Detailed Project Report on rts juice plant

RTS JUICE PLANT
[CODE NO.3246]

Juice is a beverage made from the extraction or pressing out of the natural liquid contained in fruit and vegetables. It can also refer to liquids that are flavored with these or other biological food sources such as meat and seafood (e.g., clam juice). Juice is commonly consumed as a beverage or used as an ingredient or flavoring in foods or other beverages, such as smoothies. Juice emerged as a popular beverage choice after the development of pasteurization methods allowed for its preservation without using fermentation (the approach used with wine production). The Food and Agriculture Organization of the United Nations (FAO) estimated the total world production of citrus fruit juices to be 12,840,318 tones in 2012. The largest fruit juice consumers are New Zealand (nearly a cup, or 8 ounces, each day) and Colombia (more than three quarters of a cup each day). Fruit juice consumption on average increased with country income level. To the American food industry, fruit juice is more profitable than only fruit.

Packaged juice market has charted a high growth trajectory, thanks to its easy availability, anytime-anywhere consumption, and convenience.

Within the beverages market, the fruit-based beverages category is one of the fastest growing categories, and has grown at a CAGR of over 30 percent over the past decade. As of March 2013, the Indian packaged juices market was valued at Rs 1,100 crore (~USD 200 million) and projected to grow at a CAGR of ~15 percent over the next three years.

The packaged fruit juices market can be divided into three sub-categories: fruit drinks, juices, and nectar drinks. Fruit drinks, which have a maximum of 30 percent fruit content, are the highest-selling category, with a 60 percent share of the market. Frooti, Jumpin, Maaza, etc. are the most popular products in this category. Fruit juices, on the other hand, are 100 percent composed of fruit content, and claim a 30 percent market share at present. In contrast, nectar drinks have between 25 and 90 percent fruit content, but account for only about 10 percent of the market.

The rising number of health-conscious consumers is giving a boost to fruit juices; it has been observed that consumers are shifting from fruit-based drinks to fruit juices as they consider the latter a healthier breakfast/snack option.

Dabur is the market leader in the Indian packaged juices market with its brands Real and Real Active. Other players include Parle, Fresh Gold, and Godrej. Some of the other brands of fruit juices and drinks include Frooti, Appy, Mazza, Minute Maid, Slice, Fresh Gold, and Del Monte. Considering the attractiveness of the segment, diversified consumer food companies such as ITC are working towards making a foray into packaged juices.

As per studies, the most preferred pack size is the individual (small) pack which is convenient, and easy to carry and consume. These are in great demand as out-of-home consumption is on the rise. Tetrapaks are most popular among manufacturers as well as consumers. Some companies are also offering their products in tins (eg Del Monte) and PET bottles (eg Mazza); however, they are more expensive than Tetrapaks, which adds to production costs, and, as a result, affects the market price.

Fruit juices have created a space for themselves in regular household menus, as a part of a family’s breakfast, social gatherings, and evening snacks. As a result, consumers are picking up multiple family packs at one go, which is an emerging consumption trend.

There are several reasons behind the growth of the Indian packaged juices category: Changing consumer lifestyles, increased health awareness, hygiene concerns, growing category of informed buyers, rising disposable incomes, booming modern retail, habitual purchase, and introduction to new flavours.

    
COST ESTIMATION

Plant  Capacity                                                     :    14000.00 LTRS/day  
land & Building (3024 sq.mtr)                           :   Rs. 2.86 Cr
Plant & Machinery                                                :    Rs. 2.41 Cr
Working Capital for 2 Months                            :    Rs  2.60 Cr
Total Capital Investment                                     :    Rs. 7.99 Cr
Rate of Return                                                       :    45%
Break Even Point                                                   :    39%



INTRODUCTION                                            
TOP 10 BEST PACKED FRUIT JUICE BRANDS IN INDIA                
USES AND APPLICATIONS                                    
AVAILABILITY OF RAW MATERIALS                                
B.I.S. SPECIFICATION                                        
OVERVIEW OF FRUIT BASED BEVERAGES                        
MARKET SURVEY                                            
BRANDED FRUIT JUICE SEGMENT                                
MANUFACTURERS/EXPORTERS OF FRUIT JUICES                    
MANUFACTURE OF RTS JUICE                                
PROCESS FLOW SHEET                                    
PROCESS OF FRUIT JUICE                                    
FILTRATION                                            
PRESERVATION                                            
PROCESS FLOW SHEET                                    
PRODUCTION METHOD OF FRUIT BASED BEVERAGES                
MANUFACTURE OF PASSION FRUIT JUICE                        
PREPARATION AND PROCESSING OF FRUIT JUICE                    
MANUFACTURE IN GENERAL                                    
CLEANING                                                
SORTING                                                
COMMINUTION                                            
ENZYME TRETMENT OF PULP                                
PRESS AIDS                                            
EXTRACTION                                            
CITRUS                                                
DECIDUOUS                                            
CLARIFICATION                                            
PASTEURIZATION                                            
CHEMICAL PRESERVATIVES                                    
INDIVIDUAL MANUFACTURING PROCESSES                        
1.   PROCESSING OF PINEAPPLE                                
SOURCES OF BEVERAGE JUICE                                
1.   CORES                                                
2.   JUICE TRIMMINGS                                        
3.   ERADICATOR MEAT                                        
4.   SMALL FRUIT                                            
5.   JUICE DRAINED FROM CRUSHED PINEAPPLE (KETTLE DRAINED)        
6.   JUICE DRAINED FROM ERADICATOR MEAT                        
7.   JUICE DRAINING FROM CYLINDERS AND SLICES DURING PROCESSING    
TRIMMING SLICING GRADING                                
AND PACKING OPERATIONS                                    
JUICE PREPARATION                                        
BLENDING                                                
WASHING                                                
SORTING                                                
JUICE PROCESSING                                        
UNCLARIFIED JUICE                                        
"CRUSED" APPLE JUICE                                    
CENTRIFUGED APPLE JUICE                                    
FILTERED APPLE JUICE                                    
QUALITY CONTROL IN FRUIT JUICES                            
PRESERVATIVES IN FRUIT JUICES AND FRUIT DRINKS                
DETAILS & TECHNICAL SPECIFICATION OF PLANT                    
& MACHINERY FOR RTS JUICE                                
SCHEME OF TREATMENT                                    
PROCESSING SECTION FOR JUICE PLANT                        
PLANT LAYOUT                                               
SUPPLIERS OF PLANT & MACHINERY                                    
ROTARY WASHER                                                     
PEELING MACHINE                                                                
FRUIT WASHER                                                                     
JUICE EXTRACTOR                                                                                      
LABORATORY EQUIPMENTS/LABORATORY TESTING EQUIPMENTS          
FILTER PRESS                                                                              
JUICE HOMOGENIZER                                                                           
AIR COMPRESSOR                                                                                      
BOILERS                                                        
PLATFORM WEIGHING MACHINE                                                        
SUPPLIERS OF RAW MATERIALS                                                       
PET PREFORMS                                                              

            
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