juice manufacturing industry research report
TRANSCRIPT
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Table Of Contents
Introduction
History
Juice Manufacturing Market in India
Export Market
Raw Materials
Juice Manufacturing Process
Plant & Machinery
List of Suppliers Capital investment
Storage facilities
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Over the past several decades there has been a growing trend toward adding value to rawagricultural products. As populations have become more urban, this trend has accelerated.The need for stable, convenient foods has increased along with the demand for exotic productsfor international cuisine. With the globalization of the food industry, the demand forquality juice and juice type beverages has markedly expanded. Traditionally, only ahandful of fruit and vegetable juices have served this market as large multinational companiesor their affiliates, have captured the majority of national and international juice trade. Juicessuch as orange, grape, pineapple, pomegranate, apple, tomato and blends are well established
in developed countries. Now, minor juices, tropical juices and juice products are attracting newattention.
The manufacture of juices from fruits and vegetables is as old (or older) than agriculture.During the ripening process most fruits soften to the point where simply handling ortransporting them yields more juice than flesh, albeitoften partially fermented. The resulting
pulpy fluid, easily separated from seed and skin, is generally more flavorful than the more solidportion. Hunter-gatherers could either consume quasi juices directly or collect the soft fruit inreasonably leak-free containers for later use. Simply transporting the fruit any distance soonguaranteed juice. Except for cool temperature climates, storage life was limited to mere hoursbefore incipient fermentation modified the character of the juice appreciably.
Through trial and error humans learned practical ways of extracting juice from various sourcesand, most importantly, which attractive but toxic fruits to avoid. Tool making skills fosteredthe manufacture of devices for macerating fruits and extracting juices. Containers forstoring foods, including receptacles for fluids were also devised from local resources, i.e.woven plant fiber and wood, clay soils and animal skin/intestine. Such methods and equipment
can still be found in isolated pre-industrialized regions. Otherwise they are seen only inmuseums as prehistoric or early artifacts of extinct civilizations. Until fairly recently, liquidcontainers were quite primitive compared to those of the 20th century
The perishable nature of juices dictated immediate consumption within less than 24 hours inwarm climates and extended but still limited time in cooler environs. Natural chilling orfreezing was the only alternative to microbial modification of the juice. Such fermentation wasthe basis for wine. It was found that the juice, after bubbling mysteriously, has a distinctly
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different character and affect on those consuming the product. Also, the material stored severaldays longer slowly turned harshly acidic or developed an even more unpalatable surfacegrowth and taste.
This early vinegar was used as a preservative for other fruits and vegetables. Grapedomestication followed this discovery.
With the development of agriculture over the last 10 millennia, the cultivation of cropsprovided a fairly reliable source of food, including fruits appropriate for juice and beverageuse. Unless the juice was consumed fresh, soon after pressing, fermentation was the likely,often desired consequence until preservation techniques were developed. In fact, the concept ofmaintaining a fruit destined for juicing in its whole, intact form until the juice is neededcontinues to be a sound principle. Even today, maintaining the fruit intact is one of theeasiest ways of preserving juice quality.
GLOBAL MARKET
The global market for juiceand juice products was estimated to be about 50 billion litres inthe late 1990s. In the United States of America alone, the retail commercial value of the almost20 billion litres of juice and juice products exceeded US$18 billion, roughly 3 percent of a totalfood sales expenditure of US$630 billion. World trade has accelerated over the last decadewith developing countries achieving over 60 percent of fruit juice exports. Brazil, the largestcitrus producer, accounts for about 25 percent of world production. Juice utilization in
decreasing order is: Orange, apple, grape and pineapple.
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India is the second-largest producer of fruit and vegetables in the world , contributing a
total of150 million tonnes of the produce to the global production annually. Ironically,
however, only 2.2% of the fruit and vegetable production is processed here as compared to
countries like USA (65%), Philippines (78%) and China (23%). Hence, this presents immense
opportunity for companies looking at investing in this sector in the country.
Key sector
The food processing sector is critical to Indias development. It establishes vital linkages and
synergy between industry & agriculture, the two pillars of Indias economy. The growth of
food processing will bring immense benefits to the economy, raising agricultural yields,
enhancing productivity, creating employment and raising standard of life of people across
the country, especially in rural areas.
Interestingly, this industry ranks fifth in the country and employs around 13 million
people directly and 35 million people indirectly. It accounts for 14% of total industrial
output of the GDP. Its turnoveris estimated at ` 1,44,000 crore, of which ` 1,11,200 crore is
in the unorganized sector. The liberalization of the Indian economy and world trade and rising
consumer prosperity have thrown up new opportunities for diversification in the food
processing sector and opened up new vistas for growth.
Horti success
India has made good progress on the horticultural map of the world with a total annual
production of horticultural crops touching over 149 million tonnes. As said earlier, India is the
second-largest producer of fruits (45.5 million tonnes) and vegetables (90.8 million
tonnes) in the world, contributing 10.23% and 14.45% of the total world production of fruits
and vegetables respectively. It is also a well known fact that since centuries it has been thelargest producer, consumer and exporter of spices.
Decentralized
The fruit and vegetable processing industry in India is highly decentralized. A large number of
units are in the cottage / home-scale and small-scale sector, having small capacities up to
250 tonnes / annum though big Indian and multinational companies have capacities in the
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range of 30 to 50 tonnes per hour or so. The prominent processed items are fruit pulps and
juices, fruit-based ready-to-serve beverages, canned fruits and vegetables, jams, squashes,
pickles, chutneys and dehydrated vegetables.
More recently, products like frozen pulps and vegetables, frozen dried fruits and vegetables,
fruit juice concentrates and vegetable curries in restorable pouches, canned mushroom and
mushroom products have been taken up for manufacture by the industry. The processing level
in India is estimated to be around 2%.
CAGRCompounded Annual Growth Rate
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Indias major exports are in fruit pulp, pickles, chutneys, canned fruits and vegetables,
concentrated pulps and juices, dehydrated vegetables and frozen fruits and vegetables.
Supply chain efficiencies together with a focused approach to enhance exports are the key toensure that India is able to successfully tap new product / market opportunities. India has the
potential to achieve a 3% share in the world trade of food products by 2015.
The Top 5 Countries where Indian Fruit Juices are exported are as follows:
USA (11.5%)
Netherlands (11%)
UK (9.9%)
Germany (6.8%)
Nepal (6.8%)
It was observed amongst all the above countries that Indias export growth to the above
countries has been slower as compared to the rate of imports of the above countries from the
rest of the world. This indicates our countrys weakening hold on juice exports vis--vis the
rest of world.
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Data source: Ministry of Food Processing Industries Annual Report 2010-2011
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Human selection of plants for their more desirable features has been practiced for thousands ofyears, initially by trial and error, more recently by scientific knowledge applied to plantgenetics and molecular biology. Thus even within a given fruit there are numerous varietiesavailable including some derived from the wild, others specifically developed by breeders andcombinations of both. Recent advances in understanding the molecular basis of plant geneticsand how the genes and growing environment influence traits, promises to revolutionizeagriculture, once the politics and emotions are resolved.
Fruits originating in the wild have evolved to be reasonably robust and resistant to naturalenvironmental stresses, diseases, insects and other predators. These traits, however, do notnecessarily favour concentrated production systems or edibility. The exception is ifconsumption by wildlife promotes pollination or seed dispersal. Human population pressuresfurther impact upon native plant species, therefore except for exotic plants remote fromcivilization, most fruits are substantially removed from their origin in time, genetics andlocation.
Special cultivars, developed with criteria such as yield, location adaptability, resistance todisease, insects, drought tolerance, harvest period, ease of cultivation and harvest,handling and storage durability, processing characteristics and sensory appeal (colour,taste, aroma and texture) are characteristics now determined by commercial breedingpractice. Juice quality considerations are also important in many fruits such as citrus, grape,apple, pineapple and others. Specific cultivars dominate the juice trade, while others arepreferred for the fresh market. Some cultivar end uses are dictated by fruit supply, conditionand economics and vary by season, location and market depending upon fruit quality.
Fruit Breeding Criteria
Trait Rationale
Plant hardiness Survival, resistance to drought,cold, heat, etc
Disease resistance Plant/fruit survival, reducedpesticide use
Plant morphology Ease of cultivation/harvest
Fruit morphology Ease of harvest/processing,
high yieldComposition Quality, economic/nutritive
value
Seasonality Availability, market anddemand price
Fruit durability Marketing/handling/processing
Yield Economic value
Flavor Quality, value
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Colour Appeal, value, by-productpotential
Texture Appeal, durability
Nutrients/phytochemicals Value, appeal, by-product
Cultivation Factors Influencing Quality
Factor Importance
Location Harvest period, plant survival,market
Cultivar Yield, desirable juice traits,harvest period
Plant spacing Yield, ease ofcultivation/harvest
Plant care Yield, ease of harvest, quality
Pruning(Cutting) Yield, maturation, ease of
harvest
Irrigation Fruit/juice yield, quality
Fertilization Growth, designation (i.e.organic)
Pesticide use Fruit quality, designation,regulations
Field protection Yield, quality (bird, varmintdamage)
Field sanitation Juice safety, quality
Labour training Fruit quality, cultivation/harvestefficiency
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Mainly following processes are involved in Juice Manufacturing. The below table lists the
various processes involved and their functions:
Unit Operation Result
Mass transfer Fruit delivered, drycleaned
Extraction Washed
Separation Sized, graded
Separation Peeled, cored anddeseed
Size reduction Crushed, comminuted
Pressure application Juice extracted
Separation Solids screened
Deaeration Oxygen removed
Centrifugation Solids separated
Filtration Clarification
Fluid flow Juice transferred,pumped
Heat transfer Enzymes inactivated,juice pasteurized andcooled
Concentration/evaporation Volume reduction,stability
Mass transfer Packaging, shipping
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Manufacturing Process
Pre process Stage
The logistics of production, harvest, transport and ripening dictate that many fruits must beheld prior to juicing. The seasonal harvest window may be much shorter than the time requiredprocessing the entire annual crop and stabilizing the resulting juice and finished products. Aswith the aforementioned steps, careful holding is necessary to allow optimum ripening to occuror prevent spoilage and contamination. Producers and processors should have a goodunderstanding of postharvest physiology, particularly as it relates to the species and cultivars inquestion.
With certain climacteric fruit, ripening and senescence can be controlled (delayed,maintained constant, accelerated, or promoted uniformly) by the judicious use of lowtemperature, moderate humidity and adjustment of oxygen, carbon dioxide and ethylenelevels.
With other fruit, holding is short term and serves only temporarily to prevent contaminationand damage while accommodating processing flow. Some fruit can be frozen and stored forlong periods. Freezing is costly, but promotes cellular breakdown and facilitates shipping and
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juicing. In hot climates where refrigeration or freezing facilities may be neither available norpractical for juice fruit, strategies such as just-in-time harvest, cooler night time harvestoperations, rapid transportation and shady, well ventilated storage can help balance theprocessing load and stave off deterioration for a few critical hours . Many processors aredisturbingly unaware of the importance of these procedures; but every little bit helps and the
benefits add up.
Cleaning, Sorting and Inspection
If the fruit producer has followedGAPs and the harvest and handling have been accomplishedeffectively, fruit arriving at the processing plant should be reasonably sanitary and of optimumquality, thus simplifying succeeding operations. Nevertheless, quality cannot be taken forgranted. In many cases the basis for payment is the condition of the fruit as received. Hencesampling and analysis for composition and quality are mandatory.
Government norms, an industry association, or agreement between producer and processor inadvance of the crop purchase can dictate applicable quality standards.
Inspection of Grapes at the time of delivery
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Crushing and Juicing
Fruit must be carefully peeled and deseeded or cored prior to juicing . Hand labour is thecurrent alternative with many minor fruits, although there is an economic incentive tomechanize if possible.
Contour peelers, such as used with apples (Figure below) can be adapted to a range of fruitsthat are sufficiently firm and uniform to facilitate the rotary peeling action. Peeling systemsthat are effective with some vegetables such as lye, abrasion, enzymatic, explosive, are lesssatisfactory with delicate fruit flesh. Nevertheless, cleverly designed machinery can greatlyfacilitate these labour-intensive operations. Under all circumstances, a final humaninspection and piece selection/rejection step is mandatory.
Automatic Inspection/grading system
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Pressing
The pressing operation can also range from manual to mechanical with complete automatedsystems common in the juice industry. Kitchen-scale juicers or food processors are effectivefor small quantities, but for larger multi-kilogram amounts, flow resistance and distance theexpressed juice must travel to the press surface complicate pressing. The rack and cloth pressincreases the surface area to volume ratio and is quite effective, albeit labour intensive. Figurebelow shows a simple press based on a hydraulic truck jack developed by Cornell University(Downing, 1972). All supports are wood, including the racks. Tough cottons or synthetic clothsprovide an inexpensive, durable batch press, albeit difficult to clean and sanitize.
Simple Hydraulic rack and Cloth press
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Press factors influencing juice yield and quality
Factor Effect
Fruit immature Resistance to juicing, lowyield
Fruit inadequatelycrushed
Resistance to juicing, lowyield
Fruit over mature Undesirables extracted,poor quality
Fruit over comminuted(crushed)
Undesirables extracted,poor quality
Excessive pressure Undesirables extracted,dark juice
Excessive time inpress
Dark, over extracted juice
Short press cycle Low yield, lighter juicecharacter
Long press cycle Low throughput, overextraction
Cold Press Lower yield, lightercharacter
Hot press Higher yield, stronger,darker character
Enzyme treatment Higher yield, strongercharacter
Pressing aid added Higher yield
Press cakeredistributed Increased yield
Delayed or extendedpressing
Dark juice, incipientspoilage
Juice Clarification
For more fluid juices where cloud or turbidity is not acceptable primary extracted juicemust be treated further. A settling step can help, if the juice can be held refrigerated for afew hours. At ambient tropical temperatures holding is not recommended. Rapid methodssuch as centrifugation and filtration can produce a clear juice. A continuous or a decantingcentrifuge with automatic desludging to produce a clear or nearly clear juice is quite effective.(Juices where a cloud is desired generally do not require filtration; centrifugation is adequate.)The stream should be settled or coarse strained prior to centrifugation in order to reduce thesludge load in the feed going to the centrifuge. A fine mesh shaker screen can further remove
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particulates. A centrifuge is a very costly item; however, it greatly simplifies subsequentfiltration steps and is an essential component in many juice processing operations.
Shaker Separating Screen
Filtration
As with pre-centrifugation, the juice stream should be cleaned up as much as possible to reducetreated volume and increase throughput. There are many filtration systems well suited tovarious juices. These range from plate and frame filters, fitted with porous cellulose pads,(Figure below) to plastic, ceramic, or metal membranes. Diatomaceousearth mixed with theliquid serves to greatly increase the surface area and porosity of the filter bed and hence theparticulate absorbing capacity of the filter.
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Plate, frame and vacuum filter
Deaeration
In the operations described crushing, comminution, pressing, shaker separation, centrifugationand filtration, the fruit and juice are subjected to considerable aeration. The inclusion ofoxygen can promote enzymatic browning, destroy nutrients, modify flavour andotherwise damage quality. Therefore, care should be taken to perform these steps rapidly, atlow temperature and/or protect the material from oxygen, if possible. Sometimes preheating toinactivate natural and/or added enzymes is useful, provided rapid cooling follows.
Deaeration can be accomplished by either flashing the heated juice into a vacuum chamberor saturating the juice with an inert gas. Nitrogen or carbon dioxide is bubbled through thejuice prior to storing under an inert atmosphere. Clearly, once air is removed or replaced byinert gas, the juice must be protected from the atmosphere in all subsequent processing steps.Deaeration, especially flashing off at high temperature, can also remove some desirablevolatile aroma, another compromise facing the juice technologist.
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Mostly for manufacturing of juices like orange, grapes, pomegranate etc mainly two types ofmachines are required.
Juice Extracting Machines
Juice Filling and packing Machines
Orange juice extracting Machine (US $ 1-9999)
http://www.alibaba.com/product-gs/552397578/0_5t_1_5t_2t_stainless/showimage.html -
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Grape Juice extractor (US $ 1-9999)
Pomegranate Juice extractor (US $ 1-12000 )
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Orange juice machines (US $ 10,000-10,00,000)
Grape Juice Machines (US $ 10,000-3,50,000)
http://www.alibaba.com/product-gs/483115644/Orange_Juice_Processing_Machines/showimage.htmlhttp://www.alibaba.com/product-gs/483115644/Orange_Juice_Processing_Machines/showimage.html -
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Pomegranate Juice machines (US $ 2000-50,000)
Unique Industries - India118, Kamal Estate, Nr- Bombay Conductor, Gidc Vatva, Ahmedabad, Gujarat, India
Harikrushna International - India3rd Eye-2, Third Floor-306, Opp. Parimal Garden, Near Panchvati Cross Road, C. G. Road., Ahmedabad,
Gujarat, India
Shri Ram Piston-IndiaNo. 4 Mahadev Vadi Opposite Laxminagar Haveli Rajkot Gujarat - 360 004 India
Zhangjiagang Jiayuan Machinery Co Ltd.Jiangsu, China (Mainland)
Shanghai Jimei Food Machinery Co., Ltd.Shanghai, China (Mainland)
Zhangjiagang Longquan Machinery Manufacture Co., Ltd.Jiangsu, China (Mainland)
http://jimei888.en.alibaba.com/http://zjglq.en.alibaba.com/http://zjglq.en.alibaba.com/http://www.alibaba.com/product-gs/322282595/juice_extraction_machine_juice_extractor_machine/showimage.htmlhttp://zjglq.en.alibaba.com/http://jimei888.en.alibaba.com/ -
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The initial Capital Investment required to start a juice manufacturing factory are estimated in
the table below.
Particulars`
Plant & MachineryFruit Juice ExtractorsPacking Machine
5,00,00050,00,000
Land 250,00,000
Construction 50,00,000
Vehicles 25,00,000
Furniture & Fittings 15,00,000
Other Pre-operating exp 20,00,000Total Fixed Assets (A) 41,500,000Inventory 15,00,000
Cash 20,00,000
Other Initial Exp 10,00,000
Initial Marketing Cost 10,00,000
Total Working Capital (B) 55,00,000Total Investment (A+B) 47,000,000
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Storage facilities are required at both times - before starting production and after the juice are
manufactured.
Storage facilities
There are essentially three types of storage buildings: air cooled storage, mechanicallyrefrigerated storage and refrigerated and controlled-atmosphere (CA) storage.
Air-cooled storage
These storage houses cool by admitting cold night air (applicable climates) at inlets near thefloor of an insulated building and forcing upper accumulated warm air out at outlets near theceiling. Both openings are closed during the day. These storages are economical and effectivein areas where the night air becomes cooler than the accumulated air in the storagehouse.
Mechanically refrigerated storage
For longer periods of storage than is afforded by the air-cooled storages, mechanicalrefrigeration is needed. This would become necessary to extend the season on fresh-marketfruits or to extend the cooling of processing fruits because the volume is so large they can notbe completed in the period of time afforded by the air-cooled storage situation. Normallytemperature of-25 C to 10 C is required to store fruits like oranges, grapes etc.
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Meaning of some terms
Plant Morphologystudy of development, form and internal structure of plants.
Fruit Morphology - study of development, form and internal structure of fruits.
Senescenceageing
Centrifuge-an apparatus that rotates at high speed and by centrifugalforce separates substances of different densities, as milk and cream.
Inertnot able to react
CAGRCompounded Annual Growth Rate
GAPGood Agricultural Practices
Lyehighly concentrated aqueous solution of potassium hydroxide or sodium hydroxide
Abrasiona scraped spot or area
AlbeitAlthough
Diatomaceous - consistingoforcontainingdiatomsortheirfossilremains.
Deaeration to remove air or gas
Comminution
to crush completely
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The End