dr. n. varadharaju professor and head post harvest technology centre tnau
DESCRIPTION
FOOD PRCESINGTRANSCRIPT
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Commercial Food Commercial Food Processing OpportunitiesProcessing Opportunities
Dr. N.VaradharajuProfessor & Head
Post Harvest Technology CentreAgricultural Engineering College & Research Institute
Tamil Nadu Agricultural UniversityCoimbatore 641003
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Need for Food processingNeed for Food processing
Food production in India to double in the next tenyears.
India will add more than 500 million people in the 40years.years.
Today the total food market is approximately US$69,444 million.
Consumption of value added processed food to treble
Food is one of the highest economic multipliersamong Indian industries
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ContdContd..
Today value addition to food production is only 7 per cent
India has the potential to become the largest food India has the potential to become the largest food factory
Value added foods produced from the food industries would reach Rs. 2,75,000 crores by 2010
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Investment OpportunitiesInvestment Opportunities
Diverse agro-climatic condition, it has a wide range and large raw material suitable for food processing sector
Biggest emerging sector to market over 1billion population50 per cent of population are under 30 years50 per cent of population are under 30 years250 to 300 million are in middle class
Per capita consumption levels of processes foods are low
Demand for convenience foodsIncreased female literacyIncreased number of working women
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Contd.Contd.
Institutional & Tourism sectors Hotels, Airlines, Hospitals and Defence Services
Government accord high priorityInvestment reforms Investment reforms
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Agriculture In IndiaAgriculture In India
Contributes 29.1% to GDP69% of work force depends on Agriculture 22 % of export from agricultural products
Major AchievementsMajor AchievementsMajor AchievementsMajor Achievements Self sufficient in food grain production (210 million tones)
Ranks second in fruits (48 million tones) and vegetable production (98 million tones)
Largest producer of milk (72 million tons )
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Food Processing Sector
Green Revolution
White Revolution
Blue Revolutio
India- worlds largest food factory- over 27,500 units (both large and small)
Yellow Revolution(Post Harvest Processing)
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Post Harvest LossesPost Harvest Losses
Food grain sector : 812%
Fruits and vegetable : 2030 %
Pre-harvest Factors 3-5%Harvest 2-5 %Packaging 3-6 %Transport 1-4 %Storage 4-8 %Processing 1-5 %Handling 1-5 %Urban Distribution 2-8 %Total Losses 18-48 %
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Important Sub sectorsImportant Sub sectors
Cereals & pulse processing Fruit & Vegetable Processing Milk Processing Meat & Poultry Packaged & Convenience Food Alcoholic & Non Alcoholic Beverage
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Progress of Fruits and Vegetable Progress of Fruits and Vegetable Industry in IndiaIndustry in India
Particulars 2000 2005
Production of processed Foods 9.9 12.5Production of processed Foods(Lakh tons)
9.9 12.5
Installed capacity (Lakh tons) 22.0 29.0
No. of Licenses issued under FPO 5293 5856
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Reasons for Under Utilization of Processed Reasons for Under Utilization of Processed Foods in IndiaFoods in India
High cost of processed foods
Low quality raw material affecting the final qualityof processed foodsof processed foods
Prevailing rules and regulation and high tax for processed foods
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Contd.Contd.
Lack of knowledge about process, equipment & technology
Lack of proper infrastructure like electricity,good quality water, communication facilities,good quality water, communication facilities,etc.
Inadequate cold storage and refrigerated facility
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Domestic Market
Factors Triggering Potential for New Products
Increasing nuclearisation of families
Increasing number of working women
Convenience Foods, semi cooked
Ready to cook / eat foods
Market NeedsMarket NeedsMarket NeedsMarket NeedsMarket NeedsMarket NeedsMarket NeedsMarket Needs
women
Changing role of Women
Increased health consciousness
Changing Retailing System
Ready to cook / eat foods
Organic foods, Natural Colours, Flavours, Neutraceuticals,
Fortified foods, Energy Foods, Low Fat Foods, Sprouted Foods
Packed & Branded Commodities
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Export Market
Competitiveness for Indian fresh and processed foods
Increasing number of Indian population Increasing number of Indian population in foreign countries
Acceptance of Indian Food in Foreign Markets
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APEDAs SCHEDULED PRODUCTS
Fruits, Vegetables and their products Meat and Meat Products Poultry and Poultry Products Dairy Products Confectionery, Biscuits and Bakery Products Confectionery, Biscuits and Bakery Products Honey, Jaggery and Sugar Products Cocoa Products Alcoholic and Non-Alcoholic Beverages Cereal Products Groundnuts, Peanuts and Walnuts Pickles, Papads and Chutneys Horticulture and Floriculture Products Herbal and Medicinal Plants Rice (non-Basmati)
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Methods Examples
Physical Method
Thermal processing, Concentration/drying/Dehydration, Sterilizing, Filtration, Radiation/Irradiation, etc.
Methods of Food Preservation with Methods of Food Preservation with ExamplesExamples
Chemical Method
Solidification (salting), Saccharification (sugar addition), Artificial acidification, Gaseous preservation, Ethyl alcohol addition, etc.
Biochemical Method
Lactic fermentation (natural acidification), Alcoholic fermentation
Combined Method
Combination of above methods
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Fruit and Vegetables processing 18% of gross agricultural product
Indias share in world trade is @1%
Major exports: fruit pulps, pickles, chutneys, canned fruit & vegetables, conc. juices and dehydrated vegetables
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a) Tomato Paste : 15,00,000 MTMajor Importers : Germany, UK, Japan
b) Banana Puree : 1,20,000 MTMajor Importers : USA, Japan, Russia, EU Countries
Market for Multipurpose Fruits & Vegetables PastesMarket for Multipurpose Fruits & Vegetables PastesMarket for Multipurpose Fruits & Vegetables PastesMarket for Multipurpose Fruits & Vegetables PastesMarket for Multipurpose Fruits & Vegetables PastesMarket for Multipurpose Fruits & Vegetables PastesMarket for Multipurpose Fruits & Vegetables PastesMarket for Multipurpose Fruits & Vegetables Pastes
Overseas
c) Mango Pulp : 95,000MTMajor Importers : USA, EU, Middle East Countries
d) Guava Puree : 15000 MTMajor Importers : USA, EU Countries
e) Papaya Puree : 1500 MTMajor Importers : EU, Middle East Countries
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POST HARVEST HANDLING POST HARVEST HANDLING -- BANANABANANA
SELECT UNIFORM BUNCHES ( 75 80% MATURITY)
CAREFULLY HARVEST
DE-HAND FRUITS (WITHOUT INFLICTING DAMAGE)
DE-FLOWER DE-FLOWER
CLEAN CUT TO THE CROWN
WASH HANDS
ANTIFUNGAL TREATMENT
AIR-DRY
PACK IN CORRUGATED FIBRE BOARD BOXES
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PRE-COOLING (13-14 oC)
TRANSPORT TO AIR PORT OR SEA PORT
LOAD INTO TEMPERATURE CONTROLLED REFER CONTAINERS LOAD INTO TEMPERATURE CONTROLLED REFER CONTAINERS
STORE IN COLD STORE
RIPENING
RETAIL MARKETING
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Vacuum Packaging
Product is packed in a vacuum condition
Vacuum packaging offers an extensive barrier Vacuum packaging offers an extensive barrieragainst corrosion, oxidation, moisture, dirt, fungalgrowth, etc
Best suited for dried fruits & nuts
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Vacuum packaging of banana
Increases the shelf life for 30 days
Ripening takes 7 to 10 days after
opening the bags.
No residual effect of fungicide
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VACUUM PACKED CAULIFLOWER
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Mango ProcessingMango Processing
Raw Mango pickle, chutney and beverages
Ripe Mango mango pulp , squash, juice, jam, leather
Machineries required Rotary washer, , blanching unit, mixing unit,, steam
generator, brine tank, can reformer, can flanger, can seamer, retort, sterilization unit, cooling unit, bottle capper, bottle washer , filling table bottling unit
Area required : 1000 sq.m Capacity : one tonne per day Cost : Rs. 50, 00, 000
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FRESH MANGO PROCESS FLOW CHARTFRESH MANGO PROCESS FLOW CHART
HARVESTING(With Mango Harvestors at 7o 8o Brix)
DESAPPING
WASHING
HOT WATER TREATMENT
(at 48o c / 1 hours)&
OTHER POST HARVEST TREATMENTS
FINAL GRADING(Refer standards)
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WEIGHING
PACKING(IIP APPROVED PACKING)
PALLETISATIONPALLETISATION
PRE COOLING(12o C + 0.5o C)
COLD STORAGE(12o C + 0.5o C)
STUFFING INTO CONTAINER
EXPORT BY SEA
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Mango Fruit bar Mango Fruit bar
Mango fruit
Washing
Cutting
Pulp extractionPulp extraction
Addition of sugar
Heating
Cooling
Drying
Packing
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Gherkin processingGherkin processing
Gherkin
Washing & Grading
Soaking in 14% brine solution (Barrels)
Maintaining the salt concentration
( 30 days)
Packing ( Bottle /can / barrel )
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Mushroom preservation
Poor shelf life Cold storage always not
possible Domestic consumption
Value Addition Drying Canning (2 % Nacl) Pickling
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Preservation of sugarcane Preservation of sugarcane Preservation of sugarcane Preservation of sugarcane
juicejuicejuicejuice
In aluminum pouch In glass bottle
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Sugarcane juice in PE bags
Sugarcane juice in PP bags
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Sugarcane juice preservationPre heating ( 700C for 15 min)
Cooling
Addition of preservative ( sodium benzoate 125 ppm)Addition of preservative ( )
Filling and sealing
Pasteurization (800C for 15 min)
storing
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Mr.R.RamalingamPondicherry
500Bottles/day
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Edible films and coatings
Gives the food product a protective superficial layer
Made from proteins, starches, waxes, lipids, etc.,
Also made from food-grade anti-microbial and antioxidant compounds
e.g., Ethyloleate coating for grapes increases the drying rate and gives a better quality raisin
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Paraffin wax, Carnuba wax and bee wax
Enhances the shelf life by - 10 days
Wax Application
Rate of application - 1 kg/ 1000kg
Guava, Mango, Banana - Waxol W/12
Lime, Apple, Tomato - Waxol O/12
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Name of Crop
Products
Guava Jelly, cheese, Toffee, Nectar, Canned guava, Squash, VinegarAonla Pickle, squash,RTS, dried flakes&powder, candyPapaya Jam, candy, Nectar, Pickle, Sauce, Canned papaya, Papain
Products Prepared from Fruits and VegetablesProducts Prepared from Fruits and Vegetables
Banana Pickle, squash,RTS, dried flakes&powder, candy, chips
Grape Wine, Juice, RaisinTomato Pickle, puree, ketchup,sauce,concentrate, jam, juiceOnion Dried flakes, pickle, dried powderCassava Starch based materials
Moringa Dehydrated powder, moringa seed oilCoconut Coconut water, coconut milk powder, desiccated coconut
Chillies Red chilli powder, paste, sauceSugarcane Bottling of sugarcane juice
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Machineries for fruits and vegetable processing
Fruit mill, Fruit pulpers, Juice extractors, Packing machines, Filling machines, Steam boilers, Steam boilers, Steam jacketed kettles, Sterilizers
Area required : 1000 sq.mCapacity : One tonne per dayCost of the machinery : Rs. 50,00,000
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Global Market for Potato Products
a) Potato Flour : 65,000 MTMajor Importers : Netherlands, Poland, Germany
b) Potato Flakes : 130,000 MTMajor Importers : Japan, UK, Italy, Spain
Market for Potato ProductsMarket for Potato ProductsMarket for Potato ProductsMarket for Potato Products
Major Importers : Japan, UK, Italy, Spain
c) French Fries : 10,00,000 MT Price 1500 USD/MTMajor Importers : Japan, EU Countries
d) Other Products : Granules, Wafers, Fabricated Wafer(Pringle type)
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Aseptic Packaging
Irradiation - Onions, Potatoes, Fruits, Marine, Meat, Spices
Technology Driven ProjectsTechnology Driven Projects
Cryogenic grinding Spices, Herbs.
Retort pouches prepared curries, pulses etc.
Modern Cold Storages C.A., M.A.
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ASEPTIC PACKAGING
Sterilized food material is packed in a sterile container in sterile zone
Production of ambient shelf-stable foods UHT milk and pasteurized fruit juices UHT milk and pasteurized fruit juices Alternative for metal cans and glass jars
Sterilization of product Sterilization of equipment Sterilization of packaging material
Aseptic packaging involves 3 separate sterilization process
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Food raw materials
preparation
Formulation Blending,
Mixing
SterilizationPasteurization
Heating
HoldingPackaging
materialCooling
Homogenization
FillingSealing
Product storage
Distribution&
Consumption
material
Sterilization
Aseptic zone
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Products used for aseptic packaging
Mango & Guava pulpPine apple & apple juice Tomato & banana puree Tomato paste Tomato paste Papaya syrupFlavored milk and ice cream mix
Packages used for aseptic packaginPlastic PaperMetal foils
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Advantages of aseptic packaging
Minimize degradation of heat sensitive products
Retains colour, flavour, texture and reduces the Retains colour, flavour, texture and reduces the loss of nutrients
Post processing cost is less (refrigerated storage not necessary )
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Application of Radiation
Shelf life extension fruits and vegetables
Destruction & inactivation of insects & parasites Destruction & inactivation of insects & parasites
Kills pathogenic bacteria, molds and yeasts
Inhibition of sprouting of tubers
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Food Irradiator
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Irradiated and Non-irradiated Onion and Potato
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Food products Purpose Dose (kGy) Date ofClearance
White potato Extend shelf life 0.05-.15 1965 Nov
Spices and dry seasoning Disinfect insect 30 1983 Jul
Fresh fruits Delay maturation 1 1996 Apr
Poultry (fresh or frozen) Control illness 3 1990 DecRed meat Decontamination 3 1997 Dec
FOODS APPROVED FOR IRRADIATION
Potato Inhibit sprouting 0.15 1960 Nov
Onions Sprouting inhibition 0.15 1965 Mar
Wheat, flour,wheat flour Disinfestations 0.75 1969 Mar
Poultry meat Decontamination 1.5-3 1992 Sep
Red meat(fresh) Decontamination 4.5 1997 FebCereals 1
Bulbs and tubers 0.2
Herbs Decontamination 10 1984 Oct
Condiments 10
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Commercial Applications Insect disinfestations of stored products
Quarantine treatment for fruits and vegetables
Inhibition of sprouting in tuber and bulb crops Inhibition of sprouting in tuber and bulb crops
Delay in ripening of fruits
Extended shelf life of seafood, meat and meat products
Improving food safety and decontamination of spices and sterilization of foods
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STATUS OF FOOD IRRADIATION
More than 40 countries approved the processing
of about 100 products.
About 28 countries in commercial scale About 28 countries in commercial scale
In India, Vashi and Lasalgaon(Maharastra)
(onion and potato sprout inhibition)
BARC, unit - 20 tons/day for treatment of spices
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Dairy IndustyDairy Industy India ranks first 50 per cent Buffalo milk Variation in milk consumption Only 40 per cent used for products New dairy products
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Milk & Milk ProductsMilk & Milk ProductsFluid milk, cream, butter, ghee, khoa, Cheese, buttermilk, yoghurt, ice cream, flavoured milk, casein, milk powder
Machineries required
Can washers, Plate chiller, pasteurizer, cream separator, Can washers, Plate chiller, pasteurizer, cream separator, homogeniser, butter churn, ice cream freezers, evaporators, spray driers, form fill & seal machine
Area required : 1000 sq.m Capacity : 10,000 litres per day Cost : Rs. 75,00,000
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Snack FoodsSnack Foods Overall production 3,50,000 tonnes (Rs. 14 billions) Namkeans salty snacks, chips pappadums & bakery
snacks like biscuits Potato chips
NamkeansChick peas, pulses, edible oil, groundnut and spices
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Market Trend of Snack FoodsMarket Trend of Snack Foods
Taste varies across regionsFlavour ingredientsPack size- affordablePack size- affordableAttractive packagingBaked snacks & roasted snacks are
to be potential areas
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Extruded FoodsExtruded Foods
Ragi , Rice & Wheat
Machineries requiredKneader, blender , extruder, Kneader, blender , extruder, dryer, packing equipments etc.,
Area required : 1000 sq.m Capacity : one tonne per
day Cost : Rs. 60,00,000
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Bakery ProductsBakery ProductsBread, bun, cakes, puffs, biscuits, pastries
Machineries requiredKneader, mixer, sheeter, proofer, rotary oven,moulder, slicer, packing machines, moulds, trays etcmoulder, slicer, packing machines, moulds, trays etc
Area required : 1000 sq.m Capacity : 50,000 bread per day Cost : Rs. 40,00,000
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Retort pouch processing
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Advantages of Retort pouch processing
Replacement for can
Cheaper
Simple operation
Low initial investment
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Frozen FoodsFrozen Foods Frozen vegetable peas, cauliflower
Frozen chicken
Frozen dairy dessert paneer kulfi ice cream
Frozen meat and sea foods
Cold chain
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Cold ChainCold Chain Industrial cold stores in the Production zones
Refrigerated vehicles for long distance transport
Refrigerated room in wholesale markets
Refrigerated distribution vehicles
Refrigerated rooms and display cabinet in retail stores
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Cold Storage IndustryCold Storage Industry
First cold storage plant was setup at Calcutta in 1892
Growth of the industry was negligible till 1995
Normally growth of the industry has been pronounced in north India (MP,UP,WB,Bihar ,Harayana)
90% of the cold storage unit used for potato
Remaining 10% used for other fruit and vegetables
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63.01.1
Potato Fruit & Vegetables
No. of cold storage units
(%)Commodity
Commodity wise distribution of cold storage units in India
100.0Total
1.16.90.811.32.19.75.1
Fruit & VegetablesMilk & Milk ProductsMeat Fish Meat and FishMulti-purposeOthers
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Recommended Storage conditionsFruit / vegetable
BananaPine appleAppleGrapes
Temp.(0C)
14 158 100 - 20 - 2
R.H.
80-8585-9085-9085-90
Storage period
2 months2 months8 months2 monthsGrapes
MangoPotatoOnionCarrotBhendiCabbagetomato
0 - 210 - 123 - 41- 22- 38 -101 - 28 -10
85-9085-908570-75959090-9590-95
2 months1-2 months8 months6 months6 months1 month3 months2 months
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National Horticultural Board providing capital subsidy to entrepreneurship for construction,expansion and modernization of cold storage for horticultural produce
Funds for Cold Storage UnitsFunds for Cold Storage Units
ObjectivesObjectivesTo promote cold storage in the country for reducing post harvest losses
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Eligible OrganizationsEligible Organizations
NGOS Association of growers Corporations Agricultural produce marketing committees Agricultural produce marketing committees Marketing boards/committees Agro industries corporations
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1) Market Needs Domestic as well as Overseas
2) Availability of Competitive Resources
3) New Technologies
Major Considerations for a New ProjectMajor Considerations for a New ProjectMajor Considerations for a New ProjectMajor Considerations for a New ProjectMajor Considerations for a New ProjectMajor Considerations for a New ProjectMajor Considerations for a New ProjectMajor Considerations for a New Project
4) Other Factors Socio-Economic Environment, Government Fiscal Policies,Incentives, etc.
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Food Industry LawsFood Industry Laws
PFA 1954 Prevents customers against adulterated food Domestic & imported food products Food colour, preservative, pesticide residues, packaging
labeling & saleslabeling & sales Not upto date with advances in food processing sector
Labeling requirement Language, name, address, description of product,
Constituents, date of manufacture, expiry date
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ContdContd
The Standards of Weights & Measures Act 1976 Essential Commodity Act 1955 Fruit Product Order 1955 Milk & Milk Product Order 1992 Pulses, Edible oil seeds and Edible oils Order 1977 Pulses, Edible oil seeds and Edible oils Order 1977 MRTP Act 1969 BIS 1952 Agricultural Produce Grading & Markets Act 1987 Environment Protection Act 1986 HACCP
Food Safety & Standards Authority of India (FSSAI)
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Thank You