Detailed Project Report (DPR) on Vegetable dehydration plant (4 ton/hour)

VEGETABLE DEHYDRATION PLANT (4 TON/HOUR)
[CODE NO.3431]  


 In India, Dehydration of fruits and vegetable has a bright prospects over  other foods because India has diverse geographical and climatic conditions and produces a wide range of fruits and vegetables throughout the year.  Here almost all type of fruits and vegetables are grown all over the country.  These fruits and vegetables are valuable foods.  They are a rich source of calcium, phosphorus, iron and vitamins.

Dehydrated fruits & vegetables include a no. of articles mainly, fruit juices, dehydrated fruits and vegetables, squashes, cordials, Beverages, jam, jellies, mermalades, chutney,  sauces, pickles, vinegar, pectin etc.  
     
Dehydration is at present defined industrially as drying by artificially   produced heat under carefully controlled conditions of temperature, humidity,  and air flow. The term `dried' is applied to all dried products regardless of the method of drying.

Fruits and vegetables are dried to enhance storage stability, minimize packaging requirement and reduce transport weight. Preservation of fruits and vegetables through drying based on sun and solar drying techniques which cause poor quality and product contamination. Energy consumption and quality of dried products are critical parameters in the selection of drying process. An optimum drying system for the preparation of quality dehydrated products is cost effective as it shortens the drying time and cause minimum damage to the product. To reduce the energy utilization and operational cost new dimensions came up in drying techniques. Among the technologies osmotic dehydration, vacuum drying, freeze drying, superheated steam drying, heat pump drying and spray drying have great scope for the production of quality dried products and powders.


The  keeping  quality  of a  food material is  greatly influenced   by  its  water content. Fruits and vegetables containing high percentage of water deteriorate more rapidly than cereals, and root crops.  Preservation of foods by sun drying is perhaps the oldest method known. Fruits like figs, amla, mango banana, coconut etc. and vegetables like tapioca, chillies, peas, turmeric  and  ginger are preserved by sun drying. The use of machinery for drying and the development of the dehydration industry are comparatively recent and like canning dehydration is assuming increasing importance as a process of good preservation.


COST ESTIMATION

Plant  Capacity                                             :       32.00 MT./day
land & Building (8000 Sq.mt)                   :       Rs.   4.80 Cr
Plant & Machinery                                       :       Rs.   5.00 Cr
Working Capital for 1 Month                     :       Rs.   16.31Cr
Total Capital Investment                            :       Rs.   26.41Cr
Rate of Return                                             :       39%
Break Even Point                                        :       36%

INTRODUCTION    
USES AND APPLICATIONS    
QUALITY CONTROL    
TECHNICAL ASPECTS    
DEHYDRATED FOODS    
PRINCIPLE    
BASES & PRESUMPTION    
SPECIFICATIONS    
BLANCHIUNG TIUME FOR VEGETABLES    
TYPICAL PERCENTAGE COMPOSITION OF    
FOODS OF PLANT ORIGIN    
MARKET SURVEY    
PRESENT STATUS    
FUTURE SCOPE    
EXPORT DATA OF DEHYDRATED VEGETABLES    
PRODUCTION, INSTALLED CAPACITY AND CAPACITY UTILIZATION
OF PROCESSED FRUITS & VEGETABLES    
APPARENT CONSUMPTION OF PROCESSED FRUITS & VEGETABLES    
ESTIMATED DEMAND    
MANUFACTURERS/SUPPLIERS OF VEGETABLE DEHYDRATION    
SPECIFICATION FOR DEHYDRATED GARLIC    
SCOPE    
REFERENCES    
TERMINOLOGY    
REQUIREMENTS    
PACKING    
MARKING    
DEHYDRATION AND ITS BENEFITS    
BENEFITS OF DEHYDRATION:    
TYPES OF DRYING FRUITS AND VEGETABLES    
NATURAL SUN DRYING    
DRYING WITH A FOOD DEHYDRATOR    
OVEN DRYING    
COMPOSITION OF ONION    
ONION VARIETIES SUITABLE FOR DEHYDRATION    
COMPOSITION AND EVERY VALUE OF RAW AND DEHYDRATED ONION
(PER 100 GM OF ONION)    
MANUFACTURING PROCESS OF VEGETABLE DEHYDRATION    
COMPARISON WITH CANNED VEGETABLES    
FOOD VALUE OF DEHYDRATED VEGETABLES    
PROCESS FLOW DIAGRAM    
MANUFACTURING PROCESS OF POTATO DEHYDRATION    
PROCESS FLOW DIAGRAM    
MANUFACTURING PROCESS OF GARLIC DEHYDRATION    
PROCESS FLOW DIAGRAM    
MANUFACTURING PROCESS OF ONION DEHYDRATION    
PROCESS FLOW DIAGRAM    
DEHYDRATION PRACTICES FOR ONION    
SOLAR DRYING    
CONVECTIVE AIR DRYING    
FLUIDIZED BED DRYING    
MICROWAVE AND FREEZE DRYING    
INFRA RED DRYING    
VACUUM DRYING    
FREEZE DRYING    
OSMOTIC DEHYDRATION    
PREPARING VEGETABLE FOR DEHYDRATION    
STEPS FOR STEAM BLANCHING    
STEPS FOR WATER BLANCHING (VEGETABLES ONLY):    
METHODS OF DEHYDRATION    
SUN DRYING:    
SOLAR DRYING:    
ROOM TEMPERATURE DRYING:    
FREEZE DRYING:
DRUM DRYING:    
OSMOTIC DRYING:    
PROCESS DESCRIPTION OF DEHYDRATION    
PREDRYING TREATMENTS -    
DRYING OR DEHYDRATION -    
POSTDEHYDRATION TREATMENTS -    
DETAILS FRUITS AND VEGETABLE FOR DRYING    
DEHYDRATION OF BITTER GOURD    
PROCESS IN DETAILS OF DEHYDRATION OF VEGETABLES    
PEELING    
SLICING, DICING, AND SHREDDING.    
BLANCHING    
SULFITING.    
TRAYS.    
TRAY LOAD.    
DRYING TEMPERATURES.    
VACUUM DRYING.    
MOISTURE CONTENT.    
ENZYME TESTS.    
DRYING RATIOS.    
REFRESHING AND COOKING RATIOS.    
BEANS    
BITTER GOURD (KERELA)    
BRINJAL    
CABBAGE    
CARROT    
CAULIFLOWER    
GARLIC    
KNOL KHOL    
OKRA    
ONION    
PEAS    
POTATO    
PUMPKIN    
SPINACH (PALAK):-    
TOMATO    
TURNIP    
GENERAL    
PEPPERS AND PIMIENTOS    
SWEET CORN    
PACKING AND STORAGE    
PROCESS FLOW DIAGRAM FOR DEHYDRATION OF FRUITS
& VEGETABLES BY VACUUM DRYING METHOD    
PLANT LAYOUT    
SUPPLIERS OF PLANT & MACHINERIES    
PLANT AND MACHINERY SUPPLIERS OF COLD STORAGE UNIT    
ROTARY WASHER    
BLANCHING EQUIPMENTS    
TRAY DRYER    
BOILERS    
TUNNEL DRYER    
LABORATORY TESTING EQUIPMENT    
MATERIAL HANDLING EQUIPMENTS    
INSTRUMENTATION & PROCESS CONTROL EQUIPMENTS    
SUPPLIERS OF RAW MATERIALS    
SUPPLIERS OF VEGETABLES    

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