Soy and Gluten Based Mock Meat (Capacity: 1.5 MT/Day)

SOY AND GLUTEN BASED MOCK MEAT

[EIRI/EDPR/4578] J.C.: 2795XL

INTRODUCTION

India’s food processing sector and meat substitute industry

According to the Annual Survey of Industries (ASI) 2018–19 conducted by the Ministry of Statistics and Programme Implementation (MoSPI); the output of the food processing sector was approximately $179.9 billion (Rs. 12,76,995 crore) contributing around 12.83% to total output in the manufacturing sector. The gross value added (GVA) for the food processing sector was around $30.0 billion (2.24 lakh crore) during 2019–20, which resulted in a contribution of 1.69% to the overall GVA. The ASI also states that approximately 20.05 lakh people were involved in the food processing sector during the survey period. The food processing sector is very lucrative as it permits 100% Foreign Direct Investment (FDI), through the automatic route.

However, 100% FDI under the sovereign approval route applies for retail trading and e-commerce for food products produced in the country. Primary industries of this sector include the processing of sugar, grains, edible oils, beverage, dairy products, fruits and vegetables, meat, and seafood. The built-in capacity and understanding of plant ingredients processing has encouraged Indian processors to develop plant-based substitutes over the past few year.

Current scenario

The global plant-based meat market valued USD 1630 million in 2019 which is expected to reach USD 3290 million by 2025, witnessing a CAGR of 12% (2020-2025). Increased number of vegan population, technology development, rising cholesterol-related health problems and sustainability remained the key drivers for the plant-based meat market. According to the Good Food Institute, about 63% of the Indians are likely to purchase plant-based meat regularly. The heavy use of antibiotics on animals is another key factor driving the consumer shift for plant-based meat. However, in India, the plant based meat is an emerging trend mainly in the food service channel (FSR).

At present, the market size of plant based meat in India is very small but is growing at a faster rate in urban cities. In the past few years, many start-ups entered the plant-based meat market selling through foodservice channels and online retail in India which include Ahimsa Food, Vegeta Gold, Vezlay, GoodDot Enterprises, Vegitein and The Vegan Eatery. An Indian Start-up, EVO, has developed egg dishes using lentil protein. These companies sell their products through e-commerce platforms as well. Leading ingredient players such as ADM are also assisting new entrants in Indian market in designing alternative meat products. Recently ADM partnered with Imagine Meats to offer plant based meat products. At present, the number of players in the market is less while the demand is accelerating, which provides opportunity for new players to enter the market.

Plant-based meat brief overview

Plant-based meat is basically meat derived from plants. It is manufactured to taste, look, and feel like traditional meat from animal products. Plant-based meat is heathier than regular meat as it is lower in calories and saturated fats. Coconut oil, vegetable protein extract and beet juice are some of the ingredients used in plant-based meat. Plant-based meat is healthier when consumed in moderation as part of a balanced diet. It also offers more nutritional benefits than regular meat.

Drivers of plant-based meat industry

According to Forbes, India is the largest producer of pulses in the world, accounting for 25% of the total output; however, more than 70% of the people in India are protein deficient. Deficiency can be caused by lack of awareness and less consumption of a sufficient amount of protein on a regular basis. India has an abundance of protein-rich food such as pulses, soybeans, legumes, seeds, nuts, milk, meat, fish, and poultry.

However, not all sources of protein are feasible for people across the country, which could be due to lack of awareness, affordability, and availability or because of cultural, ethical and health choices. Plant-based protein sources can play a vital role in treating deficiency as they not only offer varieties but are also pocket-friendly. A balanced diet combining two or more sources of plant-based foods can meet protein requirements in the human body.

Alternatively, consumers are very receptive to plant-based meat substitutes. Many consumers are demanding such products as they provide several health and fitness benefits such as prevention of non-communicable diseases, obesity, and digestive disorders.

Amid the Covid-19 pandemic, the popularity of these products has surged as they are being perceived as immunity boosting food products. Flexitarians, individuals, or a group that is vegetarian but tends to consume meat and fish occasionally, can relish the taste of animal meat without consuming animal products. Furthermore, urban consumers are welcoming the idea of plant-based processed food as a rich source of protein

COST ESTIMATION

Plant Capacity            1.5 MT/Day  

Land & Building (6000 sq.mt.)    Rs. 3.34 Cr    

Plant & Machinery                    Rs. 4.51 Cr 

Working Capital for 2 Months    Rs. 1.54 Cr 

Total Capital Investment          Rs. 9.67 Cr 

Rate of Return                          23%

Break Even Point                      62%

CONTENTS

INTRODUCTION

INDIA’S FOOD PROCESSING SECTOR AND MEAT SUBSTITUTE INDUSTRY

CURRENT SCENARIO

PLANT-BASED MEAT BRIEF OVERVIEW

DRIVERS OF PLANT-BASED MEAT INDUSTRY

PLANT-BASED MEAT INDUSTRY ANALYSIS

INDIA’S EMERGING PLANT-BASED MEAT MARKET OFFERS OPPORTUNITIES BUT HARD WORK LIES AHEAD

INDIA’S PLANT-BASED MEAT MARKET – MAJOR INTERNATIONAL FIRMS

ARCHER DANIELS MIDLAND:

BEYOND MEAT:

PLANT-BASED MEAT MARKET DYNAMICS AND TRENDS

INCREASE IN HEALTH CONSCIOUSNESS AMONG CONSUMERS TO NCOURAGE THE DEMAND FOR VEGAN FOOD.

THE INCREASING POPULATION FOLLOWED BY RISING DEMAND FOR MEAT

PLANT-BASED MEAT MARKET SEGMENT ANALYSIS

PLANT-BASED MEAT MARKET GEOGRAPHICAL PENETRATION

PLANT-BASED MEAT COMPANIES AND COMPETITIVE LANDSCAPE

BLUE TRIBE FOODS

IMAGINE MEATS

BEYOND MEAT

TATA CONSUMER PRODUCTS

CCL PRODUCTS

GREENEST

ITC LIMITED

SHAKA HARRY

BVEG FOODS

GOODDOT

WHAT IS PLANT-BASED MEAT

WHAT IS ALTERNATIVE PROTEIN

PROPERTIES OF TEXTURED VEGETABLE PROTEIN

THE GLOBAL PLANT-BASED INDUSTRY

OVERVIEW OF THE GLOBAL PLANT-BASED FOODS MARKET

SALES

CREDIT: GOOD FOOD INSTITUTE

CURRENT PLANT-BASED FOODS INDUSTRY AND MARKET TRENDS

CONSUMER TRENDS

MARKET TRENDS

PRODUCTION OF KEY CROPS

PROJECTED DOMESTIC AND EXPORT MARKET GROWTH

POTENTIAL INDIAN DOMESTIC MARKET IN 2030

CREDIT: GOOD FOOD INSTITUTE INDIA AND DELOITTE

POTENTIAL INDIAN EXPORT MARKET IN 2030

RECOMMENDATIONS FOR THE GOVERNMENT OF INDIA TO SUPPORT 

THE PLANT-BASED FOODS SECTOR

1. LEAD THE GLOBAL DISCOURSE ON TRANSFORMING THE FOOD SYSTEM

2. CATALYZE RESEARCH IN INDIA WITH A FOCUS ON INDIGENOUS CROPS

3. FOSTER A HEALTHY AND SUPPORTIVE ECOSYSTEM FOR PLANT-BASED FOODS

SUPPORT THE AGRI-FOOD PROCESSING INDUSTRY

LEVERAGE PUBLIC PROCUREMENT, SUBSIDIES, AND CREDIT

TRUST CONSUMERS’ UNDERSTANDING OF LABELS

PRIORITIZE EFFICIENT EVALUATION AND APPROVAL OF NOVEL INGREDIENTS

GROWTH OF INDIA’S PLANT-BASED MEAT INDUSTRY

INDIA’S FOOD PROCESSING SECTOR AND MEAT SUBSTITUTE INDUSTRY

FDI IN FOOD PROCESSING SECTOR

PLANT-BASED MEAT BRIEF OVERVIEW

DRIVERS OF PLANT-BASED MEAT INDUSTRY

PLANT-BASED MEAT INDUSTRY ANALYSIS

GOVERNMENT INITIATIVES

HOW PLANT-BASED MEAT AND SEAFOOD ARE PROCESSED

WHAT IS EXTRUSION;

PROCESS FLOW DIAGRAMS

WHOLE MUSCLE MEAT PRODUCTS;

STEP 1: TVP

FORMAT 1:

FORMAT 2:

STEP 2: HYDRATION / MARINATION

FORMAT 1:

FORMAT 2:

STEP 3: COATING

STEP 4: COOKING

STEP 5: EXTENDED SHELF-LIFE PROCESSES (ESLP)

STEPS 6 - 7: COOLING, PACKAGING, & STORAGE

EXTRUSION TECHNOLOGY

SHEAR CELL TECHNOLOGY

COMMERCIAL PRODUCTS

INGREDIENTS FOR PLANT-BASED MEATS AND SEAFOOD

ROOT VEGETABLES, CEREALS, AND OILSEED PROTEINS

SEAWEED AND ALGAE

LENTEINS

HEMP

MYCOPROTEINS

KEY INGREDIENTS PRESENT IN THE TOP 75 PLANT-BASED MEAT PRODUCTS

RESTRUCTURED MEAT PRODUCTS

STEPS 1 - 9 BELOW FOLLOW THE FIGURE 4 ILLUSTRATION, “PROCESS FLOW DIAGRAM FOR

STEP 1: TVP HYDRATION

STEPS 2 -3: INGREDIENT ADDITIONS & MIXING

STEP 4: FORMATION

STEP 5: COATING

STEP 6: COOKING

STEP 7: EXTENDED SHELF-LIFE PROCESSES (ESLP)

STEP 8 - 9: COOLING, PACKAGING, & STORAGE

RAW MATERIAL S

TABLE 1 NUTRITIONAL VALUE OF SOYBEAN

PRE-CONDITIONER/MIXING CYLINDER

LIVE BIN/FEEDER AND BLENDER

STORAGE OF DEFATTED SOY FLOUR

SCREW EXTRUDER

ADVANTAGES OF CO-ROTATING TWIN SCREW EXTRUDER VIS-À-VIS SINGLE SCREW EXTRUDER SHOW:

QUALITY CONTROL AND TESTING EQUIPMENTS:

FUNCTIONALITY AND IMPORTANCE OF SOME KEY TESTING EQUIPMENTS:

USES AND APPLICATION OF TEXTURED VEGETABLE PROTEIN

MARKET SURVEY

CULT OF THE ANALOGUE

TRACING ROOTS

SPREAD OF THE INFLUENCE

OVERVIEW OF NEW MOCK MEAT

TO MAKE NEW FOOD, EXTRUDE!

MOCK MEAT: THE CELL CULTURE APPROACH

MEAT ANALOGS

CHARACTERISTICS OF TEXTURED SOY PRODUCTS

TYPES OF SOY PROTEIN

ISOLATES

CONCENTRATES

FLOURS

SOYA PROTEIN AND ITS USES

FORMULATION OF SOY BASED MOCK MEAT

MANUFACTURING PROCESS OF SOY BASED MOCK MEAT

METHODS OF SOY PROTEIN TEXTURIZATION

SPUN-FIBRE BASED TEXTURIZATIONN

SPUN-FIBRE BASED TEXTURIZATIONN

DETAILS MOCK MEAT FROM GLUTEN

PROCESS FLOW DIAGRAM

METHOD OF PRODUCTION FOR SOY PROTEIN

PLANT LAYOUT

PRINCIPLES OF PLANT LAYOUT

MAJOR PROVISIONS IN ROAD PLANNING FOR MULTIPURPOSE SERVICE ARE:

PLANT LOCATION FACTORS

PRIMARY FACTORS

1. RAW-MATERIAL SUPPLY:

2. MARKETS:

3. POWER AND FUEL SUPPLY:

4. WATER SUPPLY:

5. CLIMATE:

SPECIFIC FACTORS

6. TRANSPORTATION:

7. WASTE DISPOSAL:

8. LABOR:

9. REGULATORY LAWS:

10. TAXES:

11. SITE CHARACTERISTICS:

12. COMMUNITY FACTORS:

13. VULNERABILITY TO WARTIME ATTACK:

14. FLOOD AND FIRE CONTROL:

EXPLANATION OF TERMS USED IN THE PROJECT REPORT

1. DEPRECIATION:

2. FIXED ASSETS:

3. WORKING CAPITAL:

4. BREAK-EVEN POINT:

5. OTHER FIXED EXPENSES:

6. MARGIN MONEY:

7. TERM LOANS:

8. TOTAL LOAD:

9. LAND AREA/MAN POWER RATIO:

UTILITIES

POWER

WORKING

TOTAL MANPOWER AND PAYROLL

UTILITIES

WATER

WATER QUALITY PARAMETERS FOR PROCESSED WATER:

STEAM

POWER

EFFLUENT TREATMENT AND DISPOSAL

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

STANDARDS

TOLERANCE LIMITS FOR INDUSTRIAL EFFLUENT DISCHARGE

WASTE TREATMENT

PRIMARY TREATMENT

ANAEROBIC TREATMENT

ANAEROBIC TREATMENT HAS THE ADVANTAGES OF

SECONDARY TREATMENT

TERTIARY TREATMENT

SOLIDS CONCENTRATION

TYPICAL WASTE SOLIDS CHARACTERISTICS

EQUIPMENT REQUIREMENT

EQUIPMENT REQUIREMENTS

SUPPLIERS OF RAW MATERIALS

SUPPLIERS OF PLANT AND MACHINERY

STORAGE TANK

AUTOMATIC CAN FILLING & SEALING MACHINERIES

WEIGHING MACHINES

PACKAGING MACHINE

D.G. SET

LABORATORY TESTING EQUIPMENTS

SUPPLIERS OF PLANT AND MACHINERY (IMPORTED)

SWOT ANALYSIS

STRENGTHS

WEAKNESSES

OPPORTUNITIES

THREATS

ORGANIZATION CHART

PLANT LAYOUT

IMPLEMENTATION SCHEDULE

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)