1. 1 Background:
Dehydrated onions and Garlic are marketed in different signifiers like chopped. kibbled. minced. granules and pulverization for the domestic and export markets. The merchandise is besides marketed in the signifier of toasted pieces processed in hot air closed uninterrupted system that preserves the natural unity of the merchandise without any loss of spirit. coloring material and olfactory property. The nutrient processing sector has recorded dramatic advancement since 1990. The end product of processed nutrient industry is estimated to be Rs. 25000 crores per twelvemonth with demand growing rate of around 10 % per annum. On a unsmooth estimation around 20 % of all processed nutrient points utilise upto 5 % Onion & A ; Garlic pulverization. In footings of demand statistics this means increased demand of both these merchandises from nutrient treating entirely. Use of Garlic pulverization in drug & A ; pharmaceutical industry as pills. pearls and capsules besides adds to the overall demand. Growth of drug industry has been about 27 % to 30 % since last many old ages. 1. 2 THE PROPOSED DEHYDRATION UNIT:
Keeping in position. the uninterrupted addition in the demand of these of import nutrient and drug company ingredients. the booster of this venture have identified a rural location at a small town Soundane. Taluk Malegaon in the Nasik Dist of Maharashtra. Apart from being in the propinquity of urban metropoliss like Nasik. Pune and Mumbai. the location is besides strategically located near the industrial hub of New Mumbai. Vapi. Surat etc. and has logistic linkage with the rail. route and sea and airdrome to work the export potency. The location is merely 25 Km from Manmad railroad station. 65 Km from the Nasik metropolis and 285 kilometer from the Mumbai city. 1. 3 PROCESS IN BRIEF:
The rule of saving by desiccation procedure is to take the wet content of a stuff to a degree where micro-organism may non be able to turn and botch it. Dehydration of onion and garlic by Sun drying is the oldest known method. Now modern techniques have been developed for desiccation. In this procedure. the dehydrated merchandise has better spirit. colour. olfactory property. re-hydration. acceptableness. etc. in comparing to sundried dehydrated merchandise.
1. 4 USES & A ; APPLICATION:
Dehydrated onion is used as condiment and seasoning agent in fabrication of tomato catsup. sauces. salad. pickles. Indian relishs. meat sausages. masala staff of lifes and buttockss. breakfast nutrient etc. .
Garlic in its natural signifier is used for spicing of veggies. meat merchandises and salted infant nutrients. Dehydrated Allium sativum is used for AIDSs in digestion and for soaking up of nutrient holding a telemetric and antiseptic belongingss and used in some medicative preparations. Garlic pulverization is utilized as spice additive. appetiser and seasoning agent in cooled and instant nutrients. Garlic pulverization has besides now been established as an ayurvedic medical specialty for bosom and arthritic upsets. Garlic pills. pearls. capsules etc. are some of the popular medium adopted by pharmaceutical companies to market this merchandise in domestic & A ; export market.
Dehydrated Garlic pulverization
1. 5 Industry Status:
Most of the Onion & A ; Garlic pulverization workss in the state are located in Gujarat. Madhya Pradesh and Maharastra State due to the abundant handiness of these trade goods in the western provinces. All the units are in little graduated table sector with combined capacity of 1800 Tonne per annum. The capacity use in this industry has by and large been about 75 % . In the last decennary. 100 % production of Garlic pulverization was being exported. but of late. around 70 % production is exported as pulverization. 20 % is consumed domestically by pharmaceutical industry and the balance 10 % is besides exported as value added merchandise of pharmaceutical industry. Garlic is sometimes imported into India as the domestic production is non sufficient. However there is high import responsibility to counterbalance the domestic manufacturers.
Tamil Nadu. peculiarly Chennai. is the market for imported Allium sativum. World’s Largest manufacturer of Garlic is the USA. Kyolic. Kwai. Garlicin. Pure-Gar are the major trade names of medicative merchandises. Producing Allium sativum for medicative intents is more complex. China & A ; Argentina are the following of import states in this trade for low monetary values of merchandises. Garlic is a really labour intensive harvest The culinary market includes chiefly fresh Allium sativum. both organic and non-organic. and smaller markets for dried or dehydrated garlic. There is small processing that is necessary for the culinary market.
2. 0 MARKET POTENTIAL:
2. 1 GENERAL:
The market for dehydrated merchandises are nutrient processing industries and the domestic consumer market. Among the consumer markets. the merchandise finds its arrangement in all self-service counters. departmental shops. “A” and “B” category retail mercantile establishments of food markets and commissariats. Dehydrated veggies can be used in the readying of puloas. soups. etc. . while dehydrated pulverizations can be used as toppings on cooked veggies and bite nutrients. They provide a assortment of gustatory sensations appealing to the roof of the mouth. These merchandises constitute ready add-ons to tin soups. salads. beefburgers. pizzas & A ; other fast nutrient readyings. Besides suited for varied nutrient readyings strong and natural spirit & A ; gustatory sensation is desired. Greatly sought after as cardinal ingredient of Sauces. canned. dry and frozen nutrient. salad dressings. meat readyings and other nutrient merchandises. Therefore. the major terminal user sectors from where the demand for Garlic pulverization emanates are Food spices. salt-cured bites ; canned bites ; Drugs and Pharmaceutical Industry etc. The nutrient processing sector has recorded dramatic advancement since 1990. The end product of processed nutrient industry is estimated to be Rs. 25000 crores per twelvemonth with demand growing rate of 8 % per annum.
On a unsmooth estimation around 20 % of all processed nutrient points utilise 3 to 5 % Garlic pulverization. In footings of demand statistics this means increased demand of Garlic pulverization from nutrient treating entirely. Use of Garlic pulverization in drug & A ; pharmaceutical industry as pills. pearls and capsules is estimated at Rs. 2 crore. Growth of drug industry has been about 27 % to 30 % since last many old ages. A demand potency of Rs. 5 crore for Garlic pulverization from this sector can be safely forcast. Thus the entire demand of Garlic pulverization by twelvemonth 2010 will be in the part of Rs. 20 crores. This is more than the dual against the estimated production from bing 15 – 20 units and the new capacity probably to be created in the close hereafter. The big demand supply spread is perceived in future. For a new enterpriser come ining into this field the market chances are bright.
The dehydrated merchandises are introduced by the nutrient processing companies into the domestic market in retail package signifiers under different and appealing trade name names. The construct has been introduced for the convenience of Indian working adult females. families. hotels. catering. resorts. eating houses. nutrient industry. etc. At a clip when several houses are providing to the demands of abroad consumers to their fullest satisfaction. their attending is drawn to function our ain state adult male.
The Indian economic system has been fast developing and tendency towards fast nutrient have come along with this. which is a boosting factor for dehydrated merchandises. The troubles faced in utilizing Onion and Garlic in fresh signifier has neccessitated to present in preserved signifiers viz. Kibbled. Flakes. Granules. Minced & A ; Powder. These have served the fast nutrient and pharmaceutical industries really good and are no uncertainty a blessing for the cookery coevals in the old ages to come.
2. 2 USA SCENARIO & A ; EXPORT MARKET:
The U. S. garlic industry is concentrated in California’s cardinal vale ( Fresno. Kern and Monterey counties ) and consists of manufacturers of fresh. dehydrated and seed Allium sativum. It is estimated that fresh garlic histories for 20 to 25 per centum of domestic production. while dehydrated garlic represents 60 per centum of production. The staying 15 per centum is used for garlic seed. During the last 20 old ages. the U. S. garlic industry has experienced lifting production and an overall upward tendency in monetary value. A greater consciousness of the wellness benefits of garlic ingestion and the lifting popularity of cultural culinary arts has contributed to the increasing demand. In footings of trade. entire garlic import degrees typically summed to an sum equal to 20 per centum of domestic production. while exports accounted for about 15 per centum of domestic production. However. in the old decennary. a rush in Chinese fresh Allium sativum imports drove the fresh garlic import to fresh garlic domestic production ratio up to 28. 5 per centum. Imports rose by 747. 38 per centum in the old decennary.
Several Indian companies are already exporting to Europe. Canada. Australia. Japan and Africa. Samples sent to prospective export marks have fetched overpowering response. Hence these companies are poised to spread out their market range and derive a conspicuous place in the universe market.
3. PRODUCTION & A ; TECHNICAL ASPECTS:
3. 1 Natural Materials:
The lone natural stuff required for this undertaking is Onion and Garlic. Merely manus picked big bulbs of Garlic and good quality white or ruddy onions are selected for processing. The output is taken approximately approximately 12 % of the input. The study and the fiscal facets are estimated on the footing of 1250 MT of one-year processing in 300 yearss.
Onions for processing are grown from specific assortments best suited for desiccation. Specific strains of the Creole Onion. Southport Globe Onion. and the Hybrid Southport Globe were developed by the desiccation industry. They are white in colour and procedure a higher solid content which yields a more flavourful and acrid onion. There are two general classs of garlic. hard-neck and soft-neck.
3. 2 THE Fabrication Procedure:
The general procedure for the desiccation of veggies. onion and Allium sativum is choice of natural stuffs. screening. crunching. rinsing. readying of veggies ( skining. cutting or paring etc. . cubing / sliting / pricking ) . paling. sulfuring. drying. packaging and labeling. The procedure adopted for assorted points differs in regard of preliminary intervention. temperature and humidness status.
Onion desiccation involves the usage of a uninterrupted operation. belt conveyer utilizing reasonably low temperature hot air from 38 – 104oC. The heat originally was generated from steam spirals. but now natural gas is more popular. Typical processing workss will manage 4500 kilogram of natural merchandise per hr ( individual line ) . cut downing the wet from around 83 per centum to 4 per centum ( 680 – 820 kilograms finished merchandise ) . These workss produce 2. 25 million kilogram of dry merchandise per twelvemonth utilizing from 35 – 46 MJ/dry kilogram produced ( +14 MJ/kg of electrical energy ) . or 9. 3 MJ/kg of H2O evaporated. An illustration of one type of treating equipment. the Proctor dehydrator. is a single-line unit 64. 5 ten 3. 8 thousand broad. necessitating 2450 M3 of air per minute and up to 42 million kJ per hr. Due to the wet remotion. the air can. in some instances. merely be used one time. and therefore. is exhausted. Particular silica gel–Bryair. dehydrations units are required in the concluding phase. Approximately $ 200. 000 in fuel are. therefore. used in a single-line drier in a year’s operation ( 180 yearss ) .
Main merchandises of Garlic are: Garlic Oil Capsules. Odor Controlled Dried Garlic Products. Aged Odorless & A ; Garlic Extract. The volatile garlic oil is obtained by steam distillment from the crushed bulbs or cloves of the common Allium sativum works. Garlicin is the chief content in garlic oil.
3. 2. 1 ONION Dehydration:
Dehydrating onions is a great manner of continuing them in an easy-to-use signifier. Due to the fact that they are 88 % H2O. they shrink quite a batch when dried. which means they take up less storage infinite & A ; will maintain for a long clip. Due to the strong odor of onions. it’s advisable non to make any other green goods at the same clip! Basically talking. to dry onions. merely skin & amp ; slit them into 5mm pieces or rings ( or whatever size the client demands ) . Spread them onto Mesh Sheets & A ; dehydrate at 55 deg C for 10 hours or until they are sharp. Similarly. to turn the dried onion into flakes or pulverization. set them into a nutrient processor or liquidizer & A ; procedure until land into the coveted size. To make onion salt. blend equal parts salt with finely ground onion pulverization. To hive away. set into an air-tight container & A ; shop in a dry. dark & A ; cool topographic point. However. these are merely domestic tips. To bring forth dehydrated merchandises on a commercial graduated table. all above operations are required to be carried out on an industrial graduated table in bigger equipment.
It was observed that the bing onion desiccation workss were confronting jobs sing quality of dehydrated onion particularly color. gustatory sensation. texture. etc. Besides. the drying clip was high. Keeping the above positions in head. the research work on desiccation of newly harvested Talaja local. white cultivar of onion. was taken for the surveies by some Indian Scientist in Michigan University. Its physical and thermic belongingss were determined. A laboratory graduated table thin bed drier was developed for carry oning the experiments on desiccation. The effects of independent variables. viz. . the drying air temperature. speed of air and thickness of onion piece on the drying clip. centripetal quality. rehydration features and bacterial counts were studied.
Based on the research findings. it could be recommended that the desiccation of white onion should be carried out at 76 °C drying temperature and 27 m / min speed of air. maintaining 3 mm thickness of piece to acquire good quality of dehydrated flakes with the lowest value of drying clip ( 58 min ) . Garlic Powder is obtained from skining. drying and pulverizing of Garlic bulbs which are normally available as vegetable additives. Garlic pulverization can be manufactured by Automatic flaking. spray drying & A ; pulverizing procedure and Semi automatic batch type flaking drying & A ; chattering procedure. The semi automatic batch type procedure is suited for little graduated table sector.
3. 2. 2 DRYERS USED IN DEHYDRATION PROCESS:
TRAY Dryers: Tray Dryer are used for Drying little and average measure stuffs. The stuffs are held in SS Trays with SS net underside. Hot air is blown through the stuff in 2 waies at interval ( top to bottom and bottom to exceed ) with the aid of a particular reversing flow valve. The drying will be fast and more unvarying. The warming can be Electric or Steam or LPG. The outer organic structure. doors etc. are with dual walled insulated MS panel punctually painted. Automatic temperature control is provided for each driers
TUNNEL TYPE DRYERS: Tunnel type drier is a uninterrupted Dryer. for treating wet solid stuffs. It is used for treating chopped veggies. onion. Allium sativum and even fruits etc. as needed. Materials fed in Trolleys or Trucks moves inside the tunnel on tracks from feeding terminal to the bringing terminal. Dried stuffs are obtained at the bringing terminal. Hot air is blown as through flow. or coincident flow or as counter flow harmonizing to the peculiar design.
The latest technique for desiccation of vegetable known as osmotic desiccation has been developed by BARC. Bombay.
3. 3 POWDER Devising:
Garlic or Onion pulverization can be manufactured by following procedures • Automatic flaking. spray drying & A ; pulverizing procedure. • Semi automatic batch type flaking drying & A ; pulversing procedure. The semi automatic batch type procedure is suited for little graduated table sector as all the qualities of Garlic and Onion are maintained in the pulverization besides. The procedure consists of flaking the bulbs and draw outing the same. so that the buds are separated from screen. The clean buds and flaked onion. as the instance may be. are now dehydrated. dried and pulverised. The pulverization therefore obtained is packed in polyethylene bags of 1 Kg and 5 Kg capacity.
3. 4 Different Forms:
Dehydrated onions and Garlic are produced in modern units in different signifiers like chopped. kibbled. minced. granules and pulverization for the domestic and export markets. The merchandise is besides in the signifier of toasted pieces. processed in hot air closed uninterrupted system that preserves the natural unity of the merchandise without any loss of spirit. coloring material and olfactory property. The procedure is wholly natural with no usage of any preservatives or chemicals. The installation for doing onion and garlic pulverization upto 500 Mesh is exhaustively extremist –modern.
3. 5 POLLUTION CONTROL:
The H2O wastewater in this industry is coming from cleaning. rinsing. pretreatment and blanching of natural stuff. It is advisable to prove the H2O discharge as per specification laid down by Bureau of Indian Standards or the State Pollution Control Board. The proviso of H2O intervention has been made in this undertaking study. The enterpriser should hold to reach State Pollution Control Board for counsel in the affair.