Project code: MAZDA N-106

ONIONS IQF PLANT-FROZEN PRODUCTS

NOTESIndividually Quick Frozen (IQF) products are value added preserved food products. Onions, various fruits and vegetables, meats, sea food are thus preserved and marketed. p

White onions are preferred. General diced, sliced onions are processed into IQF varieties.

Recommended Sizes

1/4" 3/8" 1/2" 3/4" 1"

Diced

Strips

Mazda Speciality Machine Systems,Scale NTS

PackagingSeveral different packaging options are offered. Standard sizes range from a 40 lb box to a 1,300 lb industrial reefer cargo totes.

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Onions are fed in manually. A transport system leads the onions continuously through the blades. The blades are positioned so that they adjust to the size of the onions largely independently of each other.

The design of the probe / scanner that determines the position of the blades ensures that, as far as possible, only what is necessary is cut off the onions. Precision ensures less unnecessary waste!

After inserting the onions into the transport facility, it holds them so tightly that they cannot shift around any more. This means that the g y a ey ca o s a ou d a y o e s ea s a eleaves and roots are normally cut off with great accuracy by blades.

This precision cutting saves on a lot of subsequent manual work at the inspection bench. – The onions and their tops and tails are ejected separately from the machines.

Sliced IQF Onion:2-4 mm3-5 mm Green Spring 3-5 mm4-6 mm5-7 mm

G ee Sp gOnions- diced IQF

Diced IQF Onion:4 mm6 mm10 mm

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10 mm20 mm

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Notes:Notes:

CUTTING

Mazda Speciality Machine Systems

Data Sheet # 2013.156

NOTES

The onions are stored in boxes at temperatures of 33º-34º until further processed.34 until further processed.

Onions are topped and peeled then diced to meet customer’s specifications.

After the onions are diced they are blanched and individuallyare blanched and individually quick frozen.

Mazda Speciality Machine Systems,Scale NTSINDIA

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Fresh produce handling equipment

IQF Freezing methodologyIQF Freezing methodology

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

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

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Extremely quick freezing of the surface on first bed reduces de-hydration to a y q g yminimum. Low or zero lumps keep yield to a maximum.

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BLAST FREEZING IS A LOWER COST OPTION

Notes:Notes:

FREEZING

VACUUM-PACKAGING

Mazda Speciality Machine Systems

Data Sheet # 2013.157

PRECONDITION FOR SELECTION OF TECHNOLOGY1.1 ProductVarious fruits, vegetables, meat, poultry and dairy

d t

Frozen Options------------------

-IQF Diced Product: 1/4"products

Nominal capacity1200 kg per hourIn feed temperature +5 COut feed temperature -18 C (levelled out)

1/4 3/8" 1/2" 3/4"

------------------- IQF Onion Strips:

SLICED IQF

(levelled out)1.2 Logistic dataFed from conveying elevator via in feed distribution shaker.Even feeding rate ± 5 %.

Q p3/8" 1/2" 3/4"

------------------- Onion Fines

Wet products shall be well dewatered.1.3 Production processFreezing IQF

------------------- Custom Cuts------------------

- Blanched ------------------ DICED IQF

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Packaging OptionsPackaging Options

IQF diced onions are packaged in plastic film pouches, bags ( even gas flushed), or in corrugated cartons with a plastic bag lining.

Options range from Automated FFS machines with weigh fillers to very simple pouch filling and sealing machines ( As shown)

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A By Product:

A frozen onion food product is prepared by a process which includes the steps of peeling and slicing fresh uncooked onions, cutting the resulting onion slabs into pieces most of which are composed of two or more lengths of onion scales in side-by-side relationship, separating each piece into its individual

l t ti th t d t ith b tt i t dscales or nuggets, coating the separated nuggets with a batter mixture and quick-freezing.

The separating operation includes the use of hydro, mechanical and vibratory forces to produce a continuous supply of separated nuggets ready for the coating operation If desired the coated cubes can be partially fried beforecoating operation. If desired the coated cubes can be partially fried before freezing.

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PROJECT REQUISITESPROJECT REQUISITES:

Plant Capacity: 2.20 tonnes per hour fresh onions

Plant Area: 1000 sq. mtrs

Electric Power: 175 KW

Steam: 0 5 tph at 10 kg/sq cmSteam: 0.5 tph at 10.kg/sq.cm

Water: 2500 lph

Compressed air: 100 lpm at 7 bar

Others: A Cold Store

Sensitivity factors:

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

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Y

SU

E

$

PROFIT AREA

BREAK EVEN POINT

B

OS

T A

ND

RE

VE

N

LOSS

FIXED COST LINE

CO

BREAK EVEN VOLUME

AREA

0 P Break Even Point

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ANNUAL PRODUCTION (Units)0X 100

= Annual Fixed Cost -----------------------------------Annual Fixed Cost + Profit

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NOTESFinancial InvolvementsFinancial Involvements

Land and Building As recommended in the PDD

Plant Equipment. USD 400,000.- to 500,000.-

-depending on freezer option chosen

Production of IQF Onion products venture beyond a-

Break Even Volume of: 1000 Kgs per hour -diced frozen onions

And economically sustainable: at 20 percent enhanced production.

A plant capacity of: 2200 Kgs per hour -Fresh onions.A plant capacity of: 2200 Kgs per hour Fresh onions.

Pay back period under normal conditions: 2 Years

.

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Produce that can also be processed at the facility.

Potato cubes and Green Spring Onions- diced

Produce that can also be processed at the facility…Mixed vegetables, peas, with minor additions of equipment