Detailed Project Report (DPR) on peas processing (iqf technology)

PEAS PROCESSING (IQF TECHNOLOGY)
[CODE NO.3395]  


The pea is most commonly the small spherical seed or the seed-pod of the pod fruit Pisum sativum. Each pod contains several peas, which can be green or yellow. Pea pods are botanically fruit, since they contain seeds and developed from the ovary of a (pea) flower. The name is also used to describe other edible seeds from the Fabaceae such as the pigeon pea (Cajanus cajan), the cowpea (Vigna unguiculata), and the seeds from several species of Lathyrus.

A pea is a most commonly green, occasionally golden yellow, or infrequently purple pod-shaped vegetable, widely grown as a cool season vegetable crop. The seeds may be planted as soon as the soil temperature reaches 10°C (50°F), with the plants growing best at temperatures of 13 to 18°C (55 to 64°F). They do not thrive in the summer heat of warmer temperate and lowland tropical climates, but do grow well in cooler, high altitude, tropical areas. Many cultivars reach maturity about 60 days after planting.

Peas have both low-growing and vining cultivars. The vining cultivars grow thin tendrils from leaves that coil around any available support and can climb to be 1–2m high. A traditional approach to supporting climbing peas is to thrust branches pruned from trees or other woody plants upright into the soil, providing a lattice for the peas to climb. Branches used in this fashion are sometimes called pea brush. Metal fences, twine, or netting supported by a frame are used for the same purpose. In dense plantings, peas give each other some measure of mutual support. Pea plants can self-pollinate.


COST ESTIMATION

Plant  Capacity                                            :       48.00 TON/day       
land & Building (1200)Sq.Mtr)                 :        Rs.  85.00 Lacs
Plant & Machinery                                      :        Rs.  4.00 Cr
Working Capital for 2 Months                  :       Rs.  1.06 cr
Total Capital Investment                           :      Rs.  6.8  Cr
Rate of Return                                             :    33%
Break Even Point                                        :    56%


INTRODUCTION    
FROZEN VEGETABLES    
OVERVIEW OF PEAS IN INDIA    
DISTRICT-WISE CONTRIBUTION TO TOTAL AREA AND PRODUCTION OF PEAS IN UTTAR PRADESH    
FIGURE: DISTRICT-WISE SHARE TO THE TOTAL PEA AREA & PRODUCTION    
TABLE: ESTIMATED FIELD PEA (MATAR) PRODUCTION IN UTTAR PRADESH FOR 2015-16    
FIGURE: DISTRICT-WISE FIELD PEA AREA IN UP OF 2015-16 VS 2014-15    
FIGURE: DISTRICT-WISE FIELD PEA PRODUCTION IN UP OF 2015-16 VS 2014-15    
EXPORT DATA OF FROZEN PEAS    
MARKET SURVEY    
FROZEN POTATOES AND FROZEN VEGETABLES ARE TOP-SELLING FROZEN FOOD CATEGORIES    
EXPORTING FROZEN FRUIT AND VEGETABLES TO EUROPE    
QUICK FROZEN FRUIT AND VEGETABLES CAN BE PRESENTED AS:    
THE BASIC QUALITY REQUIREMENTS FOR FROZEN FRUIT AND VEGETABLES ARE:    
ADDITIONAL BUYER QUALITY REQUIREMENTS:    
SEPARATE STANDARDS ARE FOR:    
IMPORTS OF FROZEN FRUIT AND VEGETABLES IS INCREASING    
FIGURE: EUROPEAN IMPORTS OF FROZEN FRUIT AND VEGETABLES, BY MAIN ORIGIN    
GERMANY IS THE LARGEST IMPORTER OF FROZEN FRUIT AND VEGETABLES    
FROZEN BERRIES INCREASINGLY POPULAR    
FIGURE: EUROPEAN IMPORTS OF FROZEN FRUIT AND VEGETABLES
BY COUNTRY, SHARE OF IMPORTED QUANTITY, IN 2016    
FROZEN FRUITS AND VEGETABLES MAINLY IMPORTED FROM WITHIN EUROPE    
FIGURE: LEADING SUPPLIERS OF FROZEN FRUIT AND VEGETABLES TO EUROPE    
EUROPEAN EXPORT OF FROZEN FRUIT AND VEGETABLES IS ALSO GROWING    
BELGIUM AND POLAND LARGEST EUROPEAN EXPORTERS    
FIGURE: EUROPEAN UNION EXPORTS OF FROZEN FRUIT AND VEGETABLES
BY COUNTRY, SHARE OF EXPORTED QUANTITY 2016    
UNITED STATES MAIN EXPORT DESTINATION FOR FROZEN FRUIT
AND VEGETABLES FROM EUROPE    
CHANCES FOR PRODUCTS NOT COMMONLY PRODUCED IN EUROPE    
FIGURE: TOTAL EUROPEAN PRODUCTION OF FROZEN FRUIT AND VEGETABLES    
GLOBAL OVERVIEW OF FROZEN VEGETABLES    
GLOBAL FROZEN VEGETABLES MARKET: TOP INVESTMENT POCKETS,
BY COUNTRY    
MIDDLE EAST FROZEN VEGETABLES MARKET, 2015-2023 ($MILLION)    
B.I.S. SPECIFICATION    
MANUFACTURING PROCESS OF PEAS PROCESSING    
1.   PODDING    
2.   CLEANING    
3.   GRADING (SORTING)    
4.   SOAKING    
5.   BLANCHING    
6.   FINAL WASHING    
PROCESS FLOW DIAGRAM    
DETAILS OF PEAS PROCESSING    
CULTIVATING THE PEAS    
PICKING AND WASHING    
BLANCHING    
SORTING    
INSPECTION    
PACKAGING AND FREEZING    
TESTING THE FROZEN ENTRÉE RECIPE    
PILOT PRODUCTION    
FROM THE OVEN TO THE FREEZER    
PACKAGING    
DISTRIBUTION    
QUALITY CONTROL    
TYPES OF FREEZING METHOD    
FREEZER TYPES AND THEIR APPLICATIONS    
FREEZING TECHNOLOGY & PROCESS    
FREEZING PROCESS    
FREEZING POINT OF FOODS    
FREEZING TIME    
FIGURE- A SIMPLE SCHEME FOR A ONE-STAGE CLOSED MECHANICAL REFRIGERATION SYSTEM.    
REFRIGERANTS    
FREEZING CAPACITY    
PROCESS AND TECHNOLOGY OF IQF    
CHEMICAL CHANGES DURING FREEZING    
TEXTURAL CHANGES DURING FREEZING    
RATE OF FREEZING    
CHANGES CAUSED BY FLUCTUATING TEMPERATURE    
MOISTURE LOSS    
MICROBIAL GROWTH IN THE FREEZER    
NUTRIENT VALUE OF FROZEN FOODS    
PLANT LAYOUT    
SUPPLIERS OF PLANT AND MACHINERY    
ROTARY WASHER    
COOLER    
REFRIGERATION EVAPORATORS    
DRYER    
CONTROL PANEL    
BOILERS    
FOOD PACKAGING MACHINERY    
FOOD PROCESSING MACHINERY    
MATERIAL HANDLING EQUIPMENTS    
ETP PLANTS    
LABORATORY EQUIPMENTS    
INSTRUMENTATION & PROCESS CONTROL EQUIPMENTS    
SUPPLIERS OF RAW MATERIALS     
MANUFACTURERS/EXPORTERS     

APPENDIX – A:

 1.      COST OF PLANT ECONOMICS      
 2.      LAND & BUILDING                                      
 3.      PLANT AND MACHINERY                                  
 4.      FIXED CAPITAL INVESTMENT                             
 5.      RAW MATERIAL                                         
 6.      SALARY AND WAGES                                     
 7.      UTILITIES AND OVERHEADS                              
 8.      TOTAL WORKING CAPITAL                                
 9.      COST OF PRODUCTION                                   
10.      PROFITABILITY ANALYSIS                               
11.      BREAK EVEN POINT                                     
12.      RESOURCES OF FINANCE                           
13.      INTEREST CHART                                       
14.      DEPRECIATION CHART                                   
15.      CASH FLOW STATEMENT                                   
16.      PROJECTED BALANCE SHEET