SPECIFICATION FOR DEHYDRATED GARLIC    
SCOPE    
REFERENCES    
TERMINOLOGY    
REQUIREMENTS    
PACKING    
MARKING    
SAMPLING    
DIFFERENT DEHYDRATION METHOD/PROCESS    
SUN DRYING:    
SOLAR DRYING:    
ROOM TEMPERATURE DRYING:    
FREEZE DRYING:    
DRUM DRYING:    
TYPES OF DRYING FRUITS AND VEGETABLES    
NATURAL SUN DRYING    
DRYING WITH A FOOD DEHYDRATOR    
OVEN DRYING    
TABLE. POUNDS OF DEHYDRATED FOOD FROM FRESH FRUITS AND VEGETABLES    
COMPOSITION OF ONION    
ONION VARIETIES SUITABLE FOR DEHYDRATION    
COMPOSITION AND EVERY VALUE OF RAW AND DEHYDRATED ONION
   (PER 100 GM OF ONION)    
MANUFACTURING PROCESS    
OF FRUITS AND VEGETABLE DEHYDRATION    
COMPARISON WITH CANNED FRUITS AND VEGETABLES    
FOOD VALUE OF DEHYDRATED FRUITS AND VEGETABLES    
PROCESS FLOW DIAGRAM    
MANUFACTURING PROCESS OF GARLIC DEHYDRATION    
PROCESS FLOW DIAGRAM    
MANUFACTURING PROCESS OF ONION DEHYDRATION    
PROCESS FLOW DIAGRAM    
DEHYDRATION PRACTICES FOR ONION    
SOLAR DRYING    
CONVECTIVE AIR DRYING    
FLUIDIZED BED DRYING    
MICROWAVE AND FREEZE DRYING    
INFRA RED DRYING    
VACUUM DRYING    
FREEZE DRYING    
OSMOTIC DEHYDRATION    
PREPARING VEGETABLE FOR DEHYDRATION    
STEPS FOR STEAM BLANCHING    
STEPS FOR WATER BLANCHING (VEGETABLES ONLY):    
METHODS OF DEHYDRATION    
SUN DRYING:    
SOLAR DRYING:    
ROOM TEMPERATURE DRYING:    
FREEZE DRYING:    
DRUM DRYING:    
OSMOTIC DRYING:
PROCESS DESCRIPTION OF FRUITS AND VEGETABLE DEHYDRATION    
PREDRYING TREATMENTS -    
DRYING OR DEHYDRATION    
POSTDEHYDRATION TREATMENTS -    
DETAILS FRUITS AND VEGETABLE FOR DRYING    
TABLE. FRUITS AND VEGETABLES SUITABLE FOR DRYING    
PROCESS IN DETAILS OF DEHYDRATION OF VEGETABLES    
APPROXIMATE COMPARATIVE FOOD VALUES OF SEVERAL FRESH
   AND DEHYDRATED VEGETABLES (TO 5% MOISTURE BASIS)    
WASHING    
PEELING    
SLICING, DICING, AND SHREDDING.    
BLANCHING    
SULFITING.    
TRAYS.    
TRAY LOAD.    
DRYING TEMPERATURES.    
VACUUM DRYING.    
MOISTURE CONTENT.    
ENZYME TESTS.    
DRYING RATIOS.    
ONION    
GENERAL    
PACKING AND STORAGE    
PROCESS FLOW DIAGRAM FOR DEHYDRATION OF FRUITS & VEGETABLES
   BY VACUUM DRYING METHOD    
DETAILS OF OSMOTIC DEHYDRATION    
TABLE: NUTRITIONAL COMPOSITION OF PINEAPPLE FRUIT (PER 100 G PULP).    
FIGURE: PROCESS FLOW CHART FOR THE PREPARATION
   OF OSMO-DEHYDRATED PINEAPPLE PIECES    
QUALITY IMPROVEMENT    
SUITABLE PINEAPPLE VARIETIES FOR OSMOTIC DEHYDRATION    
FIGURE: SCHEMATIC DRAWING OF MASS TRANSFER DURING
   SOAKING PROCESS.    
TABLE: PHYSICO-CHEMICAL COMPOSITION OF RAW AND
   OSMO-DEHYDRATED PINEAPPLE.    
TABLE: DIFFERENT OSMOTIC AGENTS AND THEIR EFFECTS
   IN OSMOTIC DEHYDRATION PROCESS.    
OSMO-DEHYDRATED PINEAPPLE    
GUIDE LINES AND LICENSES REQUIRED FOR FRUIT & VEGETABLE
   DEHYDRATION PLANT    
TRADING / DISTRIBUTORSHIP:    
RETAIL:    
LICENSES REQUIRED:    
PLANT LAYOUT    
SUPPLIERS OF PLANT & MACHINERIES    
PLANT AND MACHINERY SUPPLIERS OF COLD STORAGE UNIT    
ROTARY WASHER    
BLANCHING EQUIPMENTS    
TRAY DRYER    
BOILERS    
TUNNEL DRYER    
LABORATORY TESTING EQUIPMENT    
MATERIAL HANDLING EQUIPMENTS    
INSTRUMENTATION & PROCESS CONTROL EQUIPMENTS    
ETP PLANTS    
SUPPLIERS OF RAW MATERIALS    
SUPPLIERS OF VEGETABLES


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)