PROJECT PROFILE POTATO PROCESSING POWER AND FLAKES Capacity 2500 MTA Prepared By: ABHYUDAY TECHNO ECONOMIC CONSULTANTS PRIVATE LIMITED Address: 211 212, Patel Avenue, Nr Gurudwara, S. G. Highway, Thaltej, Ahmedabad 380054, Gujarat, India Contact: (O) +91 79 26856999 Email: agronfood@abhyuday.in /megaprojects@abhyuday.in/ info@abhyudayprojects.com
POTATO PROCESSING FOR POWDER AND FLAKES SECTOR: AGRO AND FOOD PROCESSING UNIT CAPACITY (PER ANNUM): 2500 MT NO. OF WORKING DAYS: 300 DAYS COST OF PLANT AND MACHINERY: RS. 120 LAC COST OF PROJECT: 714 LACS IRR: 22.50% Project Description The proposed project envisions setting up of Potato powder and flakes manufacturing unit. Product Potato flakes are the most important form of dehydrated potato products, which also include potato granules, pellets, powder, shredded and sliced potato. Dehydrated potato flakes are made by pressing cooked mashed potatoes onto a drum drier, which forms a sheet that can be broken up and ground to the required density. Potato flakes can be used anywhere, where one would use mashed potatoes. They are also used in commercially available products, like instant mashed potatoes, croquettes, pasta and fabricated snacks. As a thickener, they enhance creamy frozen desserts, gravies and chocolate milk. Like other dehydrated potato products, they extend the shelf life of baked goods. After wheat, rice and maize, potato is the most important food crop in the world. It contributes to almost 50% of the total tuber and root crop production. Potato has a good food value as compared to other staple food crops as it is rich in carbohydrates and also contain proteins, minerals like calcium and potassium and vitamins like vitamin C. Boiling the potatoes increase their protein content even more than maize has and almost doubles their calcium content. It is vastly consumed as a vegetable and is also used in various forms such as starch, flour, alcohol, dextrin and livestock fodder. Applications: Potato powder/flakes have wide application in the processed and snack food industries. It can be used in any recipe which requires mashed potatoes. Potato powder is used as a thickener or base for preparation of ready to eat vegetable gravies and soups. It is also used as an ingredient for potato chips, texturised potato products, snack pellets etc. As a Thickener - As a replacement for cornstarch or wheat flour, dehydrated potato flour, flakes and granules add volume to soups, stews, sauces, and broths. As a Binder - The starch in dehydrated potato products makes them perfect for use as a binding agent in meat, fish or vegetable patties, sausages and cakes. Abhyuday Techno Economic Consultants Pvt Ltd 2
As a Baking Ingredient - Because of their subtle earthy flavor, dehydrated potato products are popular in baked goods such as breads, cakes, muffins, etc. Moreover, they retain water better than substitute flours, increasing the shelf life of bakery goods. As an Ingredient for formed products - Formed product like Burgers, Patties etc can be conveniently made from potato flakes. As an Ingredient for packed snacks - Long shelf snacks like extruded products, fabricated chips are made from potato snacks. Market Apart from the above uses, in Indian snacks, a variety of applications can be made by using dehydrated potato products. Potato flakes can be used for various Indian delicacies like Aloo bhujia, fillings for Samosa, Dosa etc. India is a very insignificant player in the global trade of dehydrated potato products. The exports of dehydrated products from India are only to neighboring countries in form of dehydrated slices, dehydrated chips, powder, etc manufactured by small scale units. At present, good quality flakes at affordable prices are not available in the country. Therefore, only the manufacturers of premium products have been in a position to use this product. Further, as flakes are generally imported in container loads, only bulk users can afford keep stocks and the agents importing the products have never tried to reach to the small end users. The consumption of potato flakes in India can increase manifold, once a good quality product, at an economical price is available. There are very good prospects for the growth of potato flakes in India. The following factors are likely to drive demand. Manufacturing Process Washing / Sorting & Grading of Potatoes - The primary procedure consists of washing and grading the raw material as per requirement. Potatoes with high solid contents are considered the best for potato flakes for, when rehydrated, it should give the same texture as a freshly mashed potato. Peeling / Second Washing - There are three methods that can be used for peeling - steam, abrasion, and lye. Generally, for commercial processing the Peeling Grade 4 defined as a grade that has either multiple peel fragments or defects and does not appear well peeled and may also have a thin layer of outer cortical cells remaining. The potatoes falling in this cadre are not acceptable for the production of French fries without considerable trimming, while they are absolutely acceptable for dehydrated mashed potato manufacturing." on the Willard Peeling Score Chart is used. Abhyuday Techno Economic Consultants Pvt Ltd 3
Cooking - Cooking is done to separate the potato cells to the desired degree of aggregation with minimum cell rupture. There are three types of steam cookers used commercially: the conventional design, direct steam injection in a screw conveyor, and steam injection with counter rotating screws. Pulping and Drum drying of Pulp to produce flakes - A single drum dryer equipped with four to six applicator roles is the best way to accomplish the drying process. The clearance between the top roller and the drum surface determines the rate of flow of the mash to the rolls beneath; this is adjusted by the operator as required. The operator progressively transfers mash from the upper to the lower rollers, ensuring that each roll is provided with a continuous reservoir of mash to obtain maximum density of the dried sheet of potatoes, and finally discards the mash from the bottom of the roll when it has accumulated the optimum level of defects. A reciprocating doctor knife removes the dried sheet; in some cases when a thick dry sheet is being made, it peels away from the drum just ahead of the knife, leaving the drum surface quite clean. The sheet then drops into a collecting screw conveyor, which transfers the roughly broken sheet to a collecting point at one end of the dryer." The potato flakes are dried to commercial specifications of 6-7.5% moisture and bacteriological standards of coli form, 10/gram, E. coli, negative, standard plate count, 10,000/gram, and negative for Staphylococcus aureus and Salmonella. Slicing, Precooking, Cooling & Grinding of flakes into Potato powder - Potatoes should be sliced to about 5/8 of an inch thick to obtain a more uniform heat treatment during the precooking and cooling steps. The purpose of precooking is to get the starch to gelatinize within the potato cell, but not allow the softening of the intracellular bonds to take place. To accomplish this, water is heated to 71 degree C to 74 degree C. The process of a continuous screw through a processing unit heated usually does this by the direct injection of steam.. The gelatinization of the starch within the cells must be complete for the retro gradation to take place during cooling, allowing for the bonds that formed to retain their linkages through the cooking and drying steps which follow, reducing the stickiness of the reconstituted finished flake. Cold water is used to reduce the stickiness of the potato for convenience in later handling. The free starch is alsowashed from the surface of the precooked potato slices to avoid sticking and scorching during the dehydration process. In commercial processing, a screw conveyor, either U-shaped or with "wrap around" sides, is used. The potato slices advance through a counter current flow of cold water. The quality of water used depends on three factors: the water temperature, the flow rate of the potato slices, and the degree of retro gradation desired (expressed by the Blue Value Index method). High solids potatoes are generally cooled to a maximum internal pulp temperature of 21oC and low solids potatoes to an internal temperature of 10 Degree C. Abhyuday Techno Economic Consultants Pvt Ltd 4
Packaging in moisture proof multi layer plastic pouches The moisture content being low flavor deterioration is the outcome of oxidation. This can be significantly reduced or retarded by the partial exclusion of air or the use of antioxidants. Therefore, the packaging used should afford a moisture barrier and be opaque because light will greatly accelerate rancidity. Potato flakes are nitrogen packaged in tin cans with 3.5% oxygen and will remain substantially unchanged in flavor for more than a year at 73oF, about room temperature. Abhyuday Techno Economic Consultants Pvt Ltd 5
Cost of Project and Means of Finance a) Land Requirement 10,000 Sq Mt b) Build Up Area 25,00 Sq Mt c) Plant and Machinery Major plant and machinery required for the proposed project are as follows: Sr. No. 1 Potato Washer 2 Potato Peeling Machine 3 Slicing Machine 4 Dryer 5 Pulveriser 6 Sealing Machine 7 Steam Boiler 8 Electronic Weighing Scale Particulars d) Utilities WATER ELECTRIC POWER COAL 25000 ltrs per Day 125 HP 5 MTPD Estimated Cost of Project and Means of Finance (Rs in Lac) SR. NO. ESTIMATE COST OF PROJECT AMOUNT 1 Land and Development 125.00 2 Building and Civil Works 250.00 3 Plant and Machinery 120.00 4 Misc. Fixed Assets 57.00 5 Preliminary and Pre Operative 42.00 6 Provisional and Contingencies 60.00 Total Fixed Assets 654.00 Margin Money for working Capital 60.00 Total Cost of Project 714.00 SR. NO. MEANS OF FINANCE AMOUNT 1 Promoters Contribution 284.00 2 Bank Finance (Term Loan) 430.00 Total 714.00 Abhyuday Techno Economic Consultants Pvt Ltd 6
Project Time Line The proposed project will have project time line period of 9 to 10 months and project implementation period of 5 to 6 months. PLEASE NOTE: This is Model Project Profile; the actual Cost of Project will change depending on the Land and Building Prices, Actual Quote from the suppliers of the Plant and Machineries etc Abhyuday Techno Economic Consultants Pvt Ltd 7