Detailed Project Report on onion dehydration-powder, flakes/kibbled and minced

ONION DEHYDRATION-POWDER, FLAKES/KIBBLED AND MINCED [3589]

Dehydrated vegetables are being increasingly used as they retain their culinary quality and palatability, and bring about economy in storage space and transport cost. Besides, there is optimum utilization of the product during the glut season, and saving of packaging material and tinplate. Dehydrated onion is used extensively in overseas countries as a condiment. Efforts are also being made for export of dehydrated onions, which is being produced by several manufacturers. This standard is intended to help in the quality control of dehydrated Onion. Dehydrated Onions have been produced in small quantities since the nineteenth century is dehydrated onions were supplied to British naval expeditions in the mid-nineteenth  century and dehydrated onions have been produced in sizable quantities during subsequent  wars, primarily for consumption by armed forces,  but also for civilian use.  Since the quality of these products when rehydrated compared unfavourably with fresh vegetables or other types of processed onions, their usage declined rapidly after each war. However the processing techniques employed in the production of dehydrated onions have been improved greatly  since world  war II, particularly since the late nineteen fifties,  and as a  result  the  quality of  dehydrated vegetables has much improved. At the same time the demand for convenience foods have been increasing and dehydrated onions have benefited accordingly. The main advantages of dehydrated onions are that they are easy to store, being lighter in weight and smaller in bulk than fresh or other processed onions, they are cheap to  pack compared with conned goods, they do not require refrigerated storage as do frozen onions and the contents of a container can be  used  some time after opening provided they are not rehydrated. The newest dehydration process appears to be a variation on the  air-drying process and is based on the principle of vapour pressure differentials, using air circulated around the onions at relatively  low temperatures to `sweat' the water from the food. It is reported that this method of dehydration prevents a crust forming  on the outside of the pieces of food and that  the  low temperatures  have  less effect on flavour, texture,  colour  and vitamin contents of onion than do the higher temperatures used in conventional hot air-drying methods. When establishing a dehydration industry considerable thought should be given to the procurement of fresh onions for dehydration. In most countries onions for dehydration are  grown almost exclusively on contract to the processors. The contract are made up of a year in advance and cover such aspects as acreage, planting periods, varieties of onions, field inspection, stage  of  maturity for harvesting, delivery dates, grading  and prices.  To operate a dehydration plant efficiency,  a constant supply of onions is required and this involves  considerable organization  buying in supplies of fresh onion market is rarely practicable since varieties grown for the fresh market may be unsuitable for processing  and continuity  if  supply  cannot  be assured. It is usually found that specialization in  processing one or two types is more profitable then production of wide range of dehydrated onions. Ideally a  dehydration factory  should handle  only one type of onion over long periods, so as to  avoid the necessity of cleaning down all the machinery and altering the grading and cutting setting etc. when changing from one vegetable to another.

COST ESTIMATION

Plant Capacity                           2 Ton/Day  
Land & Building (1200 sq.mt)     Rs. 1.65 Cr
Plant & Machinery                    Rs. 1.25 Cr
Working Capital for 2 Months   Rs. 98 Lac
Total Capital Investment          Rs. 3.94 Cr
Rate of Return                         22%


INTRODUCTION    
PROPERTIES    
COMPOSITION OF ONION    
ONION (ALLIUM CEPA)    
DEHYDRATION    
USES OF DEHYDRATED ONIONS    
DEHYDRATED WHITE ONION FLAKES    
DEHYDRATED WHITE ONION CHOPPED    
DEHYDRATED WHITE ONION MINCED    
DEHYDRATED WHITE ONION POWDER    
B.I.S. SPECIFICATION    
SPECIFICATION OF DEHYDRATED ONION    
COMPOSITION & VARIETY OF ONION    
COMPOSITION OF ONION    
DEHYDRATED ONION    
ONION VARIETIES SUITABLE FOR DEHYDRATION    
FORMS AND APPLICATION OF DEHYDRATION ONION    
FORMS OF DEHYDRATED ONION    
ONION FLAKES/KIBBLED (10MM – 30MM)    
ONION CHOPPED (SIZE 3.0 - 5.0MM)    
ONION MINCED (SIZE 1.0 - 3.0MM)    
ONION GRANULES (SIZE 0.1 - 0.5MM & 0.5 TO 1.0MM)    
ONION POWDER    
ONION SCENARIO IN INDIA    
PRODUCTION OF ONION    
CURRENT STATUS OF SOWING OF ONION    
OVERVIEW OF GLOBAL ONION MARKET
SOUTH AFRICA EXPECTS DEFICITS    
US POSITIVE MOOD AHEAD OF THE SEASON    
AUSTRALIA EXPORT POTENTIAL DUE TO OVERSUPPLY    
EGYPT HIGH PRICES, REDUCED EXPORTS    
SPAIN EXPECTS HUGE SHORTAGE OF LARGE ONIONS    
GREECE FOCUS SHIFTS TO THE DOMESTIC MARKET    
ISRAEL    
ITALY WHITE ONION PRICES GOING UP    
THE NETHERLANDS SMALL PRODUCER, BUT WORLDWIDE
    LEADING EXPORTER    
BELGIUM DIFFICULT MARKET AND FEWER LARGE ONIONS    
PERUVIAN ONIONS BACK IN COLOMBIA    
ARGENTINA CHALLENGING SEASON FOR SANTIAGO DEL ESTERO    
BRAZIL SMALLER ACREAGE IN PIEDADE    
MEXICAN PRODUCTION INCREASING    
BOLIVIAN PRODUCTION ON THE RISE    
MARKET POSITION OF DEHYDRATED ONION    
DETAILED EXPORT DATA OF INDIAN DEHYDRATED ONION    
MARKET POSITION OF DEHYDRATED ONIONS    
THE DIMENSIONS OF CFB BOXES USED BY THE EXPORTERS
   ARE AS FOLLOWS    
PACKAGING MATERIALS COST     
PLASTIC BAGS (INTERMEDIATE PACK)    
THE DIMENSION OF THE CONTAINERS ARE AS FOLLOWS    
PRODUCTION OF DEHYDRATED ONION IN INDIA    
EXPORT OF DEHYDRATED ONION    
LIST OF EXPORTERS    
MANUFACTURERS/EXPORTERS/SUPPLIERS OF ONION POWDERS    
STEPS IN ONION DEHYDRATION    
RAW MATERIAL ONION    
FEEDING AREA    
PEELING & WASHING    
SLICING    
DRYING FIVE LAYER DRYER    
GRADING    
TEMPERATURE EQUALIZING    
COLOR SORTING & METAL DETECTION    
WEIGHING & PACKING    
STORAGE & DISPATCH    
MANUFACTURING PROCESS OF ONION DEHYDRATION    
PROCESS FLOW DIAGRAM    
DEHYDRATION METHOD AND DEHYDRATOR    
METHODS    61
FLOW SHEET FOR ONION DEHYDRATION    
PACKAGING AND STORAGE TECHNIQUE    
PROCESS FLOW SHEET DIAGRAM FOR ONION POWDER    
DEHYDRATION PRACTICES FOR ONION    65
REPORTED VARIETAL STUDIES FOR ONION DEHYDRATION    
SOLAR DRYING    
CONVECTIVE AIR DRYING    
FLUIDIZED BED DRYING    
CHEMICAL COMPOSITION OF ONION, FRESH AND DRIED
    UNDER VARIOUS TEMPERATURES    
MICROWAVE AND FREEZE DRYING    
INFRA RED DRYING    
VACUUM DRYING    
FREEZE DRYING    
OSMOTIC DEHYDRATION    
MODERN METHODS OF ONION DEHYDRATION    
PROCESSING STEPS    
POWER PRODUCTION AND ENERGY REQUIREMENTS    
GEOTHERMAL APPLICATIONS    
SUPPLIERS OF RAW MATERIALS    
ONIONS    
SUPPLIERS OF PLANT AND MACHINERY (INDIAN)    
DEHYDRATOR EQUIPMENTS    
ONION PEELING MACHINE    
ONION SLICING MACHINE    
CONVEYOR BELT    
SPRAY DRYERS    
AUTOMATIC PACKAGING MACHINES    
BOILERS    
D.G. SETS (DIESEL GENERATOR)    
SUPPLIERS OF PLANT AND MACHINERY (IMPORTED)    
PLANT LAYOUT     


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)