Radha Nutrients Ltd.

Projectsm

Concentrator 3E-250, Trople effect evaporator, capacity 250 tons/day of treated tomato
with semi barometric condenser and water cooling towers.

Products mix

Two basic products are processed in the plant namely :

1: Frozen Vegetables either whole or cutr cut
2 : Frozen fruit either whole or in cubes or as slice.

The products considered for frozen Vegetables are:

1	Sweet Garden Pas	10	Cauliflower LloretrsCauliflower
2	Green BeansBeans	11	Carrots
3	Broccolicoli	12	Spinach
4	Paprikaaprika	13	Tomato Cubes
5	OkraOkra	14	Mushroom
6	CornCorn	15	Turnip
7	CabbageCabbage	16	Asparagus
8	EggplantsEggplant	17	Gherkins
9	OnionsOnions	18	Mixed Vegetables

The products considered for Frozen Fruit are :

1	Mango	9	Carrots
2	Melon BallsBeans	10	Pineapple
3	Litchis	11	Mandarins
4	Seedless Grapesaprika	12	Strawberries
5	CherriesOkra	13	Raspberries
6	PlumsCorn	14	Gooseberries
7	ApplesCabbage	15	Mixed Fruit Cocktail
8	Papayaggplant

Complet Line for the receiving of the tomatoes in water with a mud disposal system scraped bottom type, and a leaves removal system, rollers type.
Manufacturing Process, Capacity and Requirements

The complete process for production of IQF Fruits and Vegetables can be divided in to the following steps:

1: Reception of raw products and manual sorting

2: Pneumatic Cleaning

3: Washing and de-stoning

4: Inspection

5: Trimming, Shelling, Sizing, Sniping, Pitting and Skinning

6: Blanching

7: Cooling

8: Sorting

9: Individual Quick Freezing

10: Grading

11: Packing

12: Storage

As the process line is envisaged to handle various Fruit & Vegetables each with different Characteristic, the equipment will be fixable to handle differenttreatments required for each products. The modular system Configuration with the roll-in-roll-out, approach will allow adaptation of the line for different raw material and also for introducing automation if required.

RAW MATERIAL RECEPTION AND MANUAL SORTING

IQF Processing does not change the physical characteristics of the raw products, therefor care is taken that inferior raw products are weed out beforehand. The first step is taken at the raw material store itself there unripe, blemished or decayed product is separated manually. The rae material store is quipped with a ripening chamber where the products can be stored till maturity in controlled conditions.

PNEUMATIC CLEANING

In 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 circulation generated by an electric fan. Air flow Irelgulating 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-STONER

After removal of light linpurities by pneumatic cleaning, the heavy foreign bodies and stones are removed by means gfydraulic de-stoner. By creating an upward water flow and passing the product over serrated belts the stones etc. are separated and deposited on a Icontinuous evacuation elevator which delivers them to a waste bin.

Combined with this unit is the washger with rinsing and flotation chambers to give the product a through wash in order to remove soil or secretions etc. Which may be adhering to the product. The waste that separates goes to the bottom of the machine and is easily taken out by means of inspection holes. The water used for washing is continuously filtered and recycled. the product discharge net elevator is provided with cleaning device that guarantees the separation of all the product.

INSPECTION

After 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 to adjust the speed according to the product.

PREPARATION

In 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 at frequent intervals to avoid contamination of the product by building up of bacteria due to fermentation.

BLANCHING

After 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 temprature for a certain time. The Balncher is continuous process euipment and it has automatic controls for adjusting tempratures, 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 provided.

COOLING

The products out of the Blancher is at approximately 80 to 85 deg. celsius. At such Elevated tempratures it cannot be taken 20 degrees celcius without casing thermal shock to the product. It is important therefore to cool down the product to a temprature between 1 to 20 degree celcius cooling also stop 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 counterflow cooler in order to obtain 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.

SORTING

After 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 deteched and eliminated here. Overcooked products from the Blancher and fermented material can also be eliminated.

INDIVIDUAL QUICK FREEZING

The final deep freezing is done in the IQF tunel. A stainless steel spreader shaker uniformaly 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 temprature of -18 to -21 deg. celcius the pieces remain separated and do not form a block.

GRADING

Grading, after freezing is required in some fo 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 is foreseen:

To grade Granular products such as peas, beans or chich peas, 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 forseen for the 50 gm., 1 Kg., 2.5 Kg., and 5 Kg. bags. For all bags above 5 Kg. manual weighing filling and closing is done. Packing is of types:

1: Retail Packing 2: Bulk Packing

Packing material consist of pre-printed or plain polythene bags.

The filled and closed cartons containing packed finished products are sent to the finished product store.

LOCATION

The processing plant of the company is set up at village Tepla, tehsil Ambala Distt. Ambala in Haryana. For the project company has acquired land measuring 15,898 sq.metres at a total cost of Rs. 22 Lacs. the site is well connected by road and railway and lies on the state Highway. The food producing belt Haryana, Punjab, Himachal Pradesh & Uttar Pradesh are easily accessible for the procurement of raw material.

Various infrastructure facilities such as power, water telecommunication are easily available since the site is in the Industrial Area. Delhi, located at a distance of 160 km, has a dry port and all facilities for export.Labour, both skilled and unskilled is abundary available from surrounding areas.

TECHNOLOGY

The technology used for the freezing process is known as Individual Quick Freezing (IQF) process. IQF technology was developed in the West and is being used by leading frozen Processors all over India. the promoters are well versed with the technology.

Under the IQF process each individual piece, slice, cube of fruit or vegetable is frozen separately so that even after attaining a temprature of -18 to -21 deg. Celcius, the pieces remain separated and do not form a block.

The IQF method of freezing ensures that the quality of the end product is much superior compared to other methods of food preservation like dehyration, canning or bottling as it as does not lead to any loss of nutirents, flavours, colours, shape or texture. The process also results in a longer shelf life (upto 18 months), reduced thawing loss and no product deformation.

PLANT AND MACHINERY

The major items of plant and machinery to be purchased for the project includes common preparation line IQF Freezing line for packaging, gensets, boilers etc. these are to be purchased from reputed manufaturers. The company propose to purchase lines / IQF freezing tunnel / refrigeration equipment from the world renewed suppliers like Zacmi / Bertuzzi Italy, IFS / Eurotek, U.K., Samifi, FRANCE etc. the company is also in regular tech with Allistate Group Mumbai, Servotech INDIA Delhi for the reason of better technology available at reasonable rates. Teh major part of the plant & machinery items will be imported.

A sum of Rs. 381.77 Lacs has been provided for plant & machinery in the total project cost.

RAW MATERIAL

The raw material required for processing are Fruits & Vegetables. The following Fruits are required:

Mango, Papaya, Guava, Cherries, Plums, Pineapple, Melon Balls, Litchis, Mandarins, Seedless Grapes, Strawberries, Gooseberries, Rasberries, Apple, etc.

Raw material requirement for vegetable are:

Sweet Garden Peas, Green Beans, Cauliflower, Carrtos, Broccoli, Spinach, Paprika, Tomato, Okra, Mushroom, Turnip, Cabbage, Asparagus, Eggplant, Gherkins and Onions.

The fruit and vegetable producing belt of Haryana, Punjab, Himachal Pradesh and Uttar Pradesh are Major source of raw material. Availability of fruit and vegetables is dependant on seasonal patterns, therefore acquisition and processing of raw material is scheduled accordingly.

The requirement of the raw material is just 13000 MT,for the whole year,which is available in abudance round the year in the area .The company has also chalked out an ambitious fruits and vegetables development programme which will further improve the avaibility of fruits and vegetables in a particular area.

MARKETING / SELLING ARRANGEMENTS

The project has been approved as a 100% EOU from the govt. of India and so the company has entered into a 100% Buy back arrangement and has entered into an arrangement with ABI (American Business International Inc., Birmingham, Alabama, U.S.A.), which has an equity participation in the project & an agreement to sell the products in U.S.A. Apart from this the company is the approved supplier to the Indian Armed Forces and is supplying bulk quantities to the Defence Forces.

The company also has a chain of distributors all over India to promote domestic scales which is being looked after by trained professional marketing staff.

UTILITIES

Power

The power requirement of the company are estimated to 400 kw which is proposed to met by power load sanction from H.S.E.B. from the nearby substation. Aprovision of DG Set has been made in the project cost to meet the power requirement in case of power shortage.
The company proposed to get a connection from Haryan State Electricity Board for the required Power and an application to this effect has already been amde to the concerned department.

Considering the nature of the product being processed, which requires continuous storage at sub zero tempratures, It is essential to install a stand -by generating set. The capacity envisaged is 400 kw whereby the entire plant can be run i case of a power failure.

Process	100 kw
Refrigeration	150 kw
Services	100 kw
Offices	50 kw
Total Installed	400 kw

Rotal 592- Rotating drum machine suitable for tomatoes washing.

Water

The present requirement of the water is estimated to 150 kl per day which is being met from tube well installed in the factory premises. The company proposes to install two tube wells to meet its water requirement. The cost of the installation of the tube well is estimated to be Rs. 1 Lacs. The company also proposes to install water tank underground sump with the capacity of 200 kl.
The water consumption in the process as well as in the services is fairly high. The requirements are as follows

Washer	Initial Fill	500 liters / day
	Make up	80,000 liters / day
Hydraulic conveyors	Initial Fill	5,000 liters / day
	Make up	15,000 liters / day
Cooling Tank	Initial Fill	5,000 liters / day
	cleaning	15,000 liters / day
Blancher	Make up	5,000 liters / day
Freezer belt washer	Make up	15,000 liters / day
Total Process		1,45,000 liters / day
Evap Condensers		35,000 liters / day
Boiler		20,000 liters / day
Total Services		55,000 liters / day
TOTAL WATER REQUIREMENT FOR THE DAY		2,00,000 liters / day
WATER DISCHARGE FROM THE PLANT		1,00,000 liters / day

To meet the above mentioned requirements, bore wells will be dug at the factory, the quality of the water has ascertained and it is found suitable for food processing use. The availability data of the surrounding terrain indicates an abundant water supply and a comfortable water table.

Manpower

For the proposed porject the requirement is estimated to be 145 personnel. The sompany to recruit trained technicians from the Indsutry and semi skilled and un skilled workers locally. The company does not envisage any problems in recruiting the same. The detail of the proposed is as under:

Management & Administrative	21
Technical	34
Labour	90
Total	145

Self cleaning grids, rotary drum type,
Suitable for water filteration.

Water pumping unit composed by self-priming pumps,suitable for
effluent water.