Onions are undeniably the single most important foo preparation ingredient. Its availability around the year is the obvious most sought after scenario around the world. Frozen chopped IQF frozen onions is the clear answer. MAZDA are in the forefront in this discipline of the Food Processing Sector, with complete plants from conceptualization to location-specific project design and implementation. More about us at www.mazmach.com

1. Project code: MAZDA N-106
ONIONS IQF PLANT
-FROZEN PRODUCTS

2. NOTES
Individually Quick Frozen (IQF)
products are value added preserved food
products. Onions, various fruits and
vegetables, meats, sea food are thus
preserved and marketed.p
White onions are preferred. General diced,
sliced onions are processed into IQF varieties.
Recommended Sizes
1/4" 3/8" 1/2" 3/4" 1"
Diced
Strips
Mazda Speciality Machine Systems,
Scale NTS
Packaging
Several different packaging options are offered. Standard sizes range from a
40 lb box to a 1,300 lb industrial reefer cargo totes.
INDIA
SHEET # 2011.N 106.01
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DSN

3. Onions are fed in manually. A transport system leads the onions
continuously through the blades. The blades are positioned so that
they adjust to the size of the onions largely independently of each
other.
The design of the probe / scanner that determines the position of the
blades ensures that, as far as possible, only what is necessary is cut
off the onions. Precision ensures less unnecessary waste!
After inserting the onions into the transport facility, it holds them so
tightly that they cannot shift around any more. This means that theg y a ey ca o s a ou d a y o e s ea s a e
leaves and roots are normally cut off with great accuracy by blades.
This precision cutting saves on a lot of subsequent manual work at
the inspection bench. – The onions and their tops and tails are
ejected separately from the machines.

4. Sliced IQF Onion:
2-4 mm
3-5 mm Green Spring3-5 mm
4-6 mm
5-7 mm
G ee Sp g
Onions- diced IQF
Diced IQF Onion:
4 mm
6 mm
10 mm
Mazda Speciality Machine Systems INDIAScale NTS
10 mm
20 mm
Mazda Speciality Machine Systems, INDIA
SHEET # 2011.N 106.11
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5. Notes:Notes:
CUTTING
Mazda Speciality Machine Systems
Data Sheet # 2013.156

6. NOTES
The onions are stored in
boxes at temperatures of 33º-
34º until further processed.34 until further processed.
Onions are topped and peeled
then diced to meet customer’s
specifications.
After the onions are diced they
are blanched and individuallyare blanched and individually
quick frozen.
Mazda Speciality Machine Systems,
Scale NTS
INDIA
SHEET # 2011.N 106.04
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DSN

7. Fresh produce handling equipment

8. IQF Freezing methodologyIQF Freezing methodology
Mazda Speciality Machine Systems INDIAScale NTS Mazda Speciality Machine Systems, INDIA
SHEET # 2011.N 106.06
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DSN

10. Mazda Speciality Machine Systems INDIAScale NTS Mazda Speciality Machine Systems, INDIA
SHEET # 2011.N 106.15
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DSN

12. Extremely quick freezing of the surface on first bed reduces de-hydration to ay q g y
minimum. Low or zero lumps keep yield to a maximum.
Mazda Speciality Machine Systems,
Scale NTS
INDIA
SHEET # 2011. N 106.07
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DSN

14. BLAST FREEZING IS A LOWER COST OPTION

15. Notes:Notes:
FREEZING
VACUUM-
PACKAGING
Mazda Speciality Machine Systems
Data Sheet # 2013.157

16. PRECONDITION FOR
SELECTION OF
TECHNOLOGY
1.1 Product
Various fruits, vegetables,
meat, poultry and dairy
d t
Frozen Options
------------------
-IQF Diced Product:
1/4"products
Nominal capacity
1200 kg per hour
In feed temperature +5 C
Out feed temperature -18 C
(levelled out)
1/4
3/8"
1/2"
3/4"
------------------
- IQF Onion Strips:
SLICED IQF
(levelled out)
1.2 Logistic data
Fed from conveying elevator
via in feed distribution
shaker.
Even feeding rate ± 5 %.
Q p
3/8"
1/2"
3/4"
------------------
- Onion Fines
Wet products shall be well
dewatered.
1.3 Production process
Freezing IQF
------------------
- Custom Cuts
------------------
- Blanched
------------------
DICED IQF
Mazda Speciality Machine Systems,
Scale NTS
INDIA
SHEET # 2011.N 106.09
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DSN

17. Packaging OptionsPackaging Options
IQF diced onions are packaged in plastic film pouches,
bags ( even gas flushed), or in corrugated cartons
with a plastic bag lining.
Options range from Automated FFS machines with
weigh fillers to very simple pouch filling and sealing
machines ( As shown)
Mazda Speciality Machine Systems,
Scale NTS
INDIA
SHEET # 2011.N 106.10
Scale NTS
DSN

18. A By Product:
A frozen onion food product is prepared by a process which includes the steps
of peeling and slicing fresh uncooked onions, cutting the resulting onion slabs
into pieces most of which are composed of two or more lengths of onion
scales in side-by-side relationship, separating each piece into its individual
l t ti th t d t ith b tt i t dscales or nuggets, coating the separated nuggets with a batter mixture and
quick-freezing.
The separating operation includes the use of hydro, mechanical and vibratory
forces to produce a continuous supply of separated nuggets ready for the
coating operation If desired the coated cubes can be partially fried beforecoating operation. If desired the coated cubes can be partially fried before
freezing.
Mazda Speciality Machine Systems INDIAScale NTS Mazda Speciality Machine Systems, INDIA
SHEET # 2011.N 106.12
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19. PROJECT REQUISITESPROJECT REQUISITES:
Plant Capacity: 2.20 tonnes per hour fresh onions
Plant Area: 1000 sq. mtrs
Electric Power: 175 KW
Steam: 0 5 tph at 10 kg/sq cmSteam: 0.5 tph at 10.kg/sq.cm
Water: 2500 lph
Compressed air: 100 lpm at 7 bar
Others: A Cold Store
Sensitivity factors:
Mazda Speciality Machine Systems INDIAScale NTS Mazda Speciality Machine Systems, INDIA
SHEET # 2011.N 106.17
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20. Y
SUE$
PROFIT
AREA
BREAK EVEN POINT
B
OSTANDREVEN
LOSS
FIXED COST LINE
CO
BREAK
EVEN
VOLUME
AREA
0
P Break Even Point
Mazda Speciality Machine Systems INDIAScale NTS
ANNUAL PRODUCTION (Units)
0
X 100
=
Annual Fixed Cost
-----------------------------------
Annual Fixed Cost + Profit
Mazda Speciality Machine Systems, INDIA
SHEET # 2011.N 106 . 18
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21. NOTESFinancial InvolvementsFinancial Involvements
Land and Building As recommended in the PDD
Plant Equipment. USD 400,000.- to 500,000.-
-depending on freezer option chosen
Production of IQF Onion products venture beyond a-
Break Even Volume of: 1000 Kgs per hour -diced frozen onions
And economically sustainable: at 20 percent enhanced production.
A plant capacity of: 2200 Kgs per hour -Fresh onions.A plant capacity of: 2200 Kgs per hour Fresh onions.
Pay back period under normal conditions: 2 Years
.
Mazda Speciality Machine Systems,
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INDIA
SHEET # 2011. N 106. 19
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22. Produce that can also be
processed at the facility.
Potato cubes and Green Spring Onions- diced

23. Produce that can also be processed at the facility…
Mixed vegetables, peas, with minor additions of
equipment