Project code: MAZDA N-021 AIndi id al Q ick Free ing (IQF) PlantIndividual Quick Freezing (IQF) Plant

For PEAS

Options: for Vegetables and fruits

Website: www.mazmach.com

NOTESTechnology:

The technology of IQF involves three sub sections:· Processing Equipment· Individual Quick Freezing EquipmentA ili E i t· Auxiliary Equipment

The current brief entails handling of up to 3000 kgs of frozen peas per hour.

Mazda Speciality Machine Systems,Scale NTSINDIA

SHEET # 2007.N 021.001.

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RAW MATERIAL RECEPTION AND MANUAL SORTINGIQF Processing does not change the physical characteristics of the raw products, therefore care is taken that inferior raw products are weeded out . IQF frozen vegetables are produced from fresh, field-selected raw materialswhich are sorted, washed, pitted, peeled, cut according to requirements,blanched and frozen in IQF flow-freezer and finally packed in poly linedcardboard boxes after being metal detected.Processing equipments involves Pea Podder, cross collection conveyor for peas,

aste collection con e or b cket ele ator Winno er Fr it/Vegetable asherwaste collection conveyor, bucket elevator, Winnower, Fruit/Vegetable washer,Inspection Conveyor, Pea blancher, After cooler

PNEUMATIC CLEANINGIn this part of the process the light foreign materials form the farms like leaves, twigs land particulate matter are separated out. This is achieved by a cluttered forced air circulationparticulate matter are separated out. This is achieved by a cluttered forced air circulation generated by an electric fan. Air flow regulating devices and variable speed arrangements are built in to adjust according to the weight of different products. The waste is collected in bag separately and disposed of periodically.

HY DRAULIC WASHER AND DE-STONERAfter removal of light impurities by pneumatic cleaning, the heavy foreign bodies and stones are removed by means of hydraulic de-stoner. By creating an upward water flow and passing the product over serrated belts the stones etc. are separated and deposited on a continuous evacuation elevator which delivers them to a waste bin.Combined with this unit is the washer with rinsing and flotation chambers to give the product a through wash in order to remove soilthrough wash in order to remove soil.

INSPECTIONAfter cleaning and washing, the product undergoes another visual check. the product is discharged over a non toxic plastic material belt , on both sides of which people can stand and manually remove any visible bad product. The belt drive is fitted with a variable speed drive tomanually remove any visible bad product. The belt drive is fitted with a variable speed drive to adjust the speed according to the product.

PREPARATIONIn this section different functions are performed according to the type of product being handled. Peeling, dehusking, taking out the seeds, trimming to size, cutting florets, de clustering, slicing etc. operations are performed. Waste that is generated is collected atclustering, slicing etc. operations are performed. Waste that is generated is collected at frequent intervals to avoid contamination of the product by building up of bacteria due to fermentation.BLANCHINGAfter cleaning and cutting the raw material it is essential to inactivate the enzymatic reaction which is initiated on cutting the product. The stopping of this reaction adds shelf life to the product and thereby preserves it without the addition of any preservatives.The above is achieved in the Blancher by heating the product in a definite time cycle upto a certain temperature for a certain time. The Blancher is continuous process equipment and it has automatic controls for adjusting temperatures, and holding time.the process of Blanching may not be required for certain products specially in the Fruit category In that case the arrangement to by pass the blancher is providedcategory. In that case the arrangement to by-pass the blancher is provided.

COOLING

The products out of the Blancher is at approximately 80 to 85 deg. Celsius. At such Elevated temperatures it cannot be taken 20 degrees Celsius without causing thermal shock to the product It is important therefore to cool down the product to a temperatureshock to the product. It is important therefore to cool down the product to a temperature between 1 to 20 degree Celsius Cooling also stops the deactivation process of the enzymes i.e. it ends the process of Blanching. An added advantage of cooling down is that the product can be easily handled for sorting.The cooling of the products is achieved by means of a counter flow cooler in order to g yobtain efficient cooling of the product without causing thermal shocks. The "Water -product" movement comes about in the opposite direction so that the inlet of the hot product corresponds to a hot water outlet whilst at the discharge of the cooled product corresponds the inlet of cold water.

SORTINGSORTINGAfter the blanching and cooling process, another manual inspection station is provided, This is the final check on the product and if any impurity has escaped the earlier checks it is detected and eliminated here. Overcooked products from the Blancher and fermented material can also be eliminated.

INDIVIDUAL QUICK FREEZING (IQF)

The final deep freezing is done in the IQF tunnel. A stainless steel spreader shaker uniformly loads and distributes products across the IQF belt. A vibrator beneath the belt initiates the fluidization on products and assures 100% separation without excessive agitation. Uniform air distribution through the product method of fluidization can safely handle delicate and difficult products with minimum losses by elimination of abrasion of the products.By this method of freezing each individual part of the fruit or vegetable is frozen separately so that even after attaining a temperature of -18 to -21 deg. Celsius the pieces remain separated and do not form a block.

GRADINGGRADING

Grading, after freezing is required in some for the products to sort them according to there physical dimensions as the market demand and prices for various sizes are different.Two different types of grading equipment I are considered:yp g g q pTo grade Granular products such as peas, beans a vibrating type of a grader is used which has an oscillating bed composed of various screens with different size as required. A drum grader is used for grading florets of different vegetables like Cauliflower or Broccoli.

PACKAGING

Automatic weighting and packing is done for the 400/500 gm., 1 Kg., 2.5 Kg., and 5 Kg. bags. For all bags above 5 Kg. manual weighing filling and closing is done. Packaging is in variety of stylesPackaging is in variety of styles.

NOTES

Beans/ peas:

Mango bitsg

Mazda Speciality Machine Systems,Scale NTSINDIA

SHEET # 2007.N 021.002.

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ALL FRUITS AND VEGETABLES NOTESALL FRUITS AND VEGETABLES

IQF – PROCESSING DELICATE FRUITS

Appearance - colorThe quick freezing result in natural color of the frozen product.

Appearence - shapeP d t i f d i t d th t l h fProduct is frozen on an upward air stream and the natural shape of the product is maintained.

YieldExtremely quick freezing of the surface on first bed reduces de-

Mazda Speciality Machine Systems,Scale NTS

y q ghydration to a minimum. Low or zero lumps keep yield to a maximim.

INDIA

SHEET # 2007.N 021.003.

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NOTESHandling of delicate products With the unique air control damages on delicate products are reduced to a minimum.

Mazda Speciality Machine Systems,Scale NTSINDIA

SHEET # 2007.N 021.004.

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NOTES

Mazda Speciality Machine Systems,Scale NTSINDIA

SHEET # 2007.N 021.005.

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The PlantThe Plant

IQF- Individual Quick Freeze System

Floor Space: 1000 sq mtrs

Cold store

Floor Space: 1000 sq mtrs

Electric Power: 250 KW

Water: 5000 ltrs/hour

Mazda Speciality Machine Systems INDIAScale NTS Mazda Speciality Machine Systems, INDIA

SHEET # 2007.N 021.006.

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An IQF unit in operation

Mazda Speciality Machine Systems INDIAScale NTS Mazda Speciality Machine Systems, INDIA

SHEET # 2007.N 021.007.

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PROFIT AREA

BREAK EVEN POINT

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FIXED COST LINE

CO

BREAK EVEN VOLUME

AREA

0 XP

Mazda Speciality Machine Systems INDIAScale NTS

ANNUAL PRODUCTION (Units)0 X

Mazda Speciality Machine Systems, INDIA

SHEET # 2007.N 021. COM.

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NOTESFinancial InvolvementsFinancial InvolvementsLand and Building To be provided as required

Plant Equipment USD 500,000 .- 600,000.--depending on inclusions-depending on inclusions.

Processing of PEAS, fresh vegetables and fruits to produce IQF products packed for the super markets becomes aIQF products packed for the super markets becomes a profitable venture beyond a Break Even Volume of 1000 kgs per hour and economically profitable at around 1500 kgs per hour. Plant Capacity: 2.5 to 3.0 tonnes per hour

Construction of cold storage is not included in cost

Pay back period under normal conditions: 24 months

Mazda Speciality Machine Systems,Scale NTSINDIA

SHEET # 2007.N 021.008.

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