Detailed Project Report (DPR) on Onion Dehydration-Powder, Flakes/Kibbled and Minced

ONION DEHYDRATION-POWDER, FLAKES/KIBBLED AND MINCED

[EIRI/EDPR/3589] J.C.: 1673XL

INTRODUCTION

Dehydrated vegetables are being increasingly used as they retain their culinary quality and palatability, and bring about economy in storage space and transport cost. Besides, there is optimum utilization of the product during the glut season, and saving of packaging material and tinplate.

Dehydrated onion is used extensively in overseas countries as a condiment. Efforts are also being made for export of dehydrated onions, which is being produced by several manufacturers. This standard is intended to help in the quality control of dehydrated Onion.

Dehydrated Onions have been produced in small quantities since the nineteenth century is dehydrated onions were supplied to British naval expeditions in the mid-nineteenth  century and dehydrated onions have been produced in sizable quantities during subsequent  wars, primarily for consumption by armed forces,  but also for civilian use.  Since the quality of these products when rehydrated compared unfavourably with fresh vegetables or other types of processed onions, their usage declined rapidly after each war. However the processing techniques employed in the production of dehydrated onions have been improved greatly  since world  war II, particularly since the late nineteen fifties,  and as a  result  the  quality of  dehydrated vegetables has much improved. At the same time the demand for convenience foods have been increasing and dehydrated onions have benefited accordingly.

The main advantages of dehydrated onions are that they are easy to store, being lighter in weight and smaller in bulk than fresh or other processed onions, they are cheap to pack compared with conned goods, they do not require refrigerated storage as do frozen onions and the contents of a container can be used some time after opening provided they are not rehydrated.

The newest dehydration process appears to be a variation on the  air-drying process and is based on the principle of vapour pressure differentials, using air circulated around the onions at relatively  low temperatures to `sweat' the water from the food. It is reported that this method of dehydration prevents a crust forming  on the outside of the pieces of food and that  the  low temperatures  have  less effect on flavour, texture,  colour  and vitamin contents of onion than do the higher temperatures used in conventional hot air-drying methods.

When establishing a dehydration industry considerable thought should be given to the procurement of fresh onions for dehydration. In most countries onions for dehydration are grown almost exclusively on contract to the processors. The contract are made up of a year in advance and cover such aspects as acreage, planting periods, varieties of onions, field inspection, stage  of  maturity for harvesting, delivery dates, grading  and prices.  To operate a dehydration plant efficiency,  a constant supply of onions is required and this involves  considerable organization  buying in supplies of fresh onion market is rarely practicable since varieties grown for the fresh market may be unsuitable for processing  and continuity  if  supply  cannot  be assured. It is usually found that specialization in processing one or two types is more profitable then production of wide range of dehydrated onions. Ideally a dehydration factory should handle only one type of onion over long periods, so as to avoid the necessity of cleaning down all the machinery and altering the grading and cutting setting etc. when changing from one vegetable to another.

COST ESTIMATION

Plant Capacity            2 MT/Day

Land & Building (1200 sq.mt.)    Rs. 1.65 Cr

Plant & Machinery                    Rs. 1.25 Cr

Working Capital for 2 Months    Rs. 97.79 Lac

Total Capital Investment          Rs. 3.94 Cr

Rate of Return                          22%

CONTENTS

INTRODUCTION

PROPERTIES

COMPOSITION OF ONION

ONION (ALLIUM CEPA)

DEHYDRATION

USES OF DEHYDRATED ONIONS

DEHYDRATED WHITE ONION FLAKES

DEHYDRATED WHITE ONION CHOPPED

DEHYDRATED WHITE ONION MINCED

DEHYDRATED WHITE ONION POWDER

B.I.S. SPECIFICATION

SPECIFICATION OF DEHYDRATED ONION

COMPOSITION & VARIETY OF ONION

COMPOSITION OF ONION

DEHYDRATED ONION

ONION VARIETIES SUITABLE FOR DEHYDRATION

FORMS AND APPLICATION OF DEHYDRATION ONION

FORMS OF DEHYDRATED ONION

ONION FLAKES/KIBBLED (10MM – 30MM)

ONION CHOPPED (SIZE 3.0 - 5.0MM)

ONION MINCED (SIZE 1.0 - 3.0MM)

ONION GRANULES (SIZE 0.1 - 0.5MM & 0.5 TO 1.0MM)

ONION POWDER

ONION SCENARIO IN INDIA

PRODUCTION OF ONION

CURRENT STATUS OF SOWING OF ONION

OVERVIEW OF GLOBAL ONION MARKET

SOUTH AFRICA EXPECTS DEFICITS

US POSITIVE MOOD AHEAD OF THE SEASON

AUSTRALIA EXPORT POTENTIAL DUE TO OVERSUPPLY

EGYPT HIGH PRICES, REDUCED EXPORTS

SPAIN EXPECTS HUGE SHORTAGE OF LARGE ONIONS

GREECE FOCUS SHIFTS TO THE DOMESTIC MARKET

ISRAEL

ITALY WHITE ONION PRICES GOING UP

THE NETHERLANDS SMALL PRODUCER, BUT WORLDWIDE LEADING EXPORTER

BELGIUM DIFFICULT MARKET AND FEWER LARGE ONIONS

PERUVIAN ONIONS BACK IN COLOMBIA

ARGENTINA CHALLENGING SEASON FOR SANTIAGO DEL ESTERO

BRAZIL SMALLER ACREAGE IN PIEDADE

MEXICAN PRODUCTION INCREASING

BOLIVIAN PRODUCTION ON THE RISE

MARKET POSITION OF DEHYDRATED ONION

DETAILED EXPORT DATA OF INDIAN DEHYDRATED ONION

MARKET POSITION OF DEHYDRATED ONIONS

THE DIMENSIONS OF CFB BOXES USED BY THE EXPORTERS ARE AS FOLLOWS

PACKAGING MATERIALS COST

PLASTIC BAGS (INTERMEDIATE PACK)

THE DIMENSION OF THE CONTAINERS ARE AS FOLLOWS

PRODUCTION OF DEHYDRATED ONION IN INDIA

EXPORT OF DEHYDRATED ONION

LIST OF EXPORTERS

MANUFACTURERS/EXPORTERS/SUPPLIERS OF ONION POWDERS

STEPS IN ONION DEHYDRATION

RAW MATERIAL ONION

FEEDING AREA

PEELING & WASHING

SLICING

DRYING FIVE LAYERS DRYER

GRADING

TEMPERATURE EQUALIZING

COLOR SORTING & METAL DETECTION

WEIGHING & PACKING

STORAGE & DISPATCH

MANUFACTURING PROCESS OF ONION DEHYDRATION

PROCESS FLOW DIAGRAM

DEHYDRATION METHOD AND DEHYDRATOR

METHODS

FLOW SHEET FOR ONION DEHYDRATION

PACKAGING AND STORAGE TECHNIQUE

PROCESS FLOW SHEET DIAGRAM FOR ONION POWDER

DEHYDRATION PRACTICES FOR ONION

REPORTED VARIETAL STUDIES FOR ONION DEHYDRATION

SOLAR DRYING

CONVECTIVE AIR DRYING

FLUIDIZED BED DRYING

CHEMICAL COMPOSITION OF ONION, FRESH AND DRIED UNDER VARIOUS TEMPERATURES

MICROWAVE AND FREEZE DRYING

INFRA RED DRYING

VACUUM DRYING

FREEZE DRYING

OSMOTIC DEHYDRATION

MODERN METHODS OF ONION DEHYDRATION

PROCESSING STEPS

POWER PRODUCTION AND ENERGY REQUIREMENTS

GEOTHERMAL APPLICATIONS

SUPPLIERS OF RAW MATERIALS

ONIONS

SUPPLIERS OF PLANT AND MACHINERY (INDIAN)

DEHYDRATOR EQUIPMENTS

ONION PEELING MACHINE

ONION SLICING MACHINE

CONVEYOR BELT

SPRAY DRYERS

AUTOMATIC PACKAGING MACHINES

BOILERS

D.G. SETS (DIESEL GENERATOR)

SUPPLIERS OF PLANT AND MACHINERY (IMPORTED)

PLANT LAYOUT

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)