Introduction
Jam, Jellies. Pickles and Sauces are important products of food processing industry. One or more of these items are consumed by almost everybody in our country every day. Jam & Jellies are pectin gels with high sugar concentration. Pickles are good appetizers and add to the palatability of meals. Sauces mainly consist of a vinegar extract of various flavouring materials like spices, herbs, etc.
Product
Jam, jellies and Marmalades are basically pectin gels, formed at a pH of about 3 in the presence of partially inverted sugar in high concentration along with fruit or fruit Juice. These products have attractive colour, flavour, characteristic appearance and have very long shelf life. Apple & Berry Jams, Guava, Grapes & Straw Berry Jellies and Marmalades of orange, grapes & lemon are proposed in the unit. Pickles are made of Lime, Cauliflower, mango & cucumber with salt, vinegar and lactic acid for the purpose of preservation. Sauces made of mango & tomato are common. Both thin & thick sauces are made. Thin sauces contain vinegar extract of various flavouring. Sugar content varies from 15 to 30%. Caramel is added to give dark brown colour.
Market
Jam, Jellies, Pickles & Sauces are in demand in following three major sectors:
Army & Defence;
(ii) Hotel, Catering services & Airlines;
(iii) Civilians. About one third of the production of these food products is consumed by Army & Defence personnels. The Second most important sector is institutional, comprising of hotels, restaurants, flight kitchens etc., which consume these processed fruit products. The third one that is common civilian market, which was very limited so far, now is gaining momentum due to rapid urbanisation, rise in standard of living and need for convenient food products.
Suggested Capacity
The minimum economic capacity for the production of processed fruit & vegetable products is 210 tons per annum with the product mix as follows:
Jam & Pectin (Apple & Berry) : 17 Tons.
Jellies (Guava, Grapes & Berry) : 5 Tons
Marmalades (Orange, Grapes&le
mon) : 7 Tons
Pickles (Mango, Lime & Cauliflower) : 130 Tons
Sauce/ketchup (Mango & Tomato) : 51 Tons
Land & Building
The unit requires about 700 sq. mtrs. of the land with covered area of 500 sq. mtrs.
Raw Materials
The requirement of raw materials for the manufacture of 210 tons of Jams, Jellies Pickles, and Sauces, are as under:-
1. Fruits (Apple, Berries, Guava,
Grapes, Mango, Oranges
2. Vegetables (Cauliflower,
Tomatoes, Lemon & Lime) : 125 Tons.
3. Sugar : 30 Tons
4. Common Salt & other additives : 100 Tons
Utilities
The unit will require a total connected load of 100 KVA and a maximum demand of 80 KVA. Water requirement is about 3000 KL per annum.
Manufacturing process
Jams are made from fruit by washing, pulping, screening, adding sugar, invert sugar & pectines, concentrating and filling in cans in hot conditions. For making Jellies, fruits are sliced and extracted by cooking in water, straining and mixing with sugar & Pectines. This mix is concentrated, canned and pasteurized. The pickles are made from fruits or vegetables by curing in salt or vinegar, Fermatation by adding vinegar, storage in warm place with occasional shaking. Sauces are made by pulping the vegetable in hot water, mixing with vinegar & sugar, concentration and filteration. Sauce is filled in Bottles.
Plant & Machinery
1. Spray washing machine
2. Blanching tank
3. Heating pans made of 3 mm thick SS Sheets
4. Mixing pans with enamelled steel construction
5. SS Sugar Syrup preparation tank with agitation
6. Weighing Machines
7. Canning retorts with crates.
8. Cooling tanks for processed cans.
9. Knives, tools, material handling equipment 10. Bpttle/Jar/ Cans Filling machine
Personnels
The unit requires to employ about 52 persons including staff for office and factory for production supervision and administration.
Estimated Cost of the Project
The project cost for setting up the unit to manufacture 210 tons of Jam, Jelly, Pickle & Sauces per annum is estimated at Rs. as follows:
1. Land & site development $5479.45
2. Building $20547.94
3. Plant & machinery $27397.26
4. Technical know-how & engineering
fees $2739.72
5. Other Misc. fixed assets $6849.32
6. Preliminary & preoperative expenses $8219.17
7. Margin money for working capital $9589.04
8. Contingencies $4794.12
TOTAL $86301.3
Suggested means of Financing
1. Long term loan: $57534.24
2. State cash subsidy $10273.9
3. Promoters capital $18493.15
TOTAL $86301.3
Subsidy is taken as 15% of the Fixed Capital Investment, however it varies from state to state, ranging from 10% to 25% depending upon the category of identified backward area.
