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FRUITS PROCESSING All will be equivocal micro entrepreneurship at the rural level contributes much towards overall development

t of rural economy. Without the development of rural economy, it is unthinkable to have social development and increase in the quality of life of rural folk. This can be achieved trough tapping the natural resources of the rural areas (area specific) of India and converting them to possibilities of value added products most wanted by the urban lots. Now-a days, the demand for fruit jams, jelly, squash, Pickles, Banana/ potato/ Arbi chips etc. has increased many fold due to dearth of time or leisure at the hand of the women folk at home as they are also working along with their husbands. In this monogram we make an humble attempt to provide procedures for some of the fruit and vegetable processing like Jam, Jelly, Sauce, Squash, Chips etc. along with the economics & cost effectiveness of the processes. Detailed Procedure for Preparation of Fruit Jam Jam is a nutritious and palatable product prepared from fresh fruits like Papaya, Mango, Pineapple, Plume, Apple etc. Besides, it can be manufactured from locally available fruits. Due to rapid urbanization and change in life-style the demand for jam or jelly is increasing day by day. The present article gives a detailed procedure for preparation of 1 kg of jam from mixed fruits like Mango, Pineapple, Banana, Apple etc. Ingredients :

1. Grated mixed fruits 1.250 kg of fresh fruit will yield 1 kg of grated fruit 2. Sugar 3. Citric Acid 4. Sodium Benzoate 5. Colour and Essence

1.00kg

1 kg 8-10 g 2.5 g as required

Procedure: Fruits are peeled, cut in to small pieces and grated followed by boiling in a pressure cooker for 10 minutes. The boiled materials are made into to pulp and sieved through wire mesh. Pulp and sugar are mixed in a proportion of 1:1 and heated till it is thick. The concentrated pulp is then cooled and sodium benzoate is added. In case of mixed fruit jam, addition of essence and colour may not be required as different fruits impart different colour and flavour. But for a mono fruit jam, essence and colour may be added. Well cooled material is packed in well sterilized bottles secured with pilfer proof caps. Air tightness of the packaging will ensure better shelf-life of the product.

Economics : At an yield of 1.5 kg ( Guava or Banana or Mango or Pineapple) Jam

1. Cost of 1250 of fruits 2. Sugar 3. Cost of Processing 4. cost of Packaging 5. Other over heads Total Expected sale price per kg = Rs.120.00

Rs.50.00 Rs.45.00 Rs.20.00 Rs.5.00 Rs.15.00 Rs.135.00

Total return on 1.5. kg of the product = Rs.180.00 Hence, total profit would be Rs.45.00 Note: It is always advisable and profitable too that the product should be manufactured from locally available fruits. Fresh stuff .when available in plenty should be used for the purpose. For better marketability, quality control is highly essential. Therefore, entrepreneurs are advised to get FPO licence from the appropriate authority. Detailed Procedure for Preparation of Jelly Jelly is another tasty and nutritive preparation from fresh fruits like guava, orange, mango etc. It is different from that of jam on the point that due to natural pectin available in the fruit such as banana or guava or added pectin the product looks as crystal clear jelly like material. Recipe - ! For Guava Jelly ( For 1.5 kg of product) 1. Guava 2. Water 3. Sugar 4. Citric acid 5. Raspberry red colour 1 kg 1500ml 1 kg 10 g as required

Recipe -2 for Other Fruits which do not have Pectin 1. Fruit juice - Pineapple/ Mango/ Orange 2. Sugar 3. Citric acid( Amount of citric acid will vary depending upon the sourness of the fruit) 4. Pectin powder 5. Permitted colour 6. Permitted Essence 1 litre 1 kg 5-1 0g

10g as required as required

Procedure for Guava Jelly Fresh guava ( 1 kg ) is peeled, cut into slices and boiled in a pressure cooker for 20 minutes. The juice is filtered and mixed with sugar citric acid. This mix is again filtered and heated for 10 minutes. At this stage Ladle Test is performed to determine the END POINT. For this, a small amount of the content is held on the ladle used for stirring. The end point is said to be reached when the entire lump falls at once without sticking to the ladle. If the juice falls drop by drop then it is concluded that the end point has not reached and in that case, heating is to be continued till the end point is reached. After achieving the end point the content is cooled essence and colour are added and bottled in well sterilized bottles with attractive label. Procedure for other Jelly :Juice is extracted in the similar method as described in the previous case. The juice is boiled for 10 minutes. In another container, 10 grams of pectin powder is mixed with 200 grams of sugar and then the mixture is slowly added to the boiling solution while stirring constantly. Finally, rest of sugar is added to the solution. The solution is then filtered. The filtered solution is "again heated slowly as described in case of guava jelly and ladle test is performed to determine the end point. The product is cooled and packed in well sterilized bottles with attractive label. Detailed Procedure for Preparation of Sauce Sauce is a very tasty and delicious recipe made out of fruits like tomato, Green Chilli, Red Chilli, Soybean etc. It can also be prepared from Mushroom and Fish. It can be prepared both at the domestic scale as well as commercial scale. The recipe Of typical tomato sauce is described below.

Ingredients : 1. Tomato 2. Sugar 3. Onion 4. Ginger 5. Garlic 6. Cumin (Zeera powder) 7. Red Chilli powder 8. Garam Masala 9. Salt 10. Sodium (Food grade) Benzoate 1 kg 100 9 100 9 50 9 20 9 5g 5g 5g 30g 1.6 g 1 teaspoon

11. Glacial Acetic Acid Procedure

Fresh, fleshy, red and seedless tomato is selected for the purpose of sauce manufacturing. Local tomato will not yield good sauce and will not be accepted in the market. Tomatoes are cut in to small pieces. Onion, ginger and garlic are grinded well in the grinder. Cut tomato and paste of onion, ginger, and garlic are boiled in a pressure cooker with 200 ml of water for 10-15 minutes. The juice is extracted from the boiled materials with the help of wire-mesh strainer or with the help of nylon net. In another container, all spices powder are boiled for about 10 minutes and then the juice is extracted which is then mixed with the above juice. 100 gram of sugar and salt are add d to the entire mix. The entire mix is then heated slowly while stirring constantly to achieve the End Point. The End Point an be determined by Plate Test Method in which a small quantity of the thickened pulp is put a plate and then the plate is slightly tilted. If no water drop cQmes out of the material then the end point is confirmed. If It is not confirmed then heating is continued till it is achieved. On reaching the end point, sodium benzoate is added and stirred well followed by addition of 1 teaspoonful of glacial acetic acid ( or half cup of vinegar). On cooling the product is bottles of different sizes with attractive label. The bottles should be mouth full so that less air come in contact with the material and this will increase its shelf-life. Same procedure may be followed for all kinds of sauce excepting soybean sauce which requires a different procedure. In commercial production appropriate permitted colour and flavour should be added to make the product more attractive'. Econmics The economics is worked out for the above recipe and on the above mentioned quantity as follows. Yield: 1 kg

Detailed Procedure for Preparation of Squash Squash is a very delicious soft drink prepared from various fruit pulps is very much liked by both young old. It can be easily prepared from various seasonal fruits like Mango, Pineapple, Lemon, Water Melon, Jamun, Bael etc. both at domestic and commercial scale. The typical recipe for orange squash is described below. Ingredients : 1. Orange juice1 kg of orange will give 500ml juice. 2. Sugar 3. Water 4. Citric Acid 5. Orange Essence 6. Orange red colour( Edible grade) 7. Potassium metabisulfite (KMS) Procedure: 1 kg of sugar is dissolved in 500ml of water followed by the addition of 10-15 g of citric acid ( the amount of citric acid will very depending upon the sourness of the juice) and the solution is heated till it 90C. It should not be allowed to boil in any case. The solution is then filtered and cooled. On the other end, oranges are peeled and juice is extracted with juicer. The extracted juice is filtered and added to previously cooled sugar solution. The entire solution is then stirred well for proper mixing. At this stage, recommended quantity of essence, colour and potassium meta bisulfite are added. The product is now ready for bottling. The product should be bottled in pilfer proof bottles previously sterilized. The liquid should be poured full to the brim for better preservation. The same procedure may' be followed for other squash excepting the essence and colour. Economics The above recipe and quantity will yield .1300ml of squash which can be filled in two 750 ml bottles. Production Cost. Can be calculated as per the present market price. DETAILED PROJECT REPORT ON FRUIT PROCESSING 1.0 INTRODUCTION Fruits are an important source of energy for human-beings but they are perishable items. Hence since many years various products are made from juice of fruits so that they can be consumed during off season as well. Products like jam, jelly, squash etc. are made from fruits since long. With the advent of technology and preservatives, shelf life of such products has gone up and they can be preserved for many months with proper packing. The proposed location of this activity could be many centres in India as number of tropical fruits are grown in the country. However, this note deals with a project in Manipur as several fruits like 500ml 1 kg 500ml 10-1 5 g 1ml a pinch 1.6 g

pineapples, oranges, lemons, peaches etc. are cultivated in large quantities. Hence, it is suggested to undertake fruit processing activity. 2.0 PRODUCTS 2.1 Applications Fruits are perishable in nature and for their preservation, they need to be processed to make juices, squashes, jams, nectars etc. However, this note is restricted to making of orange and pineapple juice and squash. 2.2 Availability of know-how and Compliances Strict compliances with the provisions under the FPO and PFA Act are mandatory. CFTRI, Mysore, has successfully developed the technical know-how. 3.0 MARKET POTENTIAL Demand and Supply Fruits are liked by people of all age groups but they are available only during specific season. Due to high water or juice contents, they are perishable. Certain fruits require very careful and consequently costly transportation. Hence, many down-the-line products like squash, fruit-juice concentrates, jam, nectars etc. are made from fruits with preservative which increases their shelf-life substantially. Market for such products has witnessed a quantum jump during last few years and with growing urbanisation, increase in disposable incomes and changing life styles, demand for them is steadily going up. Marketing Strategy There are some established brands available in the market but they are costly and hence people would prefer low cost, good quality products. It is possible to introduce competitive pricing for a small scale unit due to its inherent features. Proper care has to be taken in creating and maintaining adequate network. 4.0 MANUFACTURING PROCESS The manufacturing process for making fruit juice and squash is standardised and not very complicated or time consuming. CFTRI, Mysore, has successfully developed this technology. In the first process, fully ripe and matured fruits are washed, cleaned, graded and then peeled. Thereafter juice is extracted from fruits and then it is filtered to remove seeds, fibres etc. This juice is then processed, sterilised and bottled after adding preservatives. In case of squash, syrup of sugar along with preservatives are added to juice and this mixture is stirred till uniform solution is formed and then it is bottled. As regards oranges, recovery of juice is substantial and weight and process loss is 10%. But in case of pineapple, wastages are around 50%. Process loss of 5-6% is compensated by addition of sugar syrup. The process flow chart is as under:

Washing, grading and peeling of fruits Juice extraction and filtration Sterilization Packing 5.0 CAPITAL INPUTS 5.1 Land and Building Total requirement of built-up area shall be around 150 sq.mtrs. and hence land measuring about 300 sq.mtrs. will be adequate. The built-up area is adequate to have production, storage and packing facilities. Cost of land is estimated to be

Rs. 90,000/- whereas that of civil work Rs.3,75,000/-.FPO provisions about layout of factory building must be adhered to. 5.2 Plant and Machinery In view of size of the market and to ensure economic viability of the project, rated production capacity of 150 tonnes per year with 2 shift working and 300 working days is advisable. To install this capacity following machines shall be required: Sl 1 2 3 4 5 6 7 Items Fruit Washing Tanks Juice Extractors Steam Jacketed Kettles- 60 Ltrs. Capacity Stirrer Baby Boiler- 100 kgs/Hr Bottle Washing and Filling Machine Testing Equipments like Refracto Meter, Salinometer, Pipette, Burette etc. -Quantity 2 2 2 1 1 1 1 piece in each o the item Total Price in INR 10,000 85,000 40,000 15,000 60,000 75,000 30,000

3,15,000

5.3 Miscellaneous Assets Many other assets like stainless steel utensils, plastic tubs, exhaust fans, storage racks, furniture & fixtures, etc. shall be needed. A provision of Rs.50,000/- is made for the same. 5.4 Utilities Power requirement will be 40 HP whereas per day water requirement would be 2000 litres for washing of fruits and potable and sanitation purposes. Hard coke of around 25 tonnes will be required annually for boiler. 5.5 Raw Material The all-important raw material will be fresh, ripe and matured oranges and pineapples. North-East states including Manipur are famous for horticulture products. The highest fruit crop of Manipur is pineapple with production of more than 70,000 tonnes whereas that of oranges it is about 4500 tonnes. Thus, availability of few hundred tons will not pose any problems. Other items like sugar, salt, additives and preservatives etc. shall be available locally. Packing materials like food grade plastic or glass bottles, labels, corrugated boxes, BOPP tape etc. shall be required for which prior arrangement is advisable. 6.0 MANPOWER REQUIREMENTS Sl 1 2 3 4 Particulars Skilled Workers Semi-skilled Workers Helpers Salesman Nos 4 2 4 1 Monthly Salary (Rs.) 1,800 1,500 1,000 2,000 Total Total Monthly Salary (Rs.) 7,200 3,000 4,000 2,000 16,200

7.0 TENTATIVE IMPLEMENTATION SCHEDULE Sl Activity Application and sanction of loan Site selection and commencement of civil work Completion of civil work and placement of orders for machinery Erection, installation and trial runs Period (in months) 2 1 4 1

8.0 DETAILS OF THE PROPOSED PROJECT 8.1 Land and Building Items Land Building Total Square mts 300 150 Cost INR 90,000 3,75,000 4,65,000

8.2 Machinery Production capacity of 150 tons can be installed with investment under this head to the extent of Rs.3.15 lacs as discussed earlier. 8.3 Miscellaneous Assets A provision of Rs. 50,000/- is adequate to have support assets as explained earlier. 8.4 Preliminary & Pre-operative Expenses There are certain expenses which are incurred prior to the commencement of production such as registration, establishment and other administrative expenses, interest during implementation and so on. A provision of Rs.50,000/- is made towards them. 8.5 Working Capital Requirement Against installed production capacity of 150 tonnes per year, actual capacity utilisation in the first year is expected to be 65%. At this level of activity, the working capital needs will be as under: (Rs. in lacs) Sl. Particulars Stock of Packing Materials Stock of Finished Goods Receivables Working Expenses Total Period Margin 1 Month 30% Month 25% Total 0.40 0.80 1.50 0.45 3.15 Bank 0.28 0.60 1.15 -2.03 Promoters 0.12 0.20 0.35 0.45 1.12

25% Month 1 Month 100%

8.6 Cost of the Project and Means of Financing Item Amount Sl 1 2 3 4 5 6 1 2 1 Items Land and Building Plant and Machinery Miscellaneous Assets P&P Expenses Contingencies @ 10% on Land & Building and Plant & Machinery Working Capital Margin Total Means of Finance Promoters' Contribution 30% Term Loan from Bank/F Total Debt Equity Ratio (Rs. in lacs) 4.65 3.15 0.50 0.50 0.80 1.12 10.72 3.22 7.50 10.72 2.33 : 1

Financial assistance in the form of grant is available from the Ministry of Food Processing Industries, Govt. of India, towards expenditure on technical civil works and plant and machinery for eligible projects subject to certain terms and conditions. 9.0 PROFITABILITY CALCULATIONS 9.1 Production Capacity and Build-up The rated production capacity of the plant will be 150 tonnes per year. But actual utilization is restricted to 65% in the first year and 75% thereafter. 9.2 Sales Revenue at 100% Product Orange Juice Orange Squash Pineapple Juice Pineapple Squash Total Qty. 35 40 35 40 Selling Price 32,000 40,000 32,000 40,000 Sales 11.20 16.00 11.20 16.00 54.40 (Rs. in lacs)

9.3 Raw Materials Required at 100 Product Oranges Pineapples Sugar - Additives, Preservatives, Flavours, etc. -- -Packing Materials @ Rs.5000/Ton Total . Qty 80 150

Price/Ton Value 13,000 10.40 8,000 12.00 2.04 1.20

7.50 33.14

9.4 Utilities Utilities like power, water and hard coke would cost around Rs.1,00,000/- at 100% activity level. 9.5 Selling Expenses There will be competition from some established national brands and local brands as well. Hence, a provision @ 15% of sales income has been made towards selling commission, free sampling and publicity in local media. 9.6 Interest Interest on working capital assistance from bank is calculated @ 14% per annum. Interest on term loan of Rs. 7.50 lacs is calculated @ 12% per annum considering repayment of loan in 5 years including a moratorium period of 1 year. 9.7 Depreciation It is computed on WDV basis @ 10% on building and 20% on machinery and miscellaneous assets. 10.0 PROJECTED PROFITABILITY (Rs. in lacs) No. Particulars A Installed Capacity --Capacity Utilisation Sales Realisation B Cost of Production Raw Materials Packing Material Utilities Salaries Stores & Spares Repairs & Maintenance Selling and Distribution @ 15% Administrative Expenses Total C Profit before Interest & Depreciation Interest on Term Loan Interest on Working Capital Depreciation Net Profit Income-tax @ 20% Profit after Tax Cash Accruals Repayment of Term Loan 1st Year 2nd Year 150 Tonnes 65% 75% 35.36 40.80 16.66 4.87 0.65 1.94 0.24 0.36 5.30 0.42 30.44 4.92 0.98 0.28 1.11 2.55 0.51 2.04 3.15 -19.23 5.63 0.75 2.15 0.30 0.42 6.12 0.50 35.10 5.70 0.63 0.32 0.92 3.83 0.80 3.03 3.95 1.75

11.0 BREAK-EVEN ANALYSIS (Rs. in lacs) [A] Sales [B] Variable Costs Raw Materials & Packing Materials Utilities (65%) Salaries (65%) Stores & Spares Selling Expenses (75%) Admn Expenses (50%) Interest on Working Capital Total B [C] Contribution [A] - [B] [D] Fixed Cost [E] Break-Even Point [D C] 12.0 [A] LEVERAGES Financial Leverage = EBIT/EBT = 3.81 2.55 = 1.49 Operating Leverage = Contribution/EBT = 7.44 2.55 = 2.92 Degree of Total Leverage = FL/OL = 1.49 2.92 = 0.51 [B] Debt Service Coverage Ratio (DSCR) (Rs. in lacs) Particulars Cash Accruals Interest on TL Total [A] Interest on TL Repayment of TL -Total [B] DSCR [A] [B] Average DSCR 1st Yr 3.15 0.98 4.13 0.98 1.75 0.98 4.21 2nd Yr 3.95 0.63 4.58 0.63 1.75 2.38 1.92 3rd Yr 4.23 0.39 4.62 0.39 1.75 2.14 2.16 4thYr 4.51 0.24 4.75 0.24 1.75 1.99 2.39 1.89 2.63 5th Yr 4.83 0.14 4.97 0.14 21.53 0.42 1.26 0.24 3.98 0.21 0.28 27.92 27.92 7.44 4.89 65% 35.36

------------------------- 2.66 --------------------------------

[C] Internal Rate of Return (IRR) Cost of the project is Rs. 10.72 lacs. (Rs. in lacs) Year Cash 16% 18% 20% 24% Accruals 1 3.15 2.72 2.67 2.62 2.54 2 3.05 2.27 2.19 2.12 1.98 3 4.23 2.71 2.58 2.45 2.22 4 4.51 2.49 2.33 2.17 1.91 5 4.83 2.30 2.11 1.94 1.65 19.77 12.49 11.88 11.30 10.30 The IRR is around 22%. Some of the equipment and packing machinery suppliers are 1. Auric Techno Services Pvt. Ltd. C-101, Shreenath Hermitage, Baner Road, Pune- 411008. Tel No. 25898072/25899113 Fax No. 25899113 2. PRS Technologies Pvt. Ltd. D-26, NDSE Part II New Delhi-110049. Tel No. 26252176/77, Fax : 2540789 3. SS Engg. B-25, Khanpur Ext. New Delhi-110062. Tel No. 26081475 4. 4. Divecha Glass Industries, 249, Balrajeshwar Road, LBS Marg, Mulund (W), Mumbai-400080 5. 5. DK Barry and Compnay Pvt. Ltd. 11/35, West Punjab Baug, New Delhi110026. Tel No. 25160363

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