Project Report On Fruit Juice of Mango, Orange, Sweet Lime, Lime, Pineapple Plant (1200 Ltr. Per Hour Capacity) in Tin Cans

FRUIT JUICE OF MANGO, ORANGE, SWEET LIME, LIME,
PINEAPPLE PLANT (1200 LTR. PER HOUR CAPACITY) IN TIN CANS

[EIRI/EDPR/3427] J.C.: 1507
INTRODUCTION
There are two main types of fruit juice. On the one hand there is a so-called
"direct or notfrom concentrate (NFC) juice" and on the other hand the one
produced from the "juice concentrate". Both have 100% non-diluted fruit content.
The term "direct or NFC juice" or "made from fruit concentrate" on the label
explains how the juice was produced. The juice is either contained in cloudy or
clear bottles after juicing or stored for later filling in sterile tanks. This is the
usual on-farm method.
In order to get a fruit juice concentrate, the freshly squeezed juice will be
dehydrated under vacuum conditions, until the juice is reduced to about one-
sixth of its volume. After reconstitution with clean drinking water there will be a
fruit juice with 100 percent fruit content again. The use of concentrate must be
noted on the product label. The processing of concentrate has no relevance in on-
farm fruit juice production.
For an industrial juice producer it has several advantages, which are crucial due
to the low consumer prices of redilluted juice. The manufacturers can achieve
higher storage capacities, and they can spread the filling evenly over a longer
period and thus compensate for years with poor fruit harvest through storage
reserves.
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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 Activ. 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.
Among all challenges, it is difficult to control the cost of production at the price
points of juices, primarily because of rising food inflation. The continuous, year-
long supply of raw materials, and the non-stop production of juices for the full
season, is another production-linked issue which needs to be managed carefully.
Also of vital importance is controlling transportation and logistics costs.
Packaged juices are gradually cementing their place in the urban household in the
metros and tier I cities; however, replicating the same success in tier II and III
cities is still a struggle as residents in these regions still prefer fresh juices over
packaged ones because they are comparatively cheaper, and also in sync with the
traditional belief that juices are best consumed freshly pressed.
It is appropriate to say that the packaged juices market in India is still evolving.
As there are many national and international brands on the verge of succeeding
and expanding further into the field, new entrants can also cash in on this
opportunity by positioning/promoting packaged and bottled fruit juices as part of
the consumers’ daily diet. Simultaneously, it is critical to ensure affordability for
consumers, while maintaining the hygienic aspects and quality of products
throughout the year.
The commercial production of fruit juices began in Europe shortly after the term
of the century when the Boehi process was developed for the storage of apple
juices under Co2 and refrigeration. The bulk storage permitted distribution of
juice in returnable bottles over an extended period. Prior to that time fruit
juices were available for only short periods after harvest and before the onset of
fermentation.
In the united states, the sale of bottled or canned juices-tomato, grape, and eitrus-
started around 1929. During world war II, commercial Juice production was
greatly increased and the market continued to expand in the postwar years
through the application of new technologies.
CONTENTS
INTRODUCTION
TOP 10 BEST PACKED FRUIT JUICE BRANDS IN INDIA
10. SAFAL:
9. 24 MANTRA:
8. DEL MONTE:
7. MINUTE MAID:
6. CAPRI SUN:
5. B NATURAL:
4. CERES:
3. PAPER BOAT:
2. REAL:
1. TROPICANA:
USES AND APPLICATIONS
FRUIT JUICE BENEFITS:
AVAILABILITY OF RAW MATERIALS
B.I.S. SPECIFICATION
MARKET SURVEY
THE INDIAN FRUIT JUICES MARKET
GLOBAL MARKET OF FRUIT JUICE
BRANDED FRUIT JUICE SEGMENT
JUICY DETAILS
MANUFACTURERS/EXPORTERS OF FRUIT JUICES
REQUIREMENTS AND PRECONDITIONS IN FRUIT JUICE MANUFACTURE
GRINDING AND CRUSHING EQUIPMENT
PIVOTING CENTRIFUGAL MILLS (GRATING MILLS)
STRAINING AND JUICING EQUIPMENT
HYDROPRESSES
NATURALLY CLOUDY, UNFILTERED JUICES
NATURALLY CLOUDY, UNFILTERED APPLE JUICE
PROCESSING
OXIDATION PROTECTION
TECHNICAL OUTLINES OF FRUIT JUICE PROCESSING
METHOD OF PRODUCTION
PREPARATION OF RAW MATERIAL
JUICE EXTRACTION
FILTERING
BATCH PREPARATION
PASTEURISATION
FILLING AND BOTTLING
QUALITY CONTROL
THE USE OF CHEMICAL PRESERVATIVES IN FRUIT JUICES & FRUIT DRINKS
MANUFACTURING PROCESS
FILTRATION
PRESERVATION
PROCESS FLOW SHEET
PRODUCTION OF JUICE AND CONCENTRATES
I. ACCEPTANCE OF RAW MATERIAL
HYDRO-UNLOADING SYSTEM CONSISTS OF:
THE DELIVERY SCOPE OF DRY UNLOADING SYSTEM INCLUDES:
II. FRUIT PULP PREPARATION AND PROCESSING
III. JUICE YIELDING.
IV. PASTEURIZATION AND DEAROMATISATION
V. ULTRAFILTRATION
VI. CONCENTRATION
VII. STANDARDISATION AND STORAGE
MANUFACTURE IN GENERAL
CLEANING
SORTING
COMMINUTION
ENZYME TRETMENT OF PULP
PRESS AIDS
EXTRACTION
CITRUS
DECIDUOUS
CLARIFICATION
PASTEURIZATION
CHEMICAL PRESERVATIVES
INDIVIDUAL MANUFACTURING PROCESSES
PROCESSING OF PINEAPPLE
MANUFACTURING PROCESS OF SWEET LIME JUICE
PROCESS FLOW DIAGRAM
MANUFACTURING PROCESS OF LIME JUICE
PROCESS FLOW DIAGRAM OF LIME JUICE
PROCESSING DETAILS OF ORANGE JUICE
HARVESTING/COLLECTION
CLEANING/GRADING
EXTRACTION
CONCENTRATION
RECONSTITUTION
PASTEURIZATION
PACKAGING/FILLING
COMPLETE PLANT AND MACHINERY SUPPLIERS
SUPPLIERS OF PLANT & MACHINERY
ROTARY WASHER
PEELING MACHINE
FRUIT WASHER
JUICE EXTRACTOR
LABORATORY EQUIPMENTS/LABORATORY TESTING EQUIPMENTS
FILTER PRESS
JUICE HOMOGENIZER
SUPPLIERS OF RAW MATERIALS
PRESERVATIVES
SODIUM BENZOATE
PET BOTTLES OF DIFFERENT SIZES
FRUIT JUICE CANNING PLANT
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
COST ESTIMATION
Plant Capacity 9600 Ltr./Day

Land & Building (25,000 sq.ft.) Rs. 1.19 Cr
Plant & Machinery Rs. 1.95 Cr
Working Capital for 2 Months Rs. 3.86 Cr
Total Capital Investment Rs. 7.30 Cr
Rate of Return 41%
Break Even Point 43%

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Project Report On Fruit Juice of Mango, Orange, Sweet Lime, Lime, Pineapple Plant (1200 Ltr. Per Hour Capacity) in Tin Cans

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FRUIT JUICE OF MANGO, ORANGE, SWEET LIME, LIME,

PINEAPPLE PLANT (1200 LTR. PER HOUR CAPACITY) IN TIN CANS

The rising number of health-conscious consumers is giving a boost to fruit juices;

Plant Capacity 9600 Ltr./Day

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