PEACH OF SYRUP.ppt

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ELABORATION OF PEACH IN SYRUP

August, 2012

Presented by: Dante Santos

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INDEX INDEX

I. - INTRODUCTIONII. - OBJECTIVESIII. - MACROPROCESSIV. - TECHNOLOGY OPERATIONSV. - LEGALVI. - QUALITY CONTROLVII. - PERFORMANCEVIII. - FLOWCHARTSIX. - RECOMMENDATIONS AND CONCLUSIONS

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I.- INTRODUCTION

One way of preserving the quality and stability of fruits without losses in aromatics is the osmotic dehydration technique by which the fruit is kept in a sugar solution. Through this treatment the amount of water is reduced allowing to enlarge the lifetime of the fruit. In that sense we project to develop a product, like peaches in syrup, the raw material that is used for this process is a variety of peaches from Huaral Valley.

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II.- OBJECTIVES

General objective: • Develop peaches in syrup Specific Objectives: • Identify technology process• Develop flowchart, operations, material balance• Determine the performance

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III.- MACROPROCESS OF ELABORATION PEACHES IN SYRUP

OPERATING LICENSE. HEALT REGISTRATION DIGESA. NTP 203-025: 1972. NTP 209-652: 2006. NTP 203-095: 1981. CODEX STAN 212: 2001. CODEX STAN 1-1991 CODEX STAN 242-2003 

PROCESS

PEACHES IN SYRUP NATIONAL MARKET

RAW MATERIALS AND SUPPLIESBlanquillos PeachesSugarTreated Water 

MATERIALS AND EQUIPMENT

MAINTENANCE HUMAN RESOURCES MATERIAL LOGISTICS JANITORIAL SUPPLIESDISINFECTANTS BASIC SERVICES(Water, electricity, internet) INFRASTRUCTURE(Local – Processing Plant)

REGULATORY ASPECTSREGULATORY ASPECTS

MACHINES AND EQUIPMENTStoveBalance. (0 - 50 kg)Balance. (0 to 2.000 gr.)Refractometer. (0 - 60 ° Brix)pH meter.Thermometer.Workbench.Pots.Plastic jugs.Cans SealerWorking Uniforms (apron, gloves)

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Fruits in syrup are those that are preserved whole or in pieces in an aqueous medium sweet. The syrups are packaged in bottles or cans. Fruits can be whole or cut into pieces and after treatment were poured scalding sugar syrup for preservation. The products in syrup are sweet and must use high quality fruits to ensure size, color and flavor.

IV. - TECHNOLOGY OPERATIONS 4.1. - PRODUCT DESCRIPTION AND PROCESS

4.2. - RAW MATERIALS AND INGREDIENTS

1. Peach 2. Sugar3. Purified Water4. Caustic Soda

Packing Material1. Cans2. Tags  7

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EQUIPMENT:StoveBalance. (0 to 50 kg)Balance. (0 to 2.000 gr.)Refractometer. (0 - 60 ° Brix)pH meter.Thermometer.Workbench.Pots.Plastic cylinders.Plastic tubs.Plastic crates.

Cutting boards.Knives.Palettes.Plastic jugs.Set of measuring spoons.Skimmer.Sieve.Can sealerWorking Uniforms (apron, gloves)

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RELATION BETWEEN SUGAR AND WATER FOR THE PREPARATION OF SYRUP

Source: National Agrarian University – UNALM

Type of syrup degrees Brix volume sugar CommentsConsistency (approximate percentage of Water Quantity

  percentage of sugar)    

Very light 10 1500 ml 165 gr resembles the

        level of sugar in

        most fruits

Light 20 1330 ml 335 gr for sweet fruit, test

        with little fruit to see

        if you like it.

Medium 30 1220 ml 500 gr Sweet apples,

      sweet cherries,

        blackberries and grapes

Thick 40 1160 ml 720 gr for sour apples, apricots,

      nectarines, peaches, pears

        pears and plums.

Very thick 50 990 ml 990 gr for very acidic fruit, test with

      little fruit to see their

        acceptance

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VI. - QUALITY CONTROL

HYGIENE:

RAW MATERIAL CONTROL: PROCESS CONTROL: PRODUCT CONTROL:

AcidezpHVIscosidadGrados Brix

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GOOD MANUFACTURING PRACTICES (GMP)

It involves:•Personal•Establishment•Equipment•Production systemBelow mentioned are the good manufacturing practices during processing:• Wash hands. • Do not eat.• Cover the hair and ears.• Handle carefully the instruments.• Keep nails short.• Not lay hands • No run to prevent slipping.

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VII: DIAGRAMSVII: DIAGRAMS7.1. – Flowchart – PROCESSING FLOWCHART

Prunus persica “PEACH”  

LEGEND:

Product: Peaches in syrup Method: Traditional

Line: Canned fruits Date: 8/16/2012

Author: Dante Santos Diagrams N° 1: Pag.01 de 1

INSPECTION

PEELING

RECEPTION - SELECTION

WEIGHING 

SEALING AND LABELING  

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2

5

4

CUTTING AND REMOVING OF SEEDS

COOKING

MIXING AND CANNING

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6

8

WASHING

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I1: Treated water – NaClO at 50ppm R1: Peaches in disrepair I2: Treated water and 2% NaOH R2: Waste water I3: Treated water R3: peel and wastewater I4: Syrup: 40 ºBx – 90ºC R4: Seeds Cans packaging of 950 ml R5: Wastewater I5: Safety caps.

CAN SEALING 9

STERILIZING 10

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COOLING

STORAGE

I4 

I5 

I3 

I2 

I1 

R1 

R2 

R3 

R4 

R5 

PEACH IN SYRUP

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VII: DIAGRAMSVII: DIAGRAMS

9.50 % 

7.2. - Material Balance Diagram

                                                                      Prunus persica “PEACH”

LEGEND:    

Product: Peaches in Syrup Method: Traditional

Line: Canned fruits Date: 08/16/2012

Author: Dante Santos Diagrams Nº 1 Pag. 01 of 1

28.40Kg

10          STERILIZATION 

11                          COOLING

01         

RECEPTION 30Kg.

02         INSPECTION AND SELECTION  27.15Kg. 

03         WEIGHTING 27.15Kg.  

04          WASHING 

05          PEELING  23.97Kg

06          CUTTING AND REMOVING OF SEEDS

07          COOKING 

08          MIXING AND CANNING

09          CAN SEALING 

26.82Kg.  

19.65Kg 

19.18Kg  

28.40 Kg

28.40Kg 

28.40Kg 

28.40Kg

PEACHES IN SYRUP  

R1 

R2 

1.22% 

R5

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STORAGE 

I1 

I2 

I3 

I4 

I5 

I1: Treated water – NaClO at 50ppm R1: Peaches in disrepair I2: Treated water and 2% NaOH R2: Wastewater I3: Wastewater R3: Peel and wastewater I4: Syrup: 3.70Kg Sugar and 5.53 L Hot Water R4: Seeds 40ºBx – 90ºC R5: Water vapor I5: Safety caps

R3 

10.62% R4 

18.02% 

2.39% 

28.40Kg

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VII: DIAGRAMSVII: DIAGRAMS7.4. - DIAGRAM OF CRITICAL CONTROL POINTS (CCP)

                 Prunus persica “MELOCOTON”  

                                                                                                                          CP                                                                                                                                                                                                                                                                                                                      CP     CP CP                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                   

PEACHES IN SYRUP

Product: Peaches in Syrup Method: Traditional

Line: Canned fruits Date: 08/16/2012Author: Dante Santos Diagrams Nº 1 Pag. 01 of 1

INSPECTION - RECEPTION

CUTTING AND REMOVING OF SEEDS REMOVINGDESCAROZADO

SELECTION

WASHING  

WEIGHTING

1

2

6

5

3

COCKING

MIXING AND PACKAGING

SEALING

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7

9

PEELING

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STERILIZATION 10

COOLING 11

CP 

CP 

CCP 

CP 

CCP 

CP 

CP 

13 STORAGE

CP 

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Agroindustrial Process

100 % = 30Kg

Waste33.71%

Peaches in syrup63.90 %

Vapor2.39%

VIII: PERFORMANCEVIII: PERFORMANCE

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IX.- IMPORTANT PRODUCT CHARACTERISTICSIX.- IMPORTANT PRODUCT CHARACTERISTICS

IMPORTANT PRODUCT CHARACTERISTICS

PRODUCT NAME PEACH IN SYRUP

IMPORTANT PRODUCT 40 ºBx

CHARACTERISTICS 3.5 pH

HOW IT IS TO BE USED READY TO EAT

PACKAGING VACUUN SEAL

SHELF LIFE 12 MONTHS

WHERE IT WILL BE SOLD RETAILERS

LABELING INSTRUCTION KEEP IN A COOL, Refrigerate after opening

DISTRIBUTION CONDITION STORAGE IN A COOL

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IX.- MANUFACTURING COSTS

Then we determine the cost of production to 12,000 units of peaches in syrup. PRODUCTION PER MONTH500 boxes of peaches in syrup in cans of 950 ml (24 units per box).DAILY PRODUCTION (*)25 boxes of canned peaches 950 ml (24 units x boxes)*20 working days per monthNO. OF WORKERS: 6 people

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DIRECT MANUFACTURING COSTSEquipment

DETAIL QUANTITY PRICE S/. COST S/.Stove 1 650.00 650.00Balance. (0 - 50 kg) 1 350.00 350.00Balance. (0 to 2,000 gr.) 1 950.00 950.00Refractometer. (0 - 60 ° Brix) 1 450.00 450.00pH meter. 1 230.00 230.00Thermometer. 1 230.00 230.00Workbench. 2 350.00 700.00Pots. 4 250.00 1,000.00Plastic cylinders. 5 80.00 400.00Plastic tubs. 5 35.00 175.00Plastic crates. 25 25.00 625.00Cutting boards. 5 15.00 75.00Knives. 5 8.00 40.00Palettes. 4 21.00 84.00Plastic jugs. 3 5.00 15.00Set of measuring spoons. 3 15.00 45.00Skimmer. 2 15.00 30.00Cans sealer 1 850.00 850.00Sieve. 2 45.00 90.00

Working Uniforms (apron, gloves) 5 35.00 175.00

TOTAL S/. 7,164.00

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DIRECT MANUFACTURING COSTS

DETAIL QUANTITY PRICE S/. TOTAL S/.

PEACHES (Kg) 10,000 2.50 25,000.00

SUGAR (Kg) 1,700 3.00 5,100.00

WATER (Lt) 2,100 0.03 63.00

CANS ( Units) 12,000 0.45 5,400.00

LABELS 12,000 0.10 1,200.00

BOXS 500 4.00 2,000.00

FUEL (gas) 16 32.00 512.00

SUBTOTAL 39,275.00

CONTINGENCIES (3.5 %) 1,374.63

TOTAL S/. 40,649.63

Raw materials, supplies and materials

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LABORFor this production volume requires the participation of 6 people:

DIRECT MANUFACTURING COSTS

WORKER QUANTITYSALARY S/.

UNIT TOTAL

PRODUCCTION CHIEF 1 1,200.00 1,200.00

OPERATOR 5 900.00 4,500.00

TOTAL S/. 5,700.00

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DIRECT MANUFACTURING COSTS

We present the summary of direct manufacturing costs monthly:

RAW MATERIALS AND SUPPLIES = S /. 40,649.63LABOR = S /. 5,700.00TOTAL DIRECT COSTS (S /.) = S /. 53,513.63

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INDIRECT MANUFACTURING COSTS

The Company generates the following month indirect cost ratio:

Monthly Depreciation = S /. 115.00Cleaning and disinfection = S /. 400.00Repair, Maintenance. = S /. 400.00Services (electricity, water, etc.) = S /. 500.00

TOTAL INDIRECT COSTS (S /.) = S /. 1,415.00 

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PERIOD EXPENSES

Salary administrator. = S/. 1,200.00Local rental. = S/. 1,000.00Materials Management. = S/. 80.00

Total expenditure period (S /.) = S/. 2,280.00 

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TOTAL PRODUCTION COSTS

Direct costs = S /. 53,513.63Indirect costs. = S /. 1,415.00Period expenses = S/. 2,280.00

Total manufacturing costs: S /. 57,208.63

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UNIT PRODUCTION COST

MONTHLY PRODUCCTION 

S/. 57,208.63

12,000 

S/. 4.77

COST OF PRODUCTIONUnit costUnit cost

= = Unit costUnit cost

= =

The unit cost of canned peach is S/.4.77

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PROFITABILITYPROFITABILITY

ANALYSIS:1.- Net margin analysis as a percentage of sales price

SELLING PRICE S/.72,000 100%

NET MARGIN S/.14,791 X

X=21%

The company gets 21 per cent of profit margin per each product it sells

MONTHLY PRODUCTION 12,000 CANS

DETAIL TOTAL PRODUCTION PRODUCT UNIT

SELLING PRICE S/.72,000 S/.6.00

DIRECT COSTS S/.53,514 S/.4.46

INDIRECT COSTS S/.3,695 S/.0.31

TOTAL COSTS S/.57,209 S/.4.77

GROSS MARGIN S/.18,486 S/.1.54

NET MARGIN S/.14,791 S/.1.23

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PROFITABILITYPROFITABILITY

ANALYSIS:2.- Net margin analysis as a percentage of total costs

The company gets 26 per cent of profit margin per each product it produces

TOTAL COSTS S/.57,209 100%NET MARGIN S/.14,791 X

X=26%

MONTHLY PRODUCTION 12,000 CANS

DETAIL TOTAL PRODUCTION PRODUCT UNIT

SELLING PRICE S/.72,000 S/.6.00

DIRECT COSTS S/.53,514 S/.4.46

INDIRECT COSTS S/.3,695 S/.0.31

TOTAL COSTS S/.57,209 S/.4.77

GROSS MARGIN S/.18,486 S/.1.54

NET MARGIN S/.14,791 S/.1.23

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X. - RECOMMENDATIONS AND CONCLUSIONS

• Developed a product from raw material Huaral province.

• Identified processing technique.

• Also be prepared flowcharts, material balance and critical points.

• finally settled manufacturing costs and profit margins, obtaining a profit margin of 21%.

• It is recommended that all processing operations using the principles of good manufacturing practices.

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