Industry Overview
India is the second largest producer of fruits and vegetables in the world after China and accounts for about 15 per cent of global vegetable production. The country ranks first or second in the production of several fruits and vegetables. However, the perishable nature of these products and inadequate post-harvest management result in substantial wastage, estimated at 20-30 per cent across the supply chain. Only about 2 per cent of fruits and vegetables are processed into value-added products, with the majority consumed fresh.
Processing fruits and vegetables therefore offers significant scope for reducing wastage, increasing value addition, and generating income and employment in the Indian agrarian economy. Dehydration is particularly suitable for seasonal and perishable produce because properly dehydrated products can be stored for extended periods, including up to 5 years or beyond when hermetically sealed, while enabling availability during the off-season.
Apple processing presents an opportunity within this sector. According to the report, approximately 85-90 percent of Indian apples are consumed fresh, while the remainder is exported, processed, or wasted. During harvesting seasons, market gluts can force farmers to sell produce at low prices. Food processing industries can help create additional demand, support more stable returns for farmers, reduce seasonal wastage, and develop value-added products such as dehydrated apple chips.
Cost Estimation
| Cost Parameter | Value |
|---|---|
| Plant Capacity | 600 Kg./Day |
| Land & Building (1000 sq.mt.) | Rs. 1.19 Cr |
| Plant & Machinery | Rs. 1.99 Cr |
| Working Capital for 1 Month | Rs. 37.44 Lac |
| Total Capital Investment | Rs. 3.80 Cr |
| Rate of Return | 26% |
| Break Even Point | 61% |
Content Index
- INTRODUCTION
- PROPERTIES
- COMPOSITION OF THE APPLE FRUIT:
- MARKET OVERVIEW
- EXECUTIVE SUMMARY:
- INDUSTRY PERFORMANCE
- KEY EXTERNAL DRIVERS
- DOWNSTREAM DEMAND - SUPERMARKET AND GROCERY STORES
- EXTERNAL COMPETITION FOR THE GLOBAL FRUIT AND VEGETABLES PROCESSING INDUSTRY
- GLOBAL CONSUMER SPENDING
- GLOBAL POPULATION
- CURRENT PERFORMANCE
- TRENDS IN HEALTH CONSCIOUSNESS AND CONVENIENT MEALS
- SIZE AND PROFIT
- INDIA
- EXPORT MARKET DEVELOPMENT FOR THE VALUE ADDED PRODUCTS
- POST-HARVEST MANAGEMENT
- INDUSTRY OUTLOOK
- OPPORTUNITIES AND TRENDS
- INDUSTRY DEFINITION
- THE MAJOR PRODUCTS AND SERVICES IN THIS INDUSTRY ARE:
- INDIA FACTS AND FIGURES
- MARKET SIZE IN INDIA
- DEMAND DETERMINANTS
- LIFESTYLE CHANGES
- COMPETITION
- PRICE
- CHANGES IN REAL DISPOSABLE INCOME
- QUALITY
- GROCERY WHOLESALERS AND SUPERMARKETS
- MARKET SHARE CONCENTRATION
- INDUSTRY CONCENTRATION IS LOW.
- KEY SUCCESS FACTORS
- MARKETING OF DIFFERENTIATED PRODUCTS
- ACCESS TO HIGH QUALITY INPUTS
- ATTRACTIVE PRODUCT PRESENTATION
- ECONOMIES OF SCALE
- ABILITY TO PASS ON COST INCREASES
- SUPPLY CONTRACTS IN PLACE FOR KEY INPUTS
- COST STRUCTURE BENCHMARKS
- COMPETITION IS MEDIUM.
- APPLE EXPORTS OF INDIA
- MARKETING
- PROCESSED FRUITS EXPORTS FROM INDIA
- GROWTH DRIVERS
- GROWING DOMESTIC REQUIREMENTS
- EXPORT OPPORTUNITIES
- SUPPLY SIDE ADVANTAGES
- EMPHASIS ON R&D AND AUTOMATION
- TECHNOLOCICAL ASPECTS
- DRIED FRUIT MANUFACTURING PROCESS FLOW CHART.
- PROCESS FLOW DIAGRAM OF APPLE CHIPS PROCESSING
- PROCESS FLOW CHART
- QUALITY CONTROL AND STANDARDS
- ENVIRONMENT AND SAFETY ASPECTS OF THE PROJECT AND RELATED PRODUCT
- MAJOR PLAYERS
- AVAILABILITY OF TECHNOLOGY/KNOW HOW
- SPECIFICATION OF PACKAGING MATERIAL FOR APPLE CHIPS
- AVAILITY OF FRESH FRUITS AND VEGETABLES CHART IN INDIA
- PRODUCT APPLICATIONS
- NUTRITIONAL VALUE OF DRIED APPLE CHIPS (12 CHIPS)
- AVAILABILITY OF RAW MATERIAL IN VICINITY
- DOMESTIC SCENARIO
- FRUIT PRODUCTION ZONES IN HIMACHAL PRADESH
- FOREIGN EQUIPMENT MANUFACTURERS
- POTENTIAL USERS OF INTERMEDIATE PRODUCT
- OVERVIEW MARKET
- PROCESSING
- LIST OF MACHINERY & EQUIPMENTS
- DRYER:
- BUCKET ELEVATOR:
- INSPECTION CONVEYOR:
- ROTARY WASHER:
- BATCH TYPE WASHER:
- MULTI FRUIT & VEGETABLE WASHER:
- APPLE SLICER:
- FRUIT DRYER (CONTINUOUS HOT AIR BELT DRYER):
- PLANT PROJECT LOCATION
- DOCUMENTS REQUIRED FOR LICENSES
- LIST OF DOCUMENTS:
- PRINCIPLES OF PLANT LAYOUT
- 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:
- A. AVAILABILITY OF VARIOUS SERVICES AND PROJECTED RATES
- 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:
- PACKAGING TYPES
- MANUFACTURES PROCESSING MACHINES
- SOME OTHER INTERNATIONAL SUPPLIERS OF PLANT AND MACHINERY
- CONVEYOR BELT
- BUCKET ELEVATORS
- WEIGHING MACHINES
- BAG SEALING MACHINE
- D.G. SET
- LABORATORY TESTING EQUIPMENTS
- EFFLUENT TREATMENT AND DISPOSAL
- STANDARDS
- TOLERANCE LIMITS FOR INDUSTRIAL EFFLUENT DISCHARGE
- WASTE TREATMENT
- PRIMARY TREATMENT
- SECONDARY TREATMENT
- TERTIARY TREATMENT
- SOLIDS CONCENTRATION
- TYPICAL WASTE SOLIDS CHARACTERISTICS
- PHYSICAL METHODS FOR EFFLUENT TREATMENT
- MICROBIOLOGICAL APPROACH FOR EFFLUENT TREATMENT
- EQUIPMENT REQUIREMENT
- EQUIPMENT REQUIREMENTS
- MANPOWER
- GENERAL
- BASIS OF ESTIMATION
- UTILITIES
- WATER
- WATER QUALITY PARAMETERS FOR PROCESSED WATER:
- STEAM
- UTILITIES (EQUIPMENTS)
- WATER TREATMENT PLANT
- REFRIGERATION SYSTEM:
- POWER
- WORKING
- TOTAL MANPOWER AND PAYROLL
- QUALITY CONTROL
- QUALITY CONTROL PROCEDURE/ PARAMETERS
- PHYSICAL EXAMINATION
- DETERMINATION OF MOISTURE CONTENT
- PROCEDURE
- CALCULATION
- DETERMINATION OF SOLUBLE SOLIDS
- PRINCIPLE:-
- APPARATUS
- DETERMINATION OF ACIDITY
- DETERMINATION OF TOTAL ASH
- TEST FOR PRESENCE OF MINERAL ACID
- DETERMINATION OF REHYDRATION RATIO:
- PROCEDURE
- CALCULATION
- FINAL PRODUCTS PHOTOGRAPHS
- SWOL ANALYSIS
- STRENGTHS
- OPPORTUNITIES
- WEAKNESS
- LIMITATIONS
- ADDRESSES OF RELEVANT GOVERNMENT OFFICES
- ADDRESSES OF FINANCIAL INSTITUTIONS
- CLEARANCE REQUIRED
- ORGANIZATION CHART
- PLANT LAYOUT
- TURNKEY CONSULTANT
- IMPLEMENTATION SCHEDULE
- EFFLUENT TREATMENT PLANT
- EFFLUENT TREATMENT PLANT OR ETP FOR FOOD INDUSTRY
- TREATMENT CHARACTERISTICS:
- TREATMENT SCHEME:
- DETAILS OF EFFLUENT TREATMENT PLANT
- BLOCK DIAGRAM FOR S.T.P BASED ON AEROBIC TECHNOLOGY:
- TREATMENT PROCESS DESCRIPTION
- (A) PRIMARY TREATMENT:
- (I) OIL AND GREASE REMOVAL SYSTEM
- (B) SECONDARY TREATMENT:
- (I) DISINFECTION
- (C) TERTIARY TREATMENT:
- (I) BIOLOGICAL TREATMENT (MBBR)
- MBBR COMBINES:
- (II) DIFFUSED AEREATION SYSTEM
- PLANT AND MACHINERY SPECIFICATIONS
- STP PROCESS FLOW DIAGRM
- DESCRIPTION OF BLOCK DIAGRAM
Appendix
- 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)
Frequently Asked Questions
Apple chips processing offers significant scope because it converts a seasonal and perishable fruit into a value-added product with extended storage potential.
The report highlights substantial post-harvest losses in fruits and vegetables and the limited level of processing into value-added products. Dehydrated apple products can help reduce wastage, improve utilization of seasonal production, and provide consumers with products that can be marketed beyond the fresh-fruit season.
Apple chips are generally produced through preparation of fresh apples followed by slicing and controlled drying.
Industrial processing typically includes receiving and inspecting the fruit, washing, preparation or trimming, slicing, and drying under controlled conditions. The report specifically includes equipment such as rotary and batch washers, an inspection conveyor, an apple slicer, and a continuous hot air belt dryer. Quality control and appropriate packaging are also important to maintain the finished product's characteristics and storage stability.
Dehydration is suitable because it reduces the product's moisture content and supports longer-term storage when appropriate packaging and storage conditions are used.
For seasonal produce, dehydration can extend the period in which the product is available for sale and reduce dependence on immediate fresh consumption. The report notes that dehydrated seasonal fruits and vegetables can be stored for extended periods, including up to 5 years or beyond when hermetically sealed, subject to suitable processing, packaging, and storage conditions.
An apple chips processing plant requires equipment for fruit handling, washing, inspection, slicing, drying, and related plant operations.
The report identifies a dryer, bucket elevator, inspection conveyor, rotary washer, batch type washer, multi fruit and vegetable washer, apple slicer, and continuous hot air belt dryer. It also covers supporting equipment and utilities, including weighing machines, bag sealing machines, laboratory testing equipment, a water treatment plant, refrigeration systems, power facilities, and effluent treatment infrastructure.
Relevant quality control parameters include physical examination, moisture content, soluble solids, acidity, total ash, mineral acid testing, and rehydration ratio.
The report contains dedicated procedures for these quality assessments, including determination of moisture content, soluble solids, acidity, total ash, presence of mineral acid, and rehydration ratio. These checks help establish consistency and assess important characteristics of the processed product. Appropriate sampling, testing methods, documentation, and adherence to applicable food quality requirements should form part of the plant's quality control system.
Fruit processing helps reduce post-harvest losses by converting perishable fresh produce into products with a longer usable and marketing period.
Processing can absorb part of the supply during peak harvesting periods, reducing pressure caused by market gluts and limiting the amount of produce that must be sold immediately. Value-added products such as dehydrated apple chips can also be marketed beyond the harvest season. This creates opportunities for better utilization of agricultural output while supporting additional processing, employment, and income generation.
The project considers water, steam, power, refrigeration, water treatment, and effluent treatment as key utility and environmental requirements.
The report includes sections covering water quality parameters, steam, utility equipment, a water treatment plant, refrigeration, power, and total manpower. It also provides extensive coverage of effluent treatment and disposal, including primary, secondary, and tertiary treatment, biological treatment using MBBR, disinfection, diffused aeration, and an STP process flow diagram. These systems are intended to support hygienic processing and responsible management of process wastewater and related waste streams.
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