Detailed Project Report on Mango Pulp (5 Ton/Hour - 200 Kg Aseptic Packaging)

MANGO PULP (5 TON/HOUR - 200 KG ASEPTIC PACKAGING)

[EIRI/EDPR/1461] J.C.240

INTRODUCTION

India  is  the  home  of  mangoes.   A  large  number  of varieties  are  found  in  almost  all  parts  of  the   country.  According  to  statistics  collected  by  the  Fruit  Development Adviser,  Government of India, out of the total fruit acreage  of 12,79,000  ha mangoes alone covered 8,19,000 ha in  1948-49  i.e. nearly  70 per cent of total area under fruits.   Uttar  Pradesh, Tamil  Nadu,  Karnataka,  Bihar and West  Bengal  lead  in  mango growing.

Among  the  numerous varieties, `Safaida' and  `Duschri'  of U.P.  `Alphonso' of Ratnagiri, `Badami' of Mysore, `Benishan'  of East Coast, and `Raspuri' `Neelam' and `Mulgoa' of Tamil nadu and Karnataka  are  the most important varieties  for  canning.   The 'Bangalora'  or  `Totapari' mango which is an assured  and  heavy annual  beater,  and also yields an excellent pulp or  juice,  is sometimes canned to give a fairly good canned product.  Juicy and fibrous  varieties are not quite suitable for canning.  They  are mostly  used  for  making  juice,  squash,  nectar,  chutney  and pickles.

The mango is one of the oldest tropical fruits and has  been cultivated by man for over 1000 years, originating apparently  in Indo-Burma region.  to the large population of Asia, particularly Southern Asia and Malaysia, the mango plays the role as the major fruit  of  the region, much as the apple looms in  importance  in North America and Europe.

The  fruit  is  eaten  in its raw,  fresh  form  when  ripe. Unripened  fruits are commonly used for preparing  jellies,  jams and preserves.  Mango blends well with numerious processed foods, such  as  ice creams.  The pulp of the fruit is  soft  and  tasty (pequant).  Some persons not subtle presence of a turpentine like characteristics   in  some  varieties  although  the   aroma   is delicately  pleasant.  It is also used to prepare squash,  nectar beverages etc.

COST ESTIMATION

Plant Capacity                                 5 Ton/Hour - 200 Kg Aseptic Packaging

Land & Building (3 Acres)    Rs. 3.87 Cr

Plant & Machinery                    Rs. 3.75 Cr

Working Capital for 1 Month    Rs. 2.17 Cr

Total Capital Investment          Rs. 9.96 Cr

Rate of Return                          66%

Break Even Point                      34%

CONTENTS

INTRODUCTION

1. UNFERMENTED JUICE OR PURE FRUIT JUICE

2. FRUIT JUICE BEVERAGE

3. FERMENTED FRUIT BEVERAGES

4. FRUIT JUICE SQUASH

5. FRUIT JUICE CORDIAL

6. SHERBET OR SYRUP

7. FRUIT JUICE CONCENTRATE

USES AND APPLICATIONS

MANGO JUICE

MANGO PULP & SLICES

PROPERTIES AND COMPOSITION

B.I.S. SPECIFICATIONS

TOTAL PRODUCTION OF FRUITS AND VEGETABLES DURING 2008-2012

AREA AND PRODUCTION OF FRUITS FOR THE YEAR 2011­12

MARKET POSITION OF MANGO PULP

WEATHER CONDITIONS

ESTIMATES

PULP SUPPLY

INDIA EXPORT OF AGRO FOOD PRODUCTS

PRODUCT GROUP REPORT/COUNTRY WISE

TAMIL NADU MANGO PULP INDUSTRY IS SECOND LARGEST IN THE COUNTRY

FRUIT BEVERAGES

FRUIT BEVERAGES AND SQUASHES AND SYRUPS DEMAND

FRUIT JUICES AND CONCENTRATES

SQUASHES AND SYRUPS

MARKET STRUCTURE

LEADING BRANDS

CANNED MANGO PULP

MANUFACTURING PROCESS

FLOW SHEET FOR PRODUCTION OF CANNED MANGO PULP

SYSTEMATIC FLOW SHEET OF MANGO PULP PRODUCTION

ESSENTIAL REQUIREMENTS

QUALITY STANDARDS

LAND

BUILDING

PLANT AND MACHINERY

RAW MATERIAL

CANS

WAGES & SALARIES

UTILITIES

ECONOMICS OF THE PROJECT

EXPORT

DETAILS OF MANGO PULP

USAGE

PACKAGING

WEIGHT PER PACK

STORAGE RECOMMENDATIONS

SHELF LIFE

MANGO PULP

VARIETIES:

AREAS OF CULTIVATION AND PROCESSING:

PRESENT MANUFACTURERS/EXPORTERS/SUPPLIERS OF MANGO PULP

AVAILABILITY OF RAW MATERIAL

COMPARISON TABLE OF DIFFERENT VARIETIES OF MANGOES

AVERAGE CONSTITUENTS OF RAW MANGO

MANUFACTURING PROCESS

MANGO PULP MANUFACTURING

CHEMICAL PRESERVATIVES

LABELLING & LASING

STORAGE

QUALITY CONTROL

ABSENCE OF DEFECTS

FLAVOUR

OUTLINE OF THE CANNING PROCESS

DETAILS OF CANNING

CAN FILLING:-

CLINCHING:-

EXHAUSTING:-

RETORTING OR PROCESSING:-

COOLING:-

LABELING AND STORING:-

SPECIFICATIONS OF LACQUERED TIN CANS

TYPES AND APPLICATIONS OF TIN CANS

BEANS OTHER THAN FRESH GREEN BEANS: BAKED BEANS IN GRAVY

TESTING OF CANS

MECHANICAL DEFECTS:-

SIZE OF CANS:-

CANNERY:- HYGEINE:-

CONDENSATION TROUBLES:-

CLEANING ROUTINE:-

MOVABLE PLANT:-

PERSONAL HYGIENE:-

FIRST - AIR EQUIPMENT:-

CONDITIONED AND FILTERED AIR:-

SODIUM HYPOCHLORITE SOLUTION:-

FLOW SHEET OF MANGO PULP

POLLUTION CONTROL IN FRUITS & VEGETABLE PROCESSING PLANTS

OUTLINE OF THE PROCESSES:-

CHARACTERISTICS OF THE EFFLUENTS:-

SUSPENDED SOLIDS CONTENT AND BOD OF FRUIT AND VEGETABLE WASTES

CHARACTERISTICS OF POLLUTED WASTES FROM THE PROCESSING OF FRUIT AND VEGETABLES

TABLE SOURCES AND RELATIVE PROPORTIONS OF WASTES FROM INDIVISUAL PROCESSES IN A FRUIT-PROCESSING PLANT

EFFECT OF WASTES ON STREAMS:-

EFFECT OF WATES ON SEWERS:-

TREATMENT OF WASTES:-

ADDRESSES OF RAW MATERIALS SUPPLIERS

CANS (PACKAGING MATERIALS)

MANGOES AND SUGAR IS AVAILABLE ALL OVER INDIA AND  THEY CAN BE PURCHASED FROM ANY MARKET OR LOCALLY SUPPLIERS

CITRIC ACID

FOOD PRESERVATIVE

FRUIT PROCESSING PLANT

FOOD PACKAGING MACHINES

BOILERS

SEAMING MACHINES

LABEL PRINTING MACHINES

TANKS

MISCELLANEOUS PACKAGING & LAMINATION MACHINERY

WATER CHILLERS

VEGETABLE PROCESSING PLANT

IMPORTED PLANT & MACHINERY SUPPLIERS ADDRESSES

QUALITY STANDARDS CONSULTANTS:-

PLANT LAYOUT FOR MANGO PULP MFG.UNIT.

QUALITY CONTROL PROCEDURE/ PARAMETERS

PHYSICAL EXAMINATION

DETERMINATION OF MOISTURE CONTENT

PROCEDURE

CALCULATION

DETERMINATION OF SOLUBLE SOLIDS

PRINCIPLE :-

APPARATUS

DETERMINATION OF ACIDITY

DETERMINATION OF TOTAL ASH

TEST FOR PRESENCE OF MINERAL ACID

GENERAL PLANT LAYOUT

FRUIT CONVEYOR

BUCKET ELEVATOR/PULPER/FINISHER

SHOP FLOOR SIDE VIEW

FILLING AND CANNING SECTION

CAN STORAGE AREA

EFFLUENT TREATMENT AND DISPOSAL

THE WASTE FROM THE FOOD PROCESSING OPERATIONS MAY BE CLASSIFIED ON THE BASIS OF:

STANDARDS

TOLERANCE LIMITS FOR INDUSTRIAL EFFLUENT DISCHARGE

WASTE TREATMENT

PRIMARY TREATMENT

ANAEROBIC TREATMENT

SECONDARY TREATMENT

TERTIARY TREATMENT

SOLIDS CONCENTRATION

TYPICAL WASTE SOLIDS CHARACTERISTICS

EQUIPMENT REQUIREMENT

EQUIPMENT REQUIREMENTS

MANPOWER

GENERAL

BASIS OF ESTIMATION

UTILITIES

UTILITIES

WATER

WATER QUALITY PARAMETERS FOR PROCESSED WATER:

STEAM

UTILITIES (EQUIPMENTS)

WATER TREATMENT PLANT

POWER

LIST OF FOOD AND AGRO PROCESSING CONSULTANTS

SUPPLIERS OF PLANT AND MACHINERY

CONVEYOR BELT

BUCKET ELEVATORS

WEIGHING MACHINES

D.G. SET

LABORATORY TESTING EQUIPMENTS

INDUSTRIAL ETP PLANT MANUFACTURE/SUPPLIER

LIST OF MACHINERY AND EQUIPMENTS

DESIGN DATA

TECHNICAL DATA

GENERAL

PRO S PROCESS FLOW AND FUNCTION BLOCKS

DE-AERATION BALANCE TANK

HEATING

COOLING

LOW TEMPERATURE DIVERSION

PRE-STERILISATION SIP

CLEANING IN PLACE CIP

CONTROL SYSTEMTECHNICAL DESCRIPTION

SUITABLE  TO FILL ASEPTIC BAGS

FEATURES

COMPOSITION

OPERATIONS

14. TWIN PULPER (MANGO)

15. COOKING KETTLE - STEAM JACKETTED KETTLE

16. FULLY AUTOMATIC COIL TYPE BOILER  (2000 KG)

SALIENT FEATURES

TECHINICAL DETAILS

17. PASTEURISATION SYSTEM: SKID MOUNTED JUICE

STERLISATION,CAPACITY 2000 LPH ALONG WITH ACCESSORIES :

CONTACT FOR RULES FOR INVESTMENTS BY FII/FOREIGN INVESTORS

PROCEDURE FOR OBTAINING EXPORT LICENSES AND CONCERNED RULES FOR EXPORTING PULPS

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)