Detailed Project Report on mango/tomato pulp and ginger paste & powder

MANGO/TOMATO PULP AND GINGER PASTE & POWDER
[CODE NO.3720]  

    
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.

Fruit   Juices   are  prepared  from   fruits   which   have characteristic  flavour,aroma  and  posses  a  palatable  balance between  acidity  and sugar, blending of juices form  2  or  more varieties  of  fruits is often affected to secure  this  balance. Mango, pineapple, grape-fruit, orange, apple, lemon are the  most important fruits used for the preparation of fruit juice.   Their production is comparatively limited because of the high prices and the grater popularity of synthetic and aerated drinks among a bulk  of population.  Different forms of fruit juices  are  given below:-

1.   UNFERMENTED JUICE OR PURE FRUIT JUICE

This is a natural juice pressed out of a fruit and remains practically unaltered in its composition during its  preparation and preservation.

2.   FRUIT JUICE BEVERAGE

This  is  a  fruit juice which is  considerably  altered  in composition  before consumption.  It may be diluted before  being served.

3.   FERMENTED FRUIT BEVERAGES

This is a juice width has under gone alcoholic fermentation by yeast.  The product contains varying quantities of alcohol  e.g. grape wines and apple ciders.

4.   FRUIT JUICE SQUASH

This consists essentially  of  strained  juice  containing moderate  quantities of fruit pulp to which cone sugar  is  added for sweetening e.g. orange squash, lemon squash and mango squash.

5.   FRUIT JUICE CORDIAL

This  is sparkling, clear, sweetened fruit juice  which  all the  pulp  and  other suspended materials  have  been  completely eliminated e.g. lime cordial.

6.   SHERBET OR SYRUP

This is clear sugar syrup which has been artificially flavoured e.g. sherbets of sandal, sengtra and almond etc.


7.   FRUIT JUICE CONCENTRATE

This is a fruit juice which has been concentrated  by  the removal  of  water  either by heat or by  freezing. Carbonated beverage and other products are made form this.

Tomatoes are amongst the most widely grown crop in India. The largest production centers are in southern and central India-Principally the states of Andhra Pradesh, Telangana, Karnataka, Madhya Pradesh and Maharashtra. Tomatoes are produced and processed during the two main seasons across much of India-August to October (Kharif) and December to April (rabi). Where conditions suit, tomatoes are also grown during the off-season (May to July) including under protected cultivation though given the low volumes of production, prices are often the highest during this period.

India is the world’s second largest tomato producer but processes less than 1% of its production. This impacts farmers by way of high postharvest losses and low returns during periods of market glut. Indian tomato based product manufacturers import significant quantities of tomato pulp and paste at high prices which also entails an import duty of 30%. Existing Indian paste and pulp makers are unable to operate their units at optimum capacities due to a lack of fresh tomato at the required volumes at the right price. Further, the types of tomatoes currently grown in India are generally less suitable for processing  due to their low quality parameters for paste and pulp production. The overall result of these constraints is a loss of value to all stakeholders involved with tomato production and processing and its wider impact on local and regional economic development.


COST ESTIMATION



Plant Capacity            34 Ton/Day       
Land & Building (6000 sq.mt.)      Rs. 2.49 Cr         
Plant & Machinery                      Rs. 2.60 Cr     
Working Capital for 2 Months     Rs. 8.92 Cr
Total Capital Investment              Rs. 14.36 Cr
Rate of Return            40%                   
Break Even Point             30%                



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    
GINGER PASTE    
USES AND APPLICATIONS OF MANGO PULP    
MANGO JUICE    
MANGO PULP & SLICES    
PROPERTIES AND COMPOSITION OF MANGO    
B.I.S. SPECIFICATIONS    
SPECIFICATION OF ALPHONSO MANGO PULP    
COMPOSITION OF TOMATO    
COMPOSITION OF RIPE-TOMATO (PER 100 GM)    
VITAMINS    
USES AND APPLICATION OF TOMATO PURE/PULP    
(I)  TO MAKE TOMATO JUICE:-    
(II) TOMATO KETCHUP MAKING    
(III)  TOMATO SOUP:-    
(IV) TOMATO CHUTNEY:-    
(V) TOMATO COCKTAIL:-    
USES AND APPLICATION OF GINGER PASTE    
USE GINGER PASTE    
1. MIX INTO STIR-FRIES    
2. PREPARE WITH FISH    
3. INCORPORATE INTO DESSERTS    
4. STEEP IN TEA    
5. SPICE UP A COCKTAIL    
TYPES OF GINGER    
COMPOSITION OF GINGER    
ANALYSIS OF A BAZAAR SAMPLE OF GREEN GINGER GAVE THE
   FOLLOWING VALUES:-    
VERITIES OF GINGER    
MARKET OVERVIEW OF MANGO PULP    
VARIETIES:    
AREAS OF CULTIVATION AND PROCESSING:    
INDIA FACTS AND FIGURES:    
WEATHER CONDITIONS    
ESTIMATES    
PULP SUPPLY    
EXPORT OF MANGO PULP    
DETAILED EXPORT DATA OF MANGO PULP    
MARKET OVERVIEW OF TOMATO PASTE    
LEADING INDIAN TOMATO PASTE MAKERS AND PRODUCT MANUFACTURERS    
CURRENT TRENDS    
MARKET POSITION OF GINGER PASTE    
BUILDING THE MARKET    
POSITIVE OUTLOOK    
PRICE RISE: BOON FOR COOKING PASTE BRANDS LIKE DABUR, NESTLE    
DETAILED EXPORT DATA OF GINGER PASTE    
PRESENT MANUFACTURING/EXPORTERS OF GINGER PASTE    
OVERVIEW OF GINGER PROCESSING IN INDIA    
NUTRIENT COMPOSITION    
BENEFICIAL QUALITY OF GINGER    
OVERVIEW OF PROCESSED FRUITS AND VEGETABLES    
TOP 5 STATES CONTRIBUTING TO PROCESSED FRUITS AND VEGETABLES    
INDICATIVE PROCESSING OPPORTUNITIES    
OPPORTUNITIES IN FRUITS & VEGETABLES PROCESSING AT A GLANCE    
EXPORTS    
KEY STATES FOR TOP 5 FRUITS IN INDIA    
MARKET POSITION OF FRUITS PULP    
GROWING DEMAND FOR FRUIT PULP IN BABY FOOD AND ORGANIC FOOD
PRODUCTS TO BOOST REVENUE GROWTH OF THE GLOBAL FRUIT PULP MARKET    
MAIN FACTORS DRIVING INCREASING ADOPTION OF FRUIT PULP ACROSS THE GLOBE    
GLOBAL MARKET PROCESSING OF TOMATOES PROCESSING    
2016 CALIFORNIA TOMATO PASTE PROCESSING CAPACITY    
CANNED MANGO PULP    
MANUFACTURING PROCESS OF MANGO PULP    
WASHING / SORTING    
CRUSHING AND DESTONING    
THERMAL TREATMENT    
CREAMING / FILTERING    
DEAERATION    
PASTEURIZATION/STERILIZATION    
PACKAGING    
MANUFACTURING PROCESS OF MANGO PULP (CFTRI 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    
WEIGHT PER PACK    
STORAGE RECOMMENDATIONS    
SHELF LIFE    
MANGO PULP    
VARIETIES:    
AREAS OF CULTIVATION AND PROCESSING:    
AVAILABILITY OF MANGO    
COMPARISON TABLE OF DIFFERENT VARIETIES OF MANGOES    
AVERAGE CONSTITUENTS OF RAW MANGO    
RAW MANGO    
CARBOHYDRATES (GM)    
PROCESSING DETAILS OF MANGO PULP    
THE MANUFACTURING STEPS FOR MANGO PRODUCTS.    
1. FRUIT SELECTION. SEVERAL REQUIREMENTS NEED TO BE MET:    
2. WASHING    
3. BLANCHING    
4. PEELING AND CUTTING    
5. PULPING    
6. THERMAL TREATMENT    
7. ADDITIVES    
8. PACKING    
9. COOLING    
CHEMICAL PRESERVATIVES    
LABELLING & LASING    
STORAGE    
QUALITY CONTROL    
ABSENCE OF DEFECTS    
FLAVOUR    
MANUFACTURING PROCESS OF TOMATO PULP    
THE VARIOUS STAGES ARE AS FOLLOWS:-    
EFFECT OF STORAGE ON THE COLOUR AND SENSORY ATTRIBUTES
   OF TOMATO PUREE    
MATERIALS AND METHODS    
PROCUREMENT OF MATERIAL    
HOT WATER BLANCHING    
STEAM BLANCHING    
MICROWAVE BLANCHING    
MANUFACTURING PROCESS IN DETAILED    
TOMATO PRODUCTS    
TOMATO JUICE    
WASHING THE TRIMMING    
CRUSHING    
PULPING    
HOT PULPING    
EXTRACTION OF JUICE    
CONTINUOUS SPIRAL PRESS    
COLD PULPING    
TOMATO PUREE    
PREPARATION    
PULP CONCENTRATION    
OPEN COOKERS    
VACUUM PAN    
PULP CONSISTENCY    
METHOD- 1    
METHOD - II    
THE END POINT    
PACKING    
TOMATO PASTE    
QUALITY CONTROL    
PROCESS FLOW DIAGRAM FOR TOMATO PUREE    
TECHNICAL ASPECTS FOR TOMATO PROCESSING    
TOMATO JUICE    
TOMATO PUREE    
TOMATO KETCHUP    
FPO SPECIFICATION    
OPERATION IN TOMATO PROCESSING UNIT    
TOMATO PROCESSING FOR JUICE    
TOMATO PROCESSING FOR KETCHUP    
TOMATO PROCESSING FOR PULP    
TOMATO PROCESSING FOR PUREE    
FRUIT PULP PROCESSING AND ASPECTS FOR QUALITY MAINTENANCE    
FORMULATION AND PROCESS OF GINGER PASTE    
FORMULATION-1    
FORMULATION-2    
MANUFACTURING PROCESS OF GINGER PASTE    
PROCESS FLOW DIAGRAM    
PROCESS IN DETAILS    
FORMULATION    
PROCESS FLOW SHEET    
GINGER PASTE PACKING MACHINE    
FEATURES:    
PROCESS OF DRIED GINGER    
THE PROCESS FOR DRIED GINGER:    
QUALITY ASSURANCE OF DRIED GINGER    
GRADING    
PACKAGING    
STORAGE    
PROCESSING OF GINGER    
THE MATURITY STAGE AT THE TIME OF HARVEST    
NATIVE PROPERTIES OF THE TYPE GROWN    
CLEANING    
SORTING    
PEELING    
SLICING    
DRYING    
GRADING AND PACKAGING    
DRIED GINGER    
GINGER POWDER    
GINGER PASTE    
GINGER SYRUP    
GINGER OIL    
GINGER OLEORESIN    
CONVERSION OF FRESH GINGER TO DRY FORM    
THE PRIMARY PRODUCTS OF GINGER RHIZOMES ARE:    
PROCESSING OF FRESH GINGER:    
PEELING METHOD FOR LARGE SCALE PRODUCTION    
MAINLY TWO METHODS ARE FOLLOWED FOR GINGER PROCESSING:-    
1. MANUAL HANDLING    
2. MECHANICAL HANDLING    
QUALITY CHARACTER REQUIREMENTS OF DRIED GINGER    
FACTORS INFLUENCING GINGER QUALITY    
MANUFACTURING PROCESS OF GUAVA PULP    
PROCESS FLOW DIAGRAM OF GUAVA PULP    
MANUFACTURING PROCESS OF PAPAYA PULP    
MANUFACTURING PROCESS OF GINGER POWDER    
PROCESS FLOW DIAGRAM    
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:-    
PROCESS FLOW DIAGRAM OF MANGO PULP    
ANALYSIS OF MARKETING MIX OF VARIOUS MANGO PULP BRANDS
    IN SOUTH GUJARAT    
MARKETING MIX:    
TABLE : RANKING OF MANGO PULP BRANDS ON VARIOUS FACTORS
   BY RETAILERS    
TABLE  AVERAGE ANNUAL SALES VOLUME OF DIFFERENT TYPE
   OF RETAIL OUTLETS (TINS)    
TABLE : VARIANTS OF MANGO PULP OFFERED                         
TABLE : MOST PREFERRED VARIETY OF MANGO PULP ACCORDING
    TO RETAILERS    
LIST OF BUYERS    
SUPPLIERS OF RAW MATERIALS    
CANS (PACKAGING MATERIALS)    
MANGOES AND OTHER FRUITS & SUGAR IS AVAILABLE ALL OVER INDIA
   AND THEY CAN BE PURCHASED FROM ANY MARKET OR LOCALLY SUPPLIERS.    
CITRIC ACID    
FOOD PRESERVATIVE    
SUPPLIERS OF PLANT AND MACHINERIES    
FRUIT PROCESSING PLANT    
FOOD PACKAGING MACHINES    
BOILERS    
SEAMING MACHINES    
LABEL PRINTING MACHINES    
TANKS    
SUPPLIERS OF PLANT & MACHINERIES FOR GINGER PASTE AND POWDER    
SUPPLIERS OF PLANT & MACHINERIES (IMPORTED)    
RAW MATERIAL CALCULATION    
MANGO PROCESSING FOR 3 MONTHS    
TOMATO PROCESSING FOR 6 MONTHS    
OTHER FRUIT PROCESSING FOR 3 MONTHS    
GINGER PROCESSING (SEPARATELY)    
GINGER PASTE    
GINGER POWDER    

    

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)