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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
1
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
11
13
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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