fruits & vegetables processing
TRANSCRIPT
Fruit Processing
An Excellent Opportunity
In India
2/14/2015 Sunil N. Sadawarte 1
FROZEN JUICES & CONCENTRATES
READY TO USE JUICES
FRUITS PROCESSING
DEHYDRATION OF FRUITS
FRUIT BARS/ CANDIES/ ROLLUPS’
JAMS & JELLYPULPS & PUREES
BI PRODUTS SUCH AS
CATTLE FEED, ESSENTIAL OILS, FERTILIZER, ETC
VACUUM FRIED FRUITS &
VEGETABLES
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FRUIT 2010-2011 2011-2012 2012-2013
Banana 29780 28455 26509
Mango 15188 16196 18002
Citrus 7464 7922 10090
Papaya 4196 4457 5382
Guava 2462 2510 3198
Apple 2891 2203 1915
Pineapple 1415 1500 1571
Sapota 1424 1426 1495
Grapes 1235 2221 2483
Pomegranate 743 772 745
Litichi 497 538 580
Others 7583 8224 93152/14/2015 Sunil N. Sadawarte 3
The secret of a well planned fruit
and vegetable processing centre
is that it must be designed to
operate for as many months of
the year as possible.
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This means the facilities, the buildings, the material
handling and the equipment itself must be inter-linked
and coordinated properly to allow as many products as
possible to be handled at the same time, and yet the
equipment must be versatile enough to be able to
handle many products without major alterations
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The Indian Fruit Processing Industry
India can be defined clearly as a “Land of Gaps” and thus, a “Land of
opportunities”.
These gaps and the aligned opportunities are two sides of the same coin
which has a vital impact on the production of food, and on ecosystem
security.
The contrast between actual production and processing capabilities
always offers an array of opportunities.
The opportunity in the fruit processing industry is vast, but so are the
challenges; the need of the hour is to improve technology and productivity
in order to be competitive globally.
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Key Fruit Processing Influencers
Cold Chain: Crucial, Yet the Missing Link: India has close to 27
million metric tons of cold storage capacity with close to 5,800 cold
storage units. However, over 65% of this capacity is used solely for
potato storage. The cold storage market in India can be estimated
at ~ USD 2.5 billion and has grown at an annual rate of 15% over
the past 4-5 years India has close to 28,600 refrigerated/
temperature controlled trucks. The refrigerated transportation
capacity in India has grown at a rate of 5-6% per annum and is
expected to reach 38,000 trucks by 2015.
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Integrated Players are primarily companies which not only have storage
capabilities but have also developed back-end capabilities through connections
with farms.
These companies are capable of value addition though grading, sorting and
primary processing.
They primarily concentrate on product procurement, processing, storage and
distribution and outsource their transportation requirements.
Stand alone Cold Storage Companies mainly thrive by storing potatoes and
high value fruits like apples, pears and different berries. Most of the standalone
players also act as wholesalers in the product categories they store. This
segment is highly unorganized with more than 2500-3000 players.
The importance of cold chain needs no validation; perishability has a direct
impact on business economics in the food space and cold chain can bridge the
gap.2/14/2015 Sunil N. Sadawarte 8
Food Packaging: The First Customer Connect
Food packaging is one of the major sales influencers. It enhances quality and extends
the shelf life of food products.
Indian food processers are investing intensively in state-of-the-art packaging
infrastructure & technology. Recent technologies and improved packing materials are
rapidly capturing the organized segment of the Indian food processing sector.
The majority of the organized food processing segment has established or is in the
process of installing “hands free packaging” which is synonymous with “aseptic
packaging”, which serves as the primary level of improved packing in the food processing
space and ensures the safety and security of consumable products.
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Jams, Sauces, Ketchups & Dehydrated
The past decade, the Indian consumer has started accepting the innovative
products and international flavors that have been introduced in the
processed Fruits. The market witnessed new pulpy ketchups and sauces
and also acknowledged innovative products such as pre-mix purees,
marmalades, and canned, dehydrated, F&V among others. The processed
F&V market in India is valued at USD 1.7 billion and is growing at a CAGR of
15-18%. The Indian ketchup market is valued at USD 110 million to USD
120 million, supported by growth at a CAGR of 12-15%.
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Post Harvest Treatment Basic Flow Chart
Hand harvest in to baskets
Latex removal/ initial grading
Transport to field boxes in shade
Packing house Q.C & Fruit fly inspection
Dump to chlorinated water
Automated water brush rinse
Presize for hot water treatment
Hot water quarantine treatment
Hydro cooling
Rest at ambient temperature
Packing line and wax application
Grading QC &Packing Forced air cooling
Cold storageTransport via refer vansExport cold storage ware
houceQC & fruits quarantinePhyo sanitary documents
Export documentsTransfer to vessel/ air via
refer vanExport to the Destination
Country
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Fruit juices and concentrates & powder Flow Diagram
Fruits- mango pomegranate mosambi
etc
Conveying , washing, sorting
Juice extractionHeat treatment, aroma
rec. BlendingFiber pulping refining
clarification
Dump to chlorinated water
Pasteurization blending mixing
SterlizationReady to drink JuicesPackaging
Packing line QCSpray drying for
powdersTransport via refer vans Juice concentration
Freezing QCPacking
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Dehydration of Fruits Flow Diagram
Fruits- mango Pomegranate Mosambi etc Conveying , washing, sorting Peeling , Slicing
SulphonationBlanchingWashing, Draining
Vacuum Drying / Oven Drying
Freeze Drying/ Osmotic DryingQC Packing
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Fruits- mango, banana, jack fruit beans bitter gourd corn okra etc
Conveying , washing, sorting Peeling , Slicing
SulphonationBlanchingWashing, Draining
Vacuum frying QC/ addition of spices Nitrogen flushed Packing
Vacuum frying of fruits & vegetables Flow Diagram
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Major Players
Road Map For the Project
The project to be divided in phases:
Phase 1
100 TPD capacity for post harvest treatment- Cold Chain-
40 TPD capacity Dehydration Plant
40 TPD capacity Juices Concentrates ( Puree) powders
10 TPD capacity canning unit
( Balance 10 tons capacity should be utilized for service to exporters)
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Road Map For the ProjectThe project to be divided in phases:
Phase 1( 3- 5 years minimum before expansion after the production
starts)
100 TPD capacity for post harvest treatment- Cold Chain budgetary price-
Rs. 7 Cr.
40 TPD capacity Dehydration Plant- budgetary price- Rs. 6 Cr.
10 TPD capacity Juices Concentrates ( Puree) powders budgetary price-
Rs. 3 Cr.
10 TPD capacity canning unit- budgetary price- Rs. 0.5 Cr.
( Balance 10 tons capacity should be utilized for service to exporters-
Government charges for this is Rs. 5000/- Ton)
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Road Map For the Project
Phase 2
100 TPD capacity for post harvest treatment- Cold Chain- ( Additional
Capacity)
10 TPD capacity Dehydration Plant
40 TPD capacity Juices Concentrates ( Puree) powders
10 TPD capacity Vacuum Fried Fruits and Vegetables
( Balance 10 tons capacity should be utilized for service to exporters)
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Time Lines & For Complete Fruit Processing Juices, & Concentrates, Powders Dehydrated Fruits
Process/ TimelinesM1
M2
M3
M4
M5
M6
M7
M8
M9
M10
M11
M12
M13
M14
M15
M16
M17
M18
M19
M20
Project Planning
TEFR
DPR
Fresh fruits export (immediate orders)
Company Registration & Certifications
Land Selection
Conversation to Industrial
Machinery Manufacturer
EPC negotiations & Contract
Finance Application & Finance Approval
Import of Machinery
Equipment Supply
Approval of Specifications
Approval of Design
Civil Construction & Land Preparation
Erection
Business Development
Testing & Commissioning
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