Juice Manufacturing Industry Research Report

7/31/2019 Juice Manufacturing Industry Research Report

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Table Of Contents

Introduction

History

Juice Manufacturing Market in India

Export Market

Raw Materials

Juice Manufacturing Process

Plant & Machinery

List of Suppliers Capital investment

Storage facilities


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Over the past several decades there has been a growing trend toward adding value to rawagricultural products. As populations have become more urban, this trend has accelerated.The need for stable, convenient foods has increased along with the demand for exotic productsfor international cuisine. With the globalization of the food industry, the demand forquality juice and juice type beverages has markedly expanded. Traditionally, only ahandful of fruit and vegetable juices have served this market as large multinational companiesor their affiliates, have captured the majority of national and international juice trade. Juicessuch as orange, grape, pineapple, pomegranate, apple, tomato and blends are well established

in developed countries. Now, minor juices, tropical juices and juice products are attracting newattention.

The manufacture of juices from fruits and vegetables is as old (or older) than agriculture.During the ripening process most fruits soften to the point where simply handling ortransporting them yields more juice than flesh, albeitoften partially fermented. The resulting

pulpy fluid, easily separated from seed and skin, is generally more flavorful than the more solidportion. Hunter-gatherers could either consume quasi juices directly or collect the soft fruit inreasonably leak-free containers for later use. Simply transporting the fruit any distance soonguaranteed juice. Except for cool temperature climates, storage life was limited to mere hoursbefore incipient fermentation modified the character of the juice appreciably.

Through trial and error humans learned practical ways of extracting juice from various sourcesand, most importantly, which attractive but toxic fruits to avoid. Tool making skills fosteredthe manufacture of devices for macerating fruits and extracting juices. Containers forstoring foods, including receptacles for fluids were also devised from local resources, i.e.woven plant fiber and wood, clay soils and animal skin/intestine. Such methods and equipment

can still be found in isolated pre-industrialized regions. Otherwise they are seen only inmuseums as prehistoric or early artifacts of extinct civilizations. Until fairly recently, liquidcontainers were quite primitive compared to those of the 20th century

The perishable nature of juices dictated immediate consumption within less than 24 hours inwarm climates and extended but still limited time in cooler environs. Natural chilling orfreezing was the only alternative to microbial modification of the juice. Such fermentation wasthe basis for wine. It was found that the juice, after bubbling mysteriously, has a distinctly


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different character and affect on those consuming the product. Also, the material stored severaldays longer slowly turned harshly acidic or developed an even more unpalatable surfacegrowth and taste.

This early vinegar was used as a preservative for other fruits and vegetables. Grapedomestication followed this discovery.

With the development of agriculture over the last 10 millennia, the cultivation of cropsprovided a fairly reliable source of food, including fruits appropriate for juice and beverageuse. Unless the juice was consumed fresh, soon after pressing, fermentation was the likely,often desired consequence until preservation techniques were developed. In fact, the concept ofmaintaining a fruit destined for juicing in its whole, intact form until the juice is neededcontinues to be a sound principle. Even today, maintaining the fruit intact is one of theeasiest ways of preserving juice quality.

GLOBAL MARKET

The global market for juiceand juice products was estimated to be about 50 billion litres inthe late 1990s. In the United States of America alone, the retail commercial value of the almost20 billion litres of juice and juice products exceeded US$18 billion, roughly 3 percent of a totalfood sales expenditure of US$630 billion. World trade has accelerated over the last decadewith developing countries achieving over 60 percent of fruit juice exports. Brazil, the largestcitrus producer, accounts for about 25 percent of world production. Juice utilization in

decreasing order is: Orange, apple, grape and pineapple.


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India is the second-largest producer of fruit and vegetables in the world , contributing a

total of150 million tonnes of the produce to the global production annually. Ironically,

however, only 2.2% of the fruit and vegetable production is processed here as compared to

countries like USA (65%), Philippines (78%) and China (23%). Hence, this presents immense

opportunity for companies looking at investing in this sector in the country.

Key sector

The food processing sector is critical to Indias development. It establishes vital linkages and

synergy between industry & agriculture, the two pillars of Indias economy. The growth of

food processing will bring immense benefits to the economy, raising agricultural yields,

enhancing productivity, creating employment and raising standard of life of people across

the country, especially in rural areas.

Interestingly, this industry ranks fifth in the country and employs around 13 million

people directly and 35 million people indirectly. It accounts for 14% of total industrial

output of the GDP. Its turnoveris estimated at ` 1,44,000 crore, of which ` 1,11,200 crore is

in the unorganized sector. The liberalization of the Indian economy and world trade and rising

consumer prosperity have thrown up new opportunities for diversification in the food

processing sector and opened up new vistas for growth.

Horti success

India has made good progress on the horticultural map of the world with a total annual

production of horticultural crops touching over 149 million tonnes. As said earlier, India is the

second-largest producer of fruits (45.5 million tonnes) and vegetables (90.8 million

tonnes) in the world, contributing 10.23% and 14.45% of the total world production of fruits

and vegetables respectively. It is also a well known fact that since centuries it has been thelargest producer, consumer and exporter of spices.

Decentralized

The fruit and vegetable processing industry in India is highly decentralized. A large number of

units are in the cottage / home-scale and small-scale sector, having small capacities up to

250 tonnes / annum though big Indian and multinational companies have capacities in the


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range of 30 to 50 tonnes per hour or so. The prominent processed items are fruit pulps and

juices, fruit-based ready-to-serve beverages, canned fruits and vegetables, jams, squashes,

pickles, chutneys and dehydrated vegetables.

More recently, products like frozen pulps and vegetables, frozen dried fruits and vegetables,

fruit juice concentrates and vegetable curries in restorable pouches, canned mushroom and

mushroom products have been taken up for manufacture by the industry. The processing level

in India is estimated to be around 2%.

CAGRCompounded Annual Growth Rate

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Indias major exports are in fruit pulp, pickles, chutneys, canned fruits and vegetables,

concentrated pulps and juices, dehydrated vegetables and frozen fruits and vegetables.

Supply chain efficiencies together with a focused approach to enhance exports are the key toensure that India is able to successfully tap new product / market opportunities. India has the

potential to achieve a 3% share in the world trade of food products by 2015.

The Top 5 Countries where Indian Fruit Juices are exported are as follows:

USA (11.5%)

Netherlands (11%)

UK (9.9%)

Germany (6.8%)

Nepal (6.8%)

It was observed amongst all the above countries that Indias export growth to the above

countries has been slower as compared to the rate of imports of the above countries from the

rest of the world. This indicates our countrys weakening hold on juice exports vis--vis the

rest of world.

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Data source: Ministry of Food Processing Industries Annual Report 2010-2011

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Human selection of plants for their more desirable features has been practiced for thousands ofyears, initially by trial and error, more recently by scientific knowledge applied to plantgenetics and molecular biology. Thus even within a given fruit there are numerous varietiesavailable including some derived from the wild, others specifically developed by breeders andcombinations of both. Recent advances in understanding the molecular basis of plant geneticsand how the genes and growing environment influence traits, promises to revolutionizeagriculture, once the politics and emotions are resolved.

Fruits originating in the wild have evolved to be reasonably robust and resistant to naturalenvironmental stresses, diseases, insects and other predators. These traits, however, do notnecessarily favour concentrated production systems or edibility. The exception is ifconsumption by wildlife promotes pollination or seed dispersal. Human population pressuresfurther impact upon native plant species, therefore except for exotic plants remote fromcivilization, most fruits are substantially removed from their origin in time, genetics andlocation.

Special cultivars, developed with criteria such as yield, location adaptability, resistance todisease, insects, drought tolerance, harvest period, ease of cultivation and harvest,handling and storage durability, processing characteristics and sensory appeal (colour,taste, aroma and texture) are characteristics now determined by commercial breedingpractice. Juice quality considerations are also important in many fruits such as citrus, grape,apple, pineapple and others. Specific cultivars dominate the juice trade, while others arepreferred for the fresh market. Some cultivar end uses are dictated by fruit supply, conditionand economics and vary by season, location and market depending upon fruit quality.

Fruit Breeding Criteria

Trait Rationale

Plant hardiness Survival, resistance to drought,cold, heat, etc

Disease resistance Plant/fruit survival, reducedpesticide use

Plant morphology Ease of cultivation/harvest

Fruit morphology Ease of harvest/processing,

high yieldComposition Quality, economic/nutritive

value

Seasonality Availability, market anddemand price

Fruit durability Marketing/handling/processing

Yield Economic value

Flavor Quality, value


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Colour Appeal, value, by-productpotential

Texture Appeal, durability

Nutrients/phytochemicals Value, appeal, by-product

Cultivation Factors Influencing Quality

Factor Importance

Location Harvest period, plant survival,market

Cultivar Yield, desirable juice traits,harvest period

Plant spacing Yield, ease ofcultivation/harvest

Plant care Yield, ease of harvest, quality

Pruning(Cutting) Yield, maturation, ease of

harvest

Irrigation Fruit/juice yield, quality

Fertilization Growth, designation (i.e.organic)

Pesticide use Fruit quality, designation,regulations

Field protection Yield, quality (bird, varmintdamage)

Field sanitation Juice safety, quality

Labour training Fruit quality, cultivation/harvestefficiency

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Mainly following processes are involved in Juice Manufacturing. The below table lists the

various processes involved and their functions:

Unit Operation Result

Mass transfer Fruit delivered, drycleaned

Extraction Washed

Separation Sized, graded

Separation Peeled, cored anddeseed

Size reduction Crushed, comminuted

Pressure application Juice extracted

Separation Solids screened

Deaeration Oxygen removed

Centrifugation Solids separated

Filtration Clarification

Fluid flow Juice transferred,pumped

Heat transfer Enzymes inactivated,juice pasteurized andcooled

Concentration/evaporation Volume reduction,stability

Mass transfer Packaging, shipping

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Manufacturing Process

Pre process Stage

The logistics of production, harvest, transport and ripening dictate that many fruits must beheld prior to juicing. The seasonal harvest window may be much shorter than the time requiredprocessing the entire annual crop and stabilizing the resulting juice and finished products. Aswith the aforementioned steps, careful holding is necessary to allow optimum ripening to occuror prevent spoilage and contamination. Producers and processors should have a goodunderstanding of postharvest physiology, particularly as it relates to the species and cultivars inquestion.

With certain climacteric fruit, ripening and senescence can be controlled (delayed,maintained constant, accelerated, or promoted uniformly) by the judicious use of lowtemperature, moderate humidity and adjustment of oxygen, carbon dioxide and ethylenelevels.

With other fruit, holding is short term and serves only temporarily to prevent contaminationand damage while accommodating processing flow. Some fruit can be frozen and stored forlong periods. Freezing is costly, but promotes cellular breakdown and facilitates shipping and


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juicing. In hot climates where refrigeration or freezing facilities may be neither available norpractical for juice fruit, strategies such as just-in-time harvest, cooler night time harvestoperations, rapid transportation and shady, well ventilated storage can help balance theprocessing load and stave off deterioration for a few critical hours . Many processors aredisturbingly unaware of the importance of these procedures; but every little bit helps and the

benefits add up.

Cleaning, Sorting and Inspection

If the fruit producer has followedGAPs and the harvest and handling have been accomplishedeffectively, fruit arriving at the processing plant should be reasonably sanitary and of optimumquality, thus simplifying succeeding operations. Nevertheless, quality cannot be taken forgranted. In many cases the basis for payment is the condition of the fruit as received. Hencesampling and analysis for composition and quality are mandatory.

Government norms, an industry association, or agreement between producer and processor inadvance of the crop purchase can dictate applicable quality standards.

Inspection of Grapes at the time of delivery

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Crushing and Juicing

Fruit must be carefully peeled and deseeded or cored prior to juicing . Hand labour is thecurrent alternative with many minor fruits, although there is an economic incentive tomechanize if possible.

Contour peelers, such as used with apples (Figure below) can be adapted to a range of fruitsthat are sufficiently firm and uniform to facilitate the rotary peeling action. Peeling systemsthat are effective with some vegetables such as lye, abrasion, enzymatic, explosive, are lesssatisfactory with delicate fruit flesh. Nevertheless, cleverly designed machinery can greatlyfacilitate these labour-intensive operations. Under all circumstances, a final humaninspection and piece selection/rejection step is mandatory.

Automatic Inspection/grading system


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Pressing

The pressing operation can also range from manual to mechanical with complete automatedsystems common in the juice industry. Kitchen-scale juicers or food processors are effectivefor small quantities, but for larger multi-kilogram amounts, flow resistance and distance theexpressed juice must travel to the press surface complicate pressing. The rack and cloth pressincreases the surface area to volume ratio and is quite effective, albeit labour intensive. Figurebelow shows a simple press based on a hydraulic truck jack developed by Cornell University(Downing, 1972). All supports are wood, including the racks. Tough cottons or synthetic clothsprovide an inexpensive, durable batch press, albeit difficult to clean and sanitize.

Simple Hydraulic rack and Cloth press

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Press factors influencing juice yield and quality

Factor Effect

Fruit immature Resistance to juicing, lowyield

Fruit inadequatelycrushed

Resistance to juicing, lowyield

Fruit over mature Undesirables extracted,poor quality

Fruit over comminuted(crushed)

Undesirables extracted,poor quality

Excessive pressure Undesirables extracted,dark juice

Excessive time inpress

Dark, over extracted juice

Short press cycle Low yield, lighter juicecharacter

Long press cycle Low throughput, overextraction

Cold Press Lower yield, lightercharacter

Hot press Higher yield, stronger,darker character

Enzyme treatment Higher yield, strongercharacter

Pressing aid added Higher yield

Press cakeredistributed Increased yield

Delayed or extendedpressing

Dark juice, incipientspoilage

Juice Clarification

For more fluid juices where cloud or turbidity is not acceptable primary extracted juicemust be treated further. A settling step can help, if the juice can be held refrigerated for afew hours. At ambient tropical temperatures holding is not recommended. Rapid methodssuch as centrifugation and filtration can produce a clear juice. A continuous or a decantingcentrifuge with automatic desludging to produce a clear or nearly clear juice is quite effective.(Juices where a cloud is desired generally do not require filtration; centrifugation is adequate.)The stream should be settled or coarse strained prior to centrifugation in order to reduce thesludge load in the feed going to the centrifuge. A fine mesh shaker screen can further remove


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particulates. A centrifuge is a very costly item; however, it greatly simplifies subsequentfiltration steps and is an essential component in many juice processing operations.

Shaker Separating Screen

Filtration

As with pre-centrifugation, the juice stream should be cleaned up as much as possible to reducetreated volume and increase throughput. There are many filtration systems well suited tovarious juices. These range from plate and frame filters, fitted with porous cellulose pads,(Figure below) to plastic, ceramic, or metal membranes. Diatomaceousearth mixed with theliquid serves to greatly increase the surface area and porosity of the filter bed and hence theparticulate absorbing capacity of the filter.


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Plate, frame and vacuum filter

Deaeration

In the operations described crushing, comminution, pressing, shaker separation, centrifugationand filtration, the fruit and juice are subjected to considerable aeration. The inclusion ofoxygen can promote enzymatic browning, destroy nutrients, modify flavour andotherwise damage quality. Therefore, care should be taken to perform these steps rapidly, atlow temperature and/or protect the material from oxygen, if possible. Sometimes preheating toinactivate natural and/or added enzymes is useful, provided rapid cooling follows.

Deaeration can be accomplished by either flashing the heated juice into a vacuum chamberor saturating the juice with an inert gas. Nitrogen or carbon dioxide is bubbled through thejuice prior to storing under an inert atmosphere. Clearly, once air is removed or replaced byinert gas, the juice must be protected from the atmosphere in all subsequent processing steps.Deaeration, especially flashing off at high temperature, can also remove some desirablevolatile aroma, another compromise facing the juice technologist.

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Mostly for manufacturing of juices like orange, grapes, pomegranate etc mainly two types ofmachines are required.

Juice Extracting Machines

Juice Filling and packing Machines

Orange juice extracting Machine (US $ 1-9999)
http://www.alibaba.com/product-gs/552397578/0_5t_1_5t_2t_stainless/showimage.html


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Grape Juice extractor (US $ 1-9999)

Pomegranate Juice extractor (US $ 1-12000 )


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Orange juice machines (US $ 10,000-10,00,000)

Grape Juice Machines (US $ 10,000-3,50,000)
http://www.alibaba.com/product-gs/483115644/Orange_Juice_Processing_Machines/showimage.htmlhttp://www.alibaba.com/product-gs/483115644/Orange_Juice_Processing_Machines/showimage.html


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Pomegranate Juice machines (US $ 2000-50,000)

Unique Industries - India118, Kamal Estate, Nr- Bombay Conductor, Gidc Vatva, Ahmedabad, Gujarat, India

Harikrushna International - India3rd Eye-2, Third Floor-306, Opp. Parimal Garden, Near Panchvati Cross Road, C. G. Road., Ahmedabad,

Gujarat, India

Shri Ram Piston-IndiaNo. 4 Mahadev Vadi Opposite Laxminagar Haveli Rajkot Gujarat - 360 004 India

Zhangjiagang Jiayuan Machinery Co Ltd.Jiangsu, China (Mainland)

Shanghai Jimei Food Machinery Co., Ltd.Shanghai, China (Mainland)

Zhangjiagang Longquan Machinery Manufacture Co., Ltd.Jiangsu, China (Mainland)
http://jimei888.en.alibaba.com/http://zjglq.en.alibaba.com/http://zjglq.en.alibaba.com/http://www.alibaba.com/product-gs/322282595/juice_extraction_machine_juice_extractor_machine/showimage.htmlhttp://zjglq.en.alibaba.com/http://jimei888.en.alibaba.com/


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The initial Capital Investment required to start a juice manufacturing factory are estimated in

the table below.

Particulars`

Plant & MachineryFruit Juice ExtractorsPacking Machine

5,00,00050,00,000

Land 250,00,000

Construction 50,00,000

Vehicles 25,00,000

Furniture & Fittings 15,00,000

Other Pre-operating exp 20,00,000Total Fixed Assets (A) 41,500,000Inventory 15,00,000

Cash 20,00,000

Other Initial Exp 10,00,000

Initial Marketing Cost 10,00,000

Total Working Capital (B) 55,00,000Total Investment (A+B) 47,000,000

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Storage facilities are required at both times - before starting production and after the juice are

manufactured.

Storage facilities

There are essentially three types of storage buildings: air cooled storage, mechanicallyrefrigerated storage and refrigerated and controlled-atmosphere (CA) storage.

Air-cooled storage

These storage houses cool by admitting cold night air (applicable climates) at inlets near thefloor of an insulated building and forcing upper accumulated warm air out at outlets near theceiling. Both openings are closed during the day. These storages are economical and effectivein areas where the night air becomes cooler than the accumulated air in the storagehouse.

Mechanically refrigerated storage

For longer periods of storage than is afforded by the air-cooled storages, mechanicalrefrigeration is needed. This would become necessary to extend the season on fresh-marketfruits or to extend the cooling of processing fruits because the volume is so large they can notbe completed in the period of time afforded by the air-cooled storage situation. Normallytemperature of-25 C to 10 C is required to store fruits like oranges, grapes etc.

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Meaning of some terms

Plant Morphologystudy of development, form and internal structure of plants.

Fruit Morphology - study of development, form and internal structure of fruits.

Senescenceageing

Centrifuge-an apparatus that rotates at high speed and by centrifugalforce separates substances of different densities, as milk and cream.

Inertnot able to react

CAGRCompounded Annual Growth Rate

GAPGood Agricultural Practices

Lyehighly concentrated aqueous solution of potassium hydroxide or sodium hydroxide

Abrasiona scraped spot or area

AlbeitAlthough

Diatomaceous - consistingoforcontainingdiatomsortheirfossilremains.

Deaeration to remove air or gas

Comminution

to crush completely

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http://dictionary.reference.com/browse/centrifugal+forcehttp://dictionary.reference.com/browse/centrifugal+forcehttp://dictionary.reference.com/browse/centrifugal+forcehttp://dictionary.reference.com/browse/centrifugal+force


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Juice Manufacturing Industry Research Report