Detailed Project Report on potato chips, french fries & flakes

POTATO CHIPS, FRENCH FRIES & FLAKES [3572]

When American-style potato chips were introduced in Great Britain in the 1920s, to avoid confusion with the established term “chip potatoes” they were called potato crisps or simply crisps. Over time, though, these clearly drawn distinctions became blurred. For instance, British-style batter-fried fillets and fried potatoes have become popular in the United States and Canada, and even on the western side of the Atlantic they’re called “fish and chips.” Similarly, when thin French fries—along with hamburgers and other American fast foods—went global, the word “fries” became the standard term in many English-speaking countries (at least in fast-food outlets). Likewise, as American snack foods were marketed overseas, the term potato chips was adopted throughout the world, even in the United Kingdom—although most people there do still call them “crisps”. The creators of novel potato-based snacks have introduced some new coinages to the world of chips and crisps. In 1967, General Mills introduced Chipos, said to be tastier, crisper, lighter, and less oily because they were fried much faster than traditional potato chips. Two years later Procter & Gamble introduced Pringles, made from dehydrated and reconstituted potatoes. Pringles are uniform in size and shape, so they can be stacked and packaged in a tube. Chipos didn’t make the cut as a commercial product. Pringles were a tremendous success and are sold all over the world, but apparently the time has not arrived for them to be enshrined in an Oxford dictionary. Potato is widely consumed as food all over the world. Cooked potatoes, in various forms are offered in restaurants and refreshment stalls and variety of processed potato products are available in the market. Surplus and cull potatoes are used as feed for livestock and also as raw material for the manufacture of starch, ethyl alcohol and a few other industrial products. Potatoes are consumed not only as a fresh vegetable, but also in a variety of processed forms.  Dehydrated potato products have been known for long and are especially valued because they afford convenience for use; they have good storage stability and are relatively any to transport. In recent years, there has been, a great spurt in the consumption of  processed  products, such  as  potato chips, dehydrated meshed  potatoes,  and  frozen potato products. Potato chips are basically used for snacks purposes.   They are produced by rapid dehydration of potato slices by direct contact with hot fact.  Its crispness and special palatability make it the favorite of people of all age group. Different varieties of potatoes are usually used for chips.  In India, almost all part of the country produces it but the main share of the total production comes from Uttar Pradesh, Bihar, and West Bengal & Orissa. The difference between crisps and chips is quite varied, depending on where in the English speaking world one is located. The varying definitions which have emerged for these two terms illustrate the immense divergence of the English language, and in the way in which concepts disseminate between English speakers and nations which use English. Of course, for the person puzzling over the packaging in the snack foods aisle, the distinction between the two may be less academic in nature. In the United States, thin slices of potato which are fried and served cold are known as potato chips, while slices or wedges of potatoes which are fried and served hot are known as fries or French fries. A “crisp” in American parlance is a fruit dessert with a sweet crumb topping, and has absolutely nothing at all to do with potato products. Canadians also use the potato chip and French fry terminology, as do some Europeans. Great Britain and Ireland refer to potato chips as “crisps,” and fries as “chips.” In some areas, speakers of British English may talk about “chips” when they refer to thick potato wedges, and “fries” when they refer to thin potato strips, sometimes known as “shoestring potatoes” in the United States. One way to remember the distinction between crisps and chips in Britain is to recall one of the most famous dishes of this region: fish and chips, which is made with pieces of battered fried fish and potatoes, all served hot. In New Zealand, Australia, South Africa, and other regions with a recent and active British influence, people have various ways of talking about crisps and chips. In some areas, “crisps” is used as a blanket term for all fried potato products, hot or cold, and people may talk about “packet crisps” when they want to refer specifically to cold fried potato slices. “Chips” may be used to discuss things like corn or tortilla chips, which are made from materials other than potatoes. Potato snacks are popular in many regions of the world, as the plethora of flavors available indicates. Visitors to regions with unfamiliar terminology may find themselves accidentally ordering the wrong thing, or they may be quite confused over the labeling on supermarket shelves and in restaurants. People who are uncertain about the distinction between crisps and chips in the nations they visit should definitely not be afraid to ask for clarification from a native. Frozen French Fries is an important snacks food having good demand and is being appreciated by masses. Freezing food preserves it from the time it is prepared to the time it is eaten. Freezing food slows down decomposition by turning residual moisture into ice, inhibiting the growth of most bacterial species. In the food commodity industry, there are two processes: mechanical and cryogenic (or flash freezing). The freezing kinetics is important to preserve the food quality and texture. Quicker freezing generates smaller ice crystals and maintains cellular structure. Cryogenic freezing is the quickest freezing technology available due to the ultra low liquid nitrogen temperature (-196°C). Frozen products do not require any added preservatives because microorganisms do not grow when the temperature of the food is below -9.5°C, which is sufficient on its own in preventing food spoilage. Long-term preservation of food may call for food storage at even lower temperatures. Carboxymethylcellulose (CMC), a tasteless and odorless stabilizer, is typically added to frozen food because it does not adulterate the quality of the product. The freezing technique itself, just like the frozen food market, is developing to become faster, more efficient and more cost-effective. Mechanical freezers were the first to be used in the food industry and are used in the vast majority of freezing / refrigerating lines. They function by circulating a refrigerant, normally ammonia, around the system, which withdraws heat from the food product. This heat is then transferred to a condenser and dissipated into air or water. The refrigerant itself, now a high pressure, hot liquid, is directed into an evaporator. As it passes through an expansion valve, it is cooled and then vaporizes into a gaseous state. Now a low pressure, low temperature gas again, it can be reintroduced into the system. Cryogenic or (flash freezing) of food is a more recent development, but is used by many leading food manufacturers all over the world. Cryogenic equipment uses very low temperature gases – usually liquid nitrogen or solid carbon dioxide – which are applied directly to the food product.

COST ESTIMATION

Plant Capacity                           6 MT/Day  
Land & Building (3000 sq.mt)             Rs. 3.86 Cr
Plant & Machinery                        Rs. 5.90 Cr
Working Capital for 2 Months             Rs. 1.28 Cr
Total Capital Investment                 Rs. 11.30 Cr
Rate of Return                           67%
Break Even Point                         19%


INTRODUCTION    
WHAT IS THE DIFFERENCE BETWEEN CRISPS AND CHIPS?    
PACKAGED FROZEN FOODS    
THERE ARE ACTUALLY TWO MAIN TYPES OF POTATO FLAKES PRODUCED:    
FULL PROCESS FLAKES    
LOW LEACH FLAKES    
B.I.S SPECIFICATIONS    
EFFECTIVENESS AND QUALITY OF FROZEN FOODS    
EFFECTIVENESS    
QUALITY    
DETAILS OF INDIVIDUAL QUICK FREEZING (IQF)    
THE MAJOR MARKET SEGMENTS FOR IQF ARE-    
MARKET SURVEY    
REGIONAL ANALYSIS    
KEY PLAYERS    
SNACK PRODUCTS MARKET IN QATAR    
POTATO SPECIALTY SNACK PRODUCTS TO RETAIN DOMINANCE    
RETAIL PACKAGE SEGMENT DOMINATES QATAR AND GCC SNACK
    PRODUCTS MARKET    
OVERVIEW OF INDIAN SNACKS MARKET    
MARKET OVERVIEW OF POTATO CHIPS IN INDIA    
OVERVIEW OF POTATOES FLAKES    
OVERVIEW OF GLOBAL FROZEN POTATO PRODUCTS MARKET    
INDIAN POTATO TO GO GLOBAL WITH GAP CERTIFICATIONS    
VIMAL OIL TO ENTER SNACK FOOD MARKET    
PACKAGING REQUIREMENTS FOR FRIED POTATO CHIPS    
PHYSICO-CHEMICAL CHANGES DURING STORAGE    
MANUFACTURING PROCESS OF POTATO CHIPS    
(1)  SORTING, CLEANING & WASHING:    
(2)  SLICING AND WASHING:    
(3)  DRYING OF SLICES:    
TREATING WITH CHEMICALS:    
CHIP FRYING:    
BATCH FRYING METHOD:    
METHOD OF BATCH PROCESSING:    
PACKAGING:    
FLOW DIAGRAM    
STEPS IN FROZEN FRENCH FRIES    
PREWASHING PEELING MACHINE    
SORTING CONVEYER    
FRENCH FRIES CUTTING MACHINE    
IMPURITY REMOVING MACHINE    
RINSING MACHINE    
BLANCHING    
VIBRATING DEWATERING MACHINE    
AIR VIBRATING MACHINE    
FRYING MACHINE    
DEOILING MACHINE    
MANUFACTURING PROCESS OF FROZEN FRENCH FRIES    
GENERAL MAKING PROCEDURE    
KEY POINTS IN BLANCHING PROCESS    
FACTORS IN DRYING PROCESS    
IMPORTANT TIPS IN FRYING PROCESS    
PROCESS FLOW DIAGRAM OF FROZEN FRENCH FRIES    
PROCESSING DETAILS OF FROZEN FRENCH FRIES    
INDIVIDUAL QUICK FREEZING (IQF)    
TECHNOLOGY    
PROCESS FLOW DIAGRAM    
RECIPE OF FROZEN POTATO PATTY    
DIFFERENT METHOD OF MAKING FROZEN POTATO PATTIES    
A METHOD OF PREPARING A POTATO PATTY FOR FREEZING
    AND STORAGE COMPRISING:    
THE FROZEN POTATO PATTY PREPARED BY THE BELOW METHOD.    
ANOTHER METHOD OF PREPARING A FROZEN POTATO PATTY COMPRISING    
MANUFACTURING PROCESS FRENCH FRIES (MCCAIN PROCESS)    
PROCESS FOR MANUFACTURING FROZEN FRENCH POTATO SEGMENTS
    FOR OVEN RECONSTITUTION    
MANUFACTURING PROCESS FOR POTATO FLAKES    
WASHING & SORTING    
PEELING    
COOKING    
PULPING AND DRUM DRYING OF PULP TO PRODUCE FLAKES    
CONTINUOUS PROCESS TO MANUFACTURE POTATO FLAKES    
A POTATO FLAKE PRODUCTION LINE    
FIRST PHASE OF PRODUCTION    
CUTTING, PRE-COOKING AND COOLING    
DRYING, SIZING AND PACKING.    
PLANT LAYOUT    
MANUFACTURERS/EXPORTERS/SUPPLIERS      
SUPPLIERS OF PLANT & MACHINERY (IMPORTED)     
PACKAGING MACHINERY SUPPLIERS     
SUPPLIERS OF RAW MATERIALS     
SUPPLIERS OF PLANT AND EQUIPMENTS (INDIAN)     
PACKAGING MATERIALS FOR FOOD     

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)