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FOOD PROCESSING PLANT LAYOUT AND DESIGN
Er. A. Poshadri
SMS-Food Technology
Krishi Vigyan Kendra, PJTSAU, Adilabad, T.S
Email: achinna.fst@gmail.com
Cell No: +919492828965
Food processing aims to transform the agricultural products into
food and also make food more digestible, nutritious
and extend the shelf life.
• Farmers–get better returns, higher yield, and lower the risks
drastically,
• Consumers-have access to a greater variety, better prices and
new products,
• Economy-gets benefitted with new business opportunities for the
entrepreneurs and the work force gets employment
Opportunities for Agro Processing
• Contract Farming
• BCT in FARMAR/IoT devices
• On farm Processing
• Grading & Sorting
• Standardization
• Self Help Group
• Agmarknet
• Rural Gudowns
• DEMIC
• Store at Door step
The Farming Produce
Trade and
Commerce (Promotion
and
Facilitation) Ordinance, 20
20
The Farmers
(Empowerment and
Protection) Agreement
on Price Assurance and
Farm Services Act, 2020
Strength  Higher food Production
 Rising per capita income coupled with increasing awareness
among consumers
 Rapid urbanization is driving consumerism in Tier-II & Tier-III
cities
 Growing penetration of food and beverages manufacturing
companies in rural areas
 Tailor made flavors and region specific tastes
Weakness 1. Lack of state of Art Processing facilities
2. Limited shelf life for Milk, Meat and horticulture produce
3. Fresh produce preferred over processed foods
SWOT Analysis for Food Processing
Opportunities  Rising business and product innovation
 Untapped rural markets
 Low-cost price strategy is adopted so as to make the product
affordable to the consumers
 Rising farm fresh produce and health foods
 Better product packaging and preservation
 India to be the youngest nation by 2025
 Seven Point Strategy for Doubling of farm income
Threats • Product taste variations
• Competition from multinational companies
• Safety of Processed foods and adulteration
• Increasing life style diseases in India
Gaps noticed
 Small and Medium industries/Poor plant layouts and
designs
 No scope for expansion in plant due to poor design
 Low penetration in rural area and high prices for low
volume
 Poor sanitation practices
 High cost of production and Poor export subsidies
Consumer Desires
• Good and Healthy Foods
• Available all year round
• Sufficient Supply
• Conveniently packaged
• Sold in (super) all types of markets
(including e-retail platforms)
• Long shelf life and exotic taste and flavours
• Always Fresh
• Appealing taste & Appearance
• Quality/Autentically sourced Processed
Foods
• High in available nutrients
Market Challenges
• Globalisation
• New distribution strategies
• New Processing Technologies
• New Materials/Additives
• New Risks
• Climate Change
• Energy Efficiency
• Water Supply
• Procurement of
quality raw materials
• Greed- Fraud
Food Plant: Enclosed area into which food materials are brought
and modified in various ways to manufacture an end
product.
• Plant layout : means allocation of space and arrangement of
equipments in such a manner that overall operating costs are
minimized
Types of Plant layout:
1. Product layout
2. Fixed layout
3. Process layout
4. Combination layout
Objectives of Plant layout
• Minimize material handling cost.
• Effective utilization of men, equipment and space.
• Make effective utilization of cubic space.
• Provide for employee convenience- safety & comfort.
• Minimize investment in equipment.
• Minimize overall production time.
Principles of Plant layout:
1. Principle of minimum movement.
2. Principle of space utilization.
3. Principle of flexibility.
4. Principle of interdependence.
5. Principle of safety
6. Principle of smooth flow
7. Principle of supervision
8. Principle of satisfaction
The location of an industry is determined by
Primary Factors:
– Supply of raw materials
– Nearness to the market
– Transport Facilities
– Supply of Labour
– Availability of power
– Supply of Capital
Secondary factors:
1. Proximity to customers
2. Policies of management
3. Plant location
4. Total Cost
5. Volume of production
6. Availability of floor space
7. Nature of manufacturing process
Facility Layout :
It is an arrangement of different aspects of manufacturing in an
appropriate manner as to achieve desired production results.
Facility layout considers
• available space,
• final product,
• safety of users and facility and
• convenience of operations.
Product or Line layout:
• Machines and equipments are arranged in one line depending
upon the sequence of operations required for the products
Production control.
• The materials move from one work station to another
sequentially without any back-tracking.
• The output of one machine becomes the input of the next
• All the operations including assembly, testing, packing must be
included in the line.
Advantages of Product or line Layout
• Low cost of material handling
• Smooth operations
• Continuous flow of work
• Optimum use of floor space
• Shorter processing time
Disadvantages of Product or line Layout
• High initial capital investment in special purpose machine.
• Breakdown of one machine will hamper the whole production
process.
• Heavy overhead charges.
Fixed layout
• The major product being produced is fixed at one location.
• Equipments, labor and material are moved to that location.
• All facilities are brought and arranged around one work center.
Advantages and disadvantages of Fixed Layout
• It saves time and cost.
• The layout is flexible.
• It is economical
• Production period being very long, capital investment is very
heavy.
• Very large spaces required.
• There's a possibility of confusion and conflicts among
different work groups
Process layout:
• Machines of a similar type and performing similar operations are
arranged together at one place.
• The work has to be allocated to each area in such a way that no
machines are chosen to do as many different jobs as possible
• Advantages of Process layout:
• Lower initial capital investment.
• Lower overhead costs.
• Change in output design can be adopted to the output of variety of
products.
• Breakdown of one machine doesn’t lead to complete stoppage.
• Effective supervision.
• Great flexibility.
Watre Flow 9.5 - 11.5 LPM
Slicer feed auger
Slicer infeed Water spray:
Conveyor
Water spray: 15 LPM Slicer 15 LPM
Bindicator 15 LPM 10 LPM
Flume
Pre- washer conveyor
Surge Hopper
Disadvantages of Process layout
• Higher material handling costs.
• More skilled labour is required which further increases the cost.
• Time gap in production is higher.
• Work in progress inventory is high, leading to greater storage
space.
• Costly supervision.
Combined layout:
• Certain manufacturing units may require all three processes, namely
intermittent processes (job shops), the continuous process ( mass
production shops), and the representative process combined process
( miscellaneous shops).
• In most of industries, only a product layout or process layout or fixed
location layout does not exist.
• Thus in manufacturing concerns where several products are
produced in repeated number with no likelihood of continuous
production, combined layout is followed.
• Generally a combination or product & process layout or other
combination is followed in practice
Advantages of good layout
• Labour cost
•Increase in productivity with more units being produced
per man hour.
•Reduction in the number of workers.
•Minimization of motions between operations.
• Production control
•Increased production rate.
•Providing convenient and adequate storage points.
•Increased production rate.
•Improved ability of forecasting manufacturing time.
• Supervision
• Lesser requirement of supervision.
• Reduction in time spent on inspection.
• Reduction in cost of inspection.
• Other manufacturing costs
• Reduced consumption of power.
• Minimization of scrap and defectives.
• Better quality due to reduced handling.
• Reduced costs of maintenance.
• Improved utilization of materials
Factory site
• Permission from both national and local governments.
• Comply with legislations.
• Facilities for discharge of waste materials.
• Determination of possible hygienic hazards.
• Basic arrangements for workers.
• Close to market
FSSAI –Food safety Compliance
System
• https://foscos.fssai.gov.in/public/guest-login
• https://foscos.fssai.gov.in/public/assets/docs/
KoBwiseDocumentsrequiredforLicense.pdf
• https://foscos.fssai.gov.in/public/assets/docs/
DocumentsrequiredforRegistrationCertificate.
pdf
• file:///D:/FSSAI%20Jobs/PPT%20food%20plan
t%20layout/KindofBusinessEligibility.pdf
GENERAL DESIGN PRINCIPLES
• Various services
• heating
• lighting
• ventilation
• waste disposal
• Should operate efficiently.
• Fire resistant.
• Sound transmission and vibration should be minimized.
• Should resist various stresses and strains.
• Must conform to high standard of hygiene
MACHINE LAYOUT
H-LAYOUT:-
• Mixing and packing at the ends
• Production flow is smooth
• Pre -Mixing can be done on the same floor
• No bends hence less maintenance of deg conveyors 90
• Less wastages
L-LAYOUT:-
• Bends and combination bends required
• Pre - Mixing to be located on the first floor
• Maintenances cost a bit
• Best suited for area with Less space length wise
LAYOUT AND DESIGN OF PLANT
• Good Manufacturing Practices (GMP)
• Bio-security
• Black zone and White zone
• No cross movement of labours/ products/ equipment
• White zone - Exit of finished product only
• Black zone – Unhygienic
• Always a forward movement of the products
ROOFING AND LIGHTING
• Flat or slightly pitched.
• Height - critical factor.
• Roof - source of natural light.
• Lighting is from two sides: illumination is
more uniform shadowing is restricted.
• Direct sunlight - glare problems and
temperature increases
ROOFING AND LIGHTING
• Single glazed windows = heat loss restrict 10%
of the roof area.
• Wall window - glazed area of at least 30% -
• Opening windows are not recommended.
• Artificial lighting - Advantageous.
• Shadows and glare to be avoided.
• Intensity – adequate & should spread
uniformly
CEILINGS, WALLS AND FLOORS
• Junctions between ceiling and walls should be rounded and
sealed against dust and water
ROOFING AND LIGHTING
• Smooth and free from cracks and crevices
• Resistant to chemical and biological
agents.
• Impervious to grease and water.
• All wall angles, corners and junctions -
sealed and rounded
• Coving of the wall floor junctions to a
height of approx. 15 cm
FLOORS AND DRAINS
• Material should be impervious, Durable and impact
resistant.
• Resistant to grease, cleaning agents including hot water or
steam and to biochemical and microbial attack.
• Should be free from cracks, crevices
• Surface should be non-slippery
• Non-slippery floor- surface additives such
as carborundum
FLOORS AND DRAINS
• Floor - easy to clean and disinfect.
• Slope – 1:40 to 1:60 towards drains.
• Distance between drains:- restricted to 5 m
• Washing fluids should pass from cleaner to dirtier
areas
FLOORS AND MATERIALS
Prone to dust,
little resistance to acids or
to biochemical attack and
liable to wear unevenly
forming pits.
DRAINAGE SYSTEM
• Totally covered drains - avoided.
• Should have smooth, vertical sides with a rounded base and be
slopped to allow for adequate water velocity.
• Depth should be sufficient - prevent over flow.
• Should be sited adjacent to but not directly against walls
VENTILATION AND AIR CONDITIONING
• Hygienic food processing and/or comfort of
personnel.
• For overcoming condensation
• To minimize the build up of offensive fumes and
odors.
• Optimum environment temperature
21-22°C (for sedentary occupation)
13-14°C (for heavy manual work)
VENTILATION AND AIR CONDITIONING
• Humidity: 30-70%
• Rate of Air Change:
– Cooking areas 20 changes / hour
– Stores and Office 1/2 changes / hour
• Air flow - in the opposite direction to the process
flow
• Fresh air - heavy manual work.
• Air entering factory - filtered or treated
• Excess pressure with in factory relative to the
outside is recommended.
FACTORY LAYOUT
Reception area
• easy access for transport.
• Efficient unloading to avoid deterioration in the
incoming raw material.
• Liquid – may require pumps
• Dry – may require mechanical means
FACTORY LAYOUT
Storage area
• Site- efficient flow to processing line.
• Room should be clean, adequate space for inspection and
cleaning, good air circulation and correct temperature and
humidity.
• Protection from dust, insects, rodents
• Food material should not be placed directly on the floor.
• Cold stores -cuboid in shape
• Efficient air circulation- reduces temp. Fluctuations.
PROCESSING AREA
• Processed food material from one operation to the next
should be with the absolute minimum delay.
FLOW CONCEPT
1. Straight line flow (I-flow)
– Process layout is literally straight
– Separate receiving and shipping area
– Minimize the chances of recontamination
PROCESSING AREA
2. L-Flow: when straight line flow chart is to be accommodated
Process layout is literally straight.
3. U-Flow: very popular as a combination of receiving and
dispatch
4. S-Flow: when the production line is long and zigzagging on
the production floor is required.
FINISHED PRODUCT STORAGE
(i) Constant environment
 Correct temperature
 Correct humidity
 Correct good air circulation
 Adequate space
 Durable construction materials.
(ii) Clean environment: Protection from Dust, air, insects, birds and
other pets.
(iii) Careful handling.
(iv) Efficient stock rotation.
(v) Sited at distance from warm processing area.
EMPLOYEE SERVICE & WELFARE AREA
Principal amenities for employees.
• Toilets – with in 50 m distance
1 per 15 female employees
1 per 25 male
• Hand washing – in food handling areas
1 basin/ 10-12 employees
• Hot (44°C) + cold water tapes – knee/foot operated
EMPLOYEE SERVICE & WELFARE AREA
EMPLOYEE SERVICE & WELFARE AREA
Process Lines of Different Food
Processing Units
Extrusion- Cooking
Feeding Hopper
Auger
Flow Plate
Die
Threaded Flange
Die Stator
Retaining Flange Screw
Plastisizing Zone Wet Zone Free zone
Cooking Zone
Potato Chips
Watre Flow 9.5 - 11.5 LPM
Slicer feed auger
Slicer infeed Water spray:
Conveyor
Water spray: 15 LPM Slicer 15 LPM
Bindicator 15 LPM 10 LPM
Flume
Pre- washer conveyor
Surge Hopper
Air knife Air sweep
Flighted conveyor Paddle Water spray
15 LPM
Water spray 10 LPM
Fryer inlet Conveyor
Salinity Water
z
Spray Ball nozzles Oil Mist Filtre
Fryer Hood MM 710
Take out conveyor
A Type B Type C type Submerger
Oil inlet Paddles
Raw material
reception
QC
inspecti
on
Rejec
t
acce
pt
Store
s
Bottl
es
Crowns Co2 Carbon Hyflo Crate Sugar
Co2
cylinde
rs
Raw
wate
r
Chlorination
CCP
1
Syrup room
Empty
bottles from
shipping
WTP
Bottle
washer
Rejec
t
Empty
canisters from
market
Pre
inspecti
on
Caniste
r
washer
Washe
d
caniste
rs
Filing
Storage in
cold room
To market
Washe
d
bottles
W
bottle
inspecti
on
Final
inspec
tion
CCP
2
Crowning
Datecodin
g
Casin
g
Warehous
e
Crate
washer
Concentra
te (4-10 c)
Chemicals
Ready
syrup
Simple
syrup
Filing
Rejec
t
Rejec
t
Parami
x
Beverages- Soft Drinks
Dairy Industry
Instant Breakfast/foods - Layout
1-Security cabin, 2-Ripening shed, 3--Ripening shed, 4--Ripening shed,5--Ripening shed, 6--
Ripening fruit storage area, 7- Ripening fruit issue plant area, 8-Fruit cutting section, 9-
Prewashing&standardization area, 10-QA Lab, 11-Aseptic sterilizer & filler area, 12-Pannel
room, 13-Half cut area, 14-Crate washing area, 15-Warehouse, 16-Cold storage, 17-Admin
office, 18-ETP plant, 19-Ref area, 20-WTP, 21-DJ&panel room, 22-Gen store, 23- Pack material
store , 24- worker aminty, 25- Employer canteen , 26 – Boiler, 27 - Boiler Feed 28 - Site
Fruit
Processing
Pickles
Sugar-Hard
boiled Candies
Water Plant
Beer Processing
Wheat Semolina/Suji
Pasta/Vermicelli
Cereals and Millets Processing
Preparation of idly mix:
Finger Millets
Soaking in water (20 h)
Grinding
Coarse batter 1
Mix 1 and 2
Addition of rice powder
Addition of seasonings
Addition of water
Mix to prepare batter
Fermentation of batter(5h,29˚C)
Dehydration(Vacuum oven 90°C
for at 700 mmHg)
Vacuum packaging in LDPE bags
Storage at 5°C under
refrigeration
Black gram
soaking in water (4h)
Grinding
Smooth thick
Gelatinous paste 2
Instant Dosa mix
Finger millets
Soaking in water (20h)
Grinding
Coarse batter 1 Mix 1 and 2
Addition of seasonings
Addition of water
Mix to prepare dosa batter
Fermentation
Dehydration(Vacuum oven
90˚C for at 700 mmHg)
Vacuum packaging in LDPE bags
Storage at 5˚C under
refrigeration
Black gram
soaking in water (4h)
Grinding
Smooth thick
Gelatinous paste 2
Instant batter –
Water percent
40-45%
Red gram : Dhal Milling
Year
Minimum support price (MSP) for
raw red gram (Rs./100kg)
Red gram dhal Price
(Rs./100kg)
2014-2015 4350 12000
2015-2016 4625 9000
2016-2017 5050 8200
2017-2018 5450 6100
2018-2019 5675 6200
2019-2020 5800 8600
2020-2021 6000 10000
Cost of raw material and Dhal during last 5 years
Milling fractions obtained from 100 kg of raw red gram in commercial dhal
S.No Particulars
Market price
Rs./kg
Market
price
Rs./kg
1 Premium quality Dhal recovery is (57.5%) @ 100 5750
2 Second grade (B Grade) dhal recovery 18.6%) 65 1209
3 Dehusked whole or Un husked grains 4% 70 280
4 Husk and powder (20%) 15 300
Income from processing of 100 kg Red gram 7539
Raw Red gram MSP for 100 kg 6000
Processing charges in Rs. 500
Profit 1039
Oilseeds Processing
Particulars Pods Recovery A Grade B & C Grade
Quantity in Kg 100 75 40 35
Cost Per Kg( Rs.) 52.75 120 60
Total cost in (Rs.) 4800 2100
Total income per q 6900
MSP (2020-21) per q. in Rs. 5275
Profit in Rs. 1625
Edible Oil recovery( 40%)
Quantity of Per 35 kg of B&C Grade 14
Cost per kg oil (Rs.) 1820
Deoiled cake (55%) in kg 19.25
Deoiled cake cost per kg is Rs.30/kg 577.5
Total income from per 35 kg of B&C grade 2397.5
Total income in Rs. 9297.5
Total Net income in Rs. 4022.5
Groundnut Value addition
Composite Soy- Millets Value addition: Energy Dense Foods
Tribal
Villages
Average weight in kg
ICMR
Standard
Weight in Kg
for 3 years
Average Height in cm
ICMR
Standard
Height in cm
for 3 years
1st day 90th Day
Girls: 14.0 kg
Boys: 14.0kg
1st day
90th day
Girls: 94 cm
Boys: 95.2
Shaikguda 10.9 11.3 83.8 84.0
Markaguda 11.3 11.7 84.2 84.5
Pataguda 11.3 11.8 84.3 84.6
Rajgad 11.2 11.5 84.2 84.4
Sheerguda
11.4 11.8 84.3
84.7
Raiguda 11.0 11.5 83.9 84.3
Average test
Group
11.2 11.6 0.4 kg 84.1 84.4 0.3 cm
Normal group 11.3 11.5 0.2kg 84.9 85.1
0.2cm
**Age 3 years: Per day 40g of millet based nutrient dense food for 90 days
(given 8 containers net weight of 500g per children through ANGANWADI centers: 36 members )
Fortification of Atta with Soy Flour
• Permitted by Government of India
• Blends well with atta
• Atta can be substituted up to 10% with
defatted soy flour
• Improved protein content
– DSF has almost five times more
protein than atta
• Increased freshness
– Soy retains more moisture thus
increases freshness in roti
Fortification of Besan with Soy Flour
• Blends very well with besan with no
beany flavor
• Besan can be substituted up to 20%
with defatted soy flour
• Extensive research has been done on
soy fortified traditional products
Tomato Value addition- Tomato Pickle
S. No Ingredients
Total cost of
Production
1 Raw material cost 3447
2 Labour charges @ Rs. 250 day /person for 3 days (2 Person) 1500
3 Packaging cost (250g container @ Rs. 3) total 400 no.s 1200
Total cost of production 6147
S.No Ingredients Sales value (Rs.)
1 Total number of units (size of 250g) 400
2 Projected selling Price ( minimum cost) / per unit size 35
3 Total sales value in Rs. is 14000
Benefit Cost Ratio is 2.27:1
Tomato Pickle :Total inputs cost in Rs.
Sales
Value addition to Spices
• ICM Practices : Aflatoxin
level – 30 ppb
Onion and Garlic Processing
Value Chain of Capsicum /Bell pepper production in Poly house
Mahua Processing- FPO
 KVK, Adilabad given technical inputs for Mahua processing, storage life and
nutritional information for Mahua based products to the Bheem bai Adivasi
Mahila Sakara Sangam, Utnoor
 Established Multipurpose flour mill for Processing of Mahua- millet
based foods.
Year of Establishments 2019
Members 35
Active members 21
Quantity Processed (in kg) 600
Cost of raw materials Including packaging (in Rs.) 48000
Labour charges (in Rs.) 18000
Size of SKU’s (in kg) 0.5 to 1
Total expenditure or investment (in Rs.) 66000
MRP for SKU per kg (in Rs.) 400
Total earnings in Rs. 240000
Net Profit (in Rs.) 174000**
B:C ratio 3.63:1
Daily income per each member 500/-
***Profit Sharing: 25% depositing in the name of society 15% bonus for active
members and remaining will be the operational cost
Bheem bai Adivasi Mahila Sakara Sangam, Utnoor
Jamun Processing
Eco-Smart-Packaging – Banana Leaves
Custard apple Processing
Amla Processing
Frozen Fruit Cubes/Slices
Survey and Consensus Building
INTERVENTIONS
Established 17 Multipurpose
processing mills at 17 remote
tribal hamlets
Number of House holds in tribal
hamlet: 50- 80
Benefiting over 5200 tribal
household members @ a project
cost of Rs 5.2 lakhs (TSP)
One Woman farmer is managing
the unit in each village
Earning an amount of Rs. 3200 to
3800 per month apart from
regular farm income
Off and On Campus Trainings
Establishment of multipurpose processing mills
Advantages of multi-processing units in remote tribal Hamlets
 Process locally grown sorghum, millets, wheat, pulses and other foods for their
household consumption
 Benefiting over 1000 households or 5000 household members.
 Reduce the gaps in primary processing infrastructure for sorghum, millets,
soybean, red gram, Bengal gram and spices for domestic consumption
 Tribal families need not to go to mandal headquarters or major villages for flour
milling or grinding spices like chili and turmeric
 Preparation of varied diets from locally grown foods helped reduce nutritional
deficiencies among children and adolescent girls
 Tribal women were trained to produce malted foods, dhal milling and spice
powders for income generation.
Lockdown
Impact
 Paved the way for the production of
diverse balanced diet from locally
grown foods with minimum
expenditure or no cost.
 To reap benefit of scale in terms of
procurement of inputs, availing common
services and marketing of products.
 The States would identify food product
for a district keeping in view the existing
clusters and availability of raw material.
ONE District ONE Product (ODOP)
Up gradation of Individual Micro Food Processing Units
A Unit can avail credit-linked capital subsidy
@35% of the eligible project cost with a
maximum ceiling of Rs.10 lakh per unit.
The beneficiary contribution should be
minimum 10% and the balance should be
loan from a Bank.
Support to FPOs / SHGs / Cooperatives
The scheme would provide support t o F P O
s/ S H G s/ P r o d u c e r Cooperatives for
capital investment along the entire value
chain with credit linked grant @ 35%.
Seed Capital to SHG
 Seed capital @ Rs. 40,000/- per SHG member would be provided to those engaged
in food processing for working capital and purchase of small tools.
 Seed capital as grant would be provided to the SHG federation which, in turn,
would be extended to members as loan through the SHGs.
Common Infrastructure
Credit linked grant @35% would be provided to FPOs, SHGs, cooperatives, State owned
agencies and private entrepreneurs for development of common infrastructure.
Conclusion
 India’s large market size with growing incomes and changing life
styles also creates incredible market opportunities for food
producers, food processors, machinery makers, food technologists
and service providers in this sector.
 Poor agricultural performance can lead to inflation, farmer
distress and unrest and larger political and social disaffection—
all of which can hold back the economy.”
References/Acknowledgement
• MOFPI, GOI,
• Olamspice International
• ICAR-IVRI, Izatnagar
• I D fresh/JOVAKI AGROFOOD INDIA PVT LTD
• Neni Food Products
• Frubites products, Livoil,
• Source trace,
• Prajamitha Co-operative society, Utnoor
• American Soybean Association, Institute of Food Technology (IFT)
• Synthite Industries
Thank you...

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Food processing plant layout design1

  • 1. FOOD PROCESSING PLANT LAYOUT AND DESIGN Er. A. Poshadri SMS-Food Technology Krishi Vigyan Kendra, PJTSAU, Adilabad, T.S Email: achinna.fst@gmail.com Cell No: +919492828965
  • 2. Food processing aims to transform the agricultural products into food and also make food more digestible, nutritious and extend the shelf life. • Farmers–get better returns, higher yield, and lower the risks drastically, • Consumers-have access to a greater variety, better prices and new products, • Economy-gets benefitted with new business opportunities for the entrepreneurs and the work force gets employment
  • 3. Opportunities for Agro Processing • Contract Farming • BCT in FARMAR/IoT devices • On farm Processing • Grading & Sorting • Standardization • Self Help Group • Agmarknet • Rural Gudowns • DEMIC • Store at Door step The Farming Produce Trade and Commerce (Promotion and Facilitation) Ordinance, 20 20 The Farmers (Empowerment and Protection) Agreement on Price Assurance and Farm Services Act, 2020
  • 4. Strength  Higher food Production  Rising per capita income coupled with increasing awareness among consumers  Rapid urbanization is driving consumerism in Tier-II & Tier-III cities  Growing penetration of food and beverages manufacturing companies in rural areas  Tailor made flavors and region specific tastes Weakness 1. Lack of state of Art Processing facilities 2. Limited shelf life for Milk, Meat and horticulture produce 3. Fresh produce preferred over processed foods SWOT Analysis for Food Processing
  • 5. Opportunities  Rising business and product innovation  Untapped rural markets  Low-cost price strategy is adopted so as to make the product affordable to the consumers  Rising farm fresh produce and health foods  Better product packaging and preservation  India to be the youngest nation by 2025  Seven Point Strategy for Doubling of farm income Threats • Product taste variations • Competition from multinational companies • Safety of Processed foods and adulteration • Increasing life style diseases in India
  • 6. Gaps noticed  Small and Medium industries/Poor plant layouts and designs  No scope for expansion in plant due to poor design  Low penetration in rural area and high prices for low volume  Poor sanitation practices  High cost of production and Poor export subsidies
  • 7. Consumer Desires • Good and Healthy Foods • Available all year round • Sufficient Supply • Conveniently packaged • Sold in (super) all types of markets (including e-retail platforms) • Long shelf life and exotic taste and flavours • Always Fresh • Appealing taste & Appearance • Quality/Autentically sourced Processed Foods • High in available nutrients
  • 8. Market Challenges • Globalisation • New distribution strategies • New Processing Technologies • New Materials/Additives • New Risks • Climate Change • Energy Efficiency • Water Supply • Procurement of quality raw materials • Greed- Fraud
  • 9. Food Plant: Enclosed area into which food materials are brought and modified in various ways to manufacture an end product. • Plant layout : means allocation of space and arrangement of equipments in such a manner that overall operating costs are minimized Types of Plant layout: 1. Product layout 2. Fixed layout 3. Process layout 4. Combination layout
  • 10. Objectives of Plant layout • Minimize material handling cost. • Effective utilization of men, equipment and space. • Make effective utilization of cubic space. • Provide for employee convenience- safety & comfort. • Minimize investment in equipment. • Minimize overall production time.
  • 11. Principles of Plant layout: 1. Principle of minimum movement. 2. Principle of space utilization. 3. Principle of flexibility. 4. Principle of interdependence. 5. Principle of safety 6. Principle of smooth flow 7. Principle of supervision 8. Principle of satisfaction
  • 12. The location of an industry is determined by Primary Factors: – Supply of raw materials – Nearness to the market – Transport Facilities – Supply of Labour – Availability of power – Supply of Capital
  • 13. Secondary factors: 1. Proximity to customers 2. Policies of management 3. Plant location 4. Total Cost 5. Volume of production 6. Availability of floor space 7. Nature of manufacturing process
  • 14. Facility Layout : It is an arrangement of different aspects of manufacturing in an appropriate manner as to achieve desired production results. Facility layout considers • available space, • final product, • safety of users and facility and • convenience of operations.
  • 15. Product or Line layout: • Machines and equipments are arranged in one line depending upon the sequence of operations required for the products Production control. • The materials move from one work station to another sequentially without any back-tracking. • The output of one machine becomes the input of the next • All the operations including assembly, testing, packing must be included in the line.
  • 16.
  • 17. Advantages of Product or line Layout • Low cost of material handling • Smooth operations • Continuous flow of work • Optimum use of floor space • Shorter processing time
  • 18. Disadvantages of Product or line Layout • High initial capital investment in special purpose machine. • Breakdown of one machine will hamper the whole production process. • Heavy overhead charges.
  • 19. Fixed layout • The major product being produced is fixed at one location. • Equipments, labor and material are moved to that location. • All facilities are brought and arranged around one work center.
  • 20. Advantages and disadvantages of Fixed Layout • It saves time and cost. • The layout is flexible. • It is economical • Production period being very long, capital investment is very heavy. • Very large spaces required. • There's a possibility of confusion and conflicts among different work groups
  • 21. Process layout: • Machines of a similar type and performing similar operations are arranged together at one place. • The work has to be allocated to each area in such a way that no machines are chosen to do as many different jobs as possible • Advantages of Process layout: • Lower initial capital investment. • Lower overhead costs. • Change in output design can be adopted to the output of variety of products. • Breakdown of one machine doesn’t lead to complete stoppage. • Effective supervision. • Great flexibility.
  • 22. Watre Flow 9.5 - 11.5 LPM Slicer feed auger Slicer infeed Water spray: Conveyor Water spray: 15 LPM Slicer 15 LPM Bindicator 15 LPM 10 LPM Flume Pre- washer conveyor Surge Hopper
  • 23. Disadvantages of Process layout • Higher material handling costs. • More skilled labour is required which further increases the cost. • Time gap in production is higher. • Work in progress inventory is high, leading to greater storage space. • Costly supervision.
  • 24. Combined layout: • Certain manufacturing units may require all three processes, namely intermittent processes (job shops), the continuous process ( mass production shops), and the representative process combined process ( miscellaneous shops). • In most of industries, only a product layout or process layout or fixed location layout does not exist. • Thus in manufacturing concerns where several products are produced in repeated number with no likelihood of continuous production, combined layout is followed. • Generally a combination or product & process layout or other combination is followed in practice
  • 25. Advantages of good layout • Labour cost •Increase in productivity with more units being produced per man hour. •Reduction in the number of workers. •Minimization of motions between operations. • Production control •Increased production rate. •Providing convenient and adequate storage points. •Increased production rate. •Improved ability of forecasting manufacturing time.
  • 26. • Supervision • Lesser requirement of supervision. • Reduction in time spent on inspection. • Reduction in cost of inspection. • Other manufacturing costs • Reduced consumption of power. • Minimization of scrap and defectives. • Better quality due to reduced handling. • Reduced costs of maintenance. • Improved utilization of materials
  • 27. Factory site • Permission from both national and local governments. • Comply with legislations. • Facilities for discharge of waste materials. • Determination of possible hygienic hazards. • Basic arrangements for workers. • Close to market
  • 28.
  • 29. FSSAI –Food safety Compliance System • https://foscos.fssai.gov.in/public/guest-login • https://foscos.fssai.gov.in/public/assets/docs/ KoBwiseDocumentsrequiredforLicense.pdf • https://foscos.fssai.gov.in/public/assets/docs/ DocumentsrequiredforRegistrationCertificate. pdf • file:///D:/FSSAI%20Jobs/PPT%20food%20plan t%20layout/KindofBusinessEligibility.pdf
  • 30. GENERAL DESIGN PRINCIPLES • Various services • heating • lighting • ventilation • waste disposal • Should operate efficiently. • Fire resistant. • Sound transmission and vibration should be minimized. • Should resist various stresses and strains. • Must conform to high standard of hygiene
  • 31. MACHINE LAYOUT H-LAYOUT:- • Mixing and packing at the ends • Production flow is smooth • Pre -Mixing can be done on the same floor • No bends hence less maintenance of deg conveyors 90 • Less wastages
  • 32.
  • 33. L-LAYOUT:- • Bends and combination bends required • Pre - Mixing to be located on the first floor • Maintenances cost a bit • Best suited for area with Less space length wise
  • 34.
  • 35. LAYOUT AND DESIGN OF PLANT • Good Manufacturing Practices (GMP) • Bio-security • Black zone and White zone • No cross movement of labours/ products/ equipment • White zone - Exit of finished product only • Black zone – Unhygienic • Always a forward movement of the products
  • 36.
  • 37. ROOFING AND LIGHTING • Flat or slightly pitched. • Height - critical factor. • Roof - source of natural light. • Lighting is from two sides: illumination is more uniform shadowing is restricted. • Direct sunlight - glare problems and temperature increases
  • 38. ROOFING AND LIGHTING • Single glazed windows = heat loss restrict 10% of the roof area. • Wall window - glazed area of at least 30% - • Opening windows are not recommended. • Artificial lighting - Advantageous. • Shadows and glare to be avoided. • Intensity – adequate & should spread uniformly
  • 39. CEILINGS, WALLS AND FLOORS • Junctions between ceiling and walls should be rounded and sealed against dust and water
  • 40. ROOFING AND LIGHTING • Smooth and free from cracks and crevices • Resistant to chemical and biological agents. • Impervious to grease and water. • All wall angles, corners and junctions - sealed and rounded • Coving of the wall floor junctions to a height of approx. 15 cm
  • 41. FLOORS AND DRAINS • Material should be impervious, Durable and impact resistant. • Resistant to grease, cleaning agents including hot water or steam and to biochemical and microbial attack. • Should be free from cracks, crevices • Surface should be non-slippery • Non-slippery floor- surface additives such as carborundum
  • 42. FLOORS AND DRAINS • Floor - easy to clean and disinfect. • Slope – 1:40 to 1:60 towards drains. • Distance between drains:- restricted to 5 m • Washing fluids should pass from cleaner to dirtier areas
  • 43. FLOORS AND MATERIALS Prone to dust, little resistance to acids or to biochemical attack and liable to wear unevenly forming pits.
  • 44. DRAINAGE SYSTEM • Totally covered drains - avoided. • Should have smooth, vertical sides with a rounded base and be slopped to allow for adequate water velocity. • Depth should be sufficient - prevent over flow. • Should be sited adjacent to but not directly against walls
  • 45. VENTILATION AND AIR CONDITIONING • Hygienic food processing and/or comfort of personnel. • For overcoming condensation • To minimize the build up of offensive fumes and odors. • Optimum environment temperature 21-22°C (for sedentary occupation) 13-14°C (for heavy manual work)
  • 46. VENTILATION AND AIR CONDITIONING • Humidity: 30-70% • Rate of Air Change: – Cooking areas 20 changes / hour – Stores and Office 1/2 changes / hour • Air flow - in the opposite direction to the process flow • Fresh air - heavy manual work. • Air entering factory - filtered or treated • Excess pressure with in factory relative to the outside is recommended.
  • 47.
  • 48. FACTORY LAYOUT Reception area • easy access for transport. • Efficient unloading to avoid deterioration in the incoming raw material. • Liquid – may require pumps • Dry – may require mechanical means
  • 49. FACTORY LAYOUT Storage area • Site- efficient flow to processing line. • Room should be clean, adequate space for inspection and cleaning, good air circulation and correct temperature and humidity. • Protection from dust, insects, rodents • Food material should not be placed directly on the floor. • Cold stores -cuboid in shape • Efficient air circulation- reduces temp. Fluctuations.
  • 50. PROCESSING AREA • Processed food material from one operation to the next should be with the absolute minimum delay. FLOW CONCEPT 1. Straight line flow (I-flow) – Process layout is literally straight – Separate receiving and shipping area – Minimize the chances of recontamination
  • 51. PROCESSING AREA 2. L-Flow: when straight line flow chart is to be accommodated Process layout is literally straight. 3. U-Flow: very popular as a combination of receiving and dispatch 4. S-Flow: when the production line is long and zigzagging on the production floor is required.
  • 52. FINISHED PRODUCT STORAGE (i) Constant environment  Correct temperature  Correct humidity  Correct good air circulation  Adequate space  Durable construction materials. (ii) Clean environment: Protection from Dust, air, insects, birds and other pets. (iii) Careful handling. (iv) Efficient stock rotation. (v) Sited at distance from warm processing area.
  • 53. EMPLOYEE SERVICE & WELFARE AREA Principal amenities for employees. • Toilets – with in 50 m distance 1 per 15 female employees 1 per 25 male • Hand washing – in food handling areas 1 basin/ 10-12 employees • Hot (44°C) + cold water tapes – knee/foot operated
  • 54. EMPLOYEE SERVICE & WELFARE AREA
  • 55. EMPLOYEE SERVICE & WELFARE AREA
  • 56. Process Lines of Different Food Processing Units
  • 57. Extrusion- Cooking Feeding Hopper Auger Flow Plate Die Threaded Flange Die Stator Retaining Flange Screw Plastisizing Zone Wet Zone Free zone Cooking Zone
  • 58.
  • 59. Potato Chips Watre Flow 9.5 - 11.5 LPM Slicer feed auger Slicer infeed Water spray: Conveyor Water spray: 15 LPM Slicer 15 LPM Bindicator 15 LPM 10 LPM Flume Pre- washer conveyor Surge Hopper
  • 60. Air knife Air sweep Flighted conveyor Paddle Water spray 15 LPM Water spray 10 LPM Fryer inlet Conveyor Salinity Water z Spray Ball nozzles Oil Mist Filtre Fryer Hood MM 710 Take out conveyor A Type B Type C type Submerger Oil inlet Paddles
  • 61.
  • 62. Raw material reception QC inspecti on Rejec t acce pt Store s Bottl es Crowns Co2 Carbon Hyflo Crate Sugar Co2 cylinde rs Raw wate r Chlorination CCP 1 Syrup room Empty bottles from shipping WTP Bottle washer Rejec t Empty canisters from market Pre inspecti on Caniste r washer Washe d caniste rs Filing Storage in cold room To market Washe d bottles W bottle inspecti on Final inspec tion CCP 2 Crowning Datecodin g Casin g Warehous e Crate washer Concentra te (4-10 c) Chemicals Ready syrup Simple syrup Filing Rejec t Rejec t Parami x Beverages- Soft Drinks
  • 65. 1-Security cabin, 2-Ripening shed, 3--Ripening shed, 4--Ripening shed,5--Ripening shed, 6-- Ripening fruit storage area, 7- Ripening fruit issue plant area, 8-Fruit cutting section, 9- Prewashing&standardization area, 10-QA Lab, 11-Aseptic sterilizer & filler area, 12-Pannel room, 13-Half cut area, 14-Crate washing area, 15-Warehouse, 16-Cold storage, 17-Admin office, 18-ETP plant, 19-Ref area, 20-WTP, 21-DJ&panel room, 22-Gen store, 23- Pack material store , 24- worker aminty, 25- Employer canteen , 26 – Boiler, 27 - Boiler Feed 28 - Site Fruit Processing
  • 66.
  • 71.
  • 74. Cereals and Millets Processing
  • 75. Preparation of idly mix: Finger Millets Soaking in water (20 h) Grinding Coarse batter 1 Mix 1 and 2 Addition of rice powder Addition of seasonings Addition of water Mix to prepare batter Fermentation of batter(5h,29˚C) Dehydration(Vacuum oven 90°C for at 700 mmHg) Vacuum packaging in LDPE bags Storage at 5°C under refrigeration Black gram soaking in water (4h) Grinding Smooth thick Gelatinous paste 2
  • 76. Instant Dosa mix Finger millets Soaking in water (20h) Grinding Coarse batter 1 Mix 1 and 2 Addition of seasonings Addition of water Mix to prepare dosa batter Fermentation Dehydration(Vacuum oven 90˚C for at 700 mmHg) Vacuum packaging in LDPE bags Storage at 5˚C under refrigeration Black gram soaking in water (4h) Grinding Smooth thick Gelatinous paste 2
  • 77. Instant batter – Water percent 40-45%
  • 78. Red gram : Dhal Milling
  • 79. Year Minimum support price (MSP) for raw red gram (Rs./100kg) Red gram dhal Price (Rs./100kg) 2014-2015 4350 12000 2015-2016 4625 9000 2016-2017 5050 8200 2017-2018 5450 6100 2018-2019 5675 6200 2019-2020 5800 8600 2020-2021 6000 10000 Cost of raw material and Dhal during last 5 years
  • 80. Milling fractions obtained from 100 kg of raw red gram in commercial dhal S.No Particulars Market price Rs./kg Market price Rs./kg 1 Premium quality Dhal recovery is (57.5%) @ 100 5750 2 Second grade (B Grade) dhal recovery 18.6%) 65 1209 3 Dehusked whole or Un husked grains 4% 70 280 4 Husk and powder (20%) 15 300 Income from processing of 100 kg Red gram 7539 Raw Red gram MSP for 100 kg 6000 Processing charges in Rs. 500 Profit 1039
  • 82. Particulars Pods Recovery A Grade B & C Grade Quantity in Kg 100 75 40 35 Cost Per Kg( Rs.) 52.75 120 60 Total cost in (Rs.) 4800 2100 Total income per q 6900 MSP (2020-21) per q. in Rs. 5275 Profit in Rs. 1625 Edible Oil recovery( 40%) Quantity of Per 35 kg of B&C Grade 14 Cost per kg oil (Rs.) 1820 Deoiled cake (55%) in kg 19.25 Deoiled cake cost per kg is Rs.30/kg 577.5 Total income from per 35 kg of B&C grade 2397.5 Total income in Rs. 9297.5 Total Net income in Rs. 4022.5 Groundnut Value addition
  • 83.
  • 84. Composite Soy- Millets Value addition: Energy Dense Foods
  • 85.
  • 86. Tribal Villages Average weight in kg ICMR Standard Weight in Kg for 3 years Average Height in cm ICMR Standard Height in cm for 3 years 1st day 90th Day Girls: 14.0 kg Boys: 14.0kg 1st day 90th day Girls: 94 cm Boys: 95.2 Shaikguda 10.9 11.3 83.8 84.0 Markaguda 11.3 11.7 84.2 84.5 Pataguda 11.3 11.8 84.3 84.6 Rajgad 11.2 11.5 84.2 84.4 Sheerguda 11.4 11.8 84.3 84.7 Raiguda 11.0 11.5 83.9 84.3 Average test Group 11.2 11.6 0.4 kg 84.1 84.4 0.3 cm Normal group 11.3 11.5 0.2kg 84.9 85.1 0.2cm **Age 3 years: Per day 40g of millet based nutrient dense food for 90 days (given 8 containers net weight of 500g per children through ANGANWADI centers: 36 members )
  • 87. Fortification of Atta with Soy Flour • Permitted by Government of India • Blends well with atta • Atta can be substituted up to 10% with defatted soy flour • Improved protein content – DSF has almost five times more protein than atta • Increased freshness – Soy retains more moisture thus increases freshness in roti
  • 88. Fortification of Besan with Soy Flour • Blends very well with besan with no beany flavor • Besan can be substituted up to 20% with defatted soy flour • Extensive research has been done on soy fortified traditional products
  • 89. Tomato Value addition- Tomato Pickle
  • 90. S. No Ingredients Total cost of Production 1 Raw material cost 3447 2 Labour charges @ Rs. 250 day /person for 3 days (2 Person) 1500 3 Packaging cost (250g container @ Rs. 3) total 400 no.s 1200 Total cost of production 6147 S.No Ingredients Sales value (Rs.) 1 Total number of units (size of 250g) 400 2 Projected selling Price ( minimum cost) / per unit size 35 3 Total sales value in Rs. is 14000 Benefit Cost Ratio is 2.27:1 Tomato Pickle :Total inputs cost in Rs. Sales
  • 91. Value addition to Spices • ICM Practices : Aflatoxin level – 30 ppb
  • 92.
  • 93.
  • 94. Onion and Garlic Processing
  • 95. Value Chain of Capsicum /Bell pepper production in Poly house
  • 96. Mahua Processing- FPO  KVK, Adilabad given technical inputs for Mahua processing, storage life and nutritional information for Mahua based products to the Bheem bai Adivasi Mahila Sakara Sangam, Utnoor  Established Multipurpose flour mill for Processing of Mahua- millet based foods.
  • 97.
  • 98. Year of Establishments 2019 Members 35 Active members 21 Quantity Processed (in kg) 600 Cost of raw materials Including packaging (in Rs.) 48000 Labour charges (in Rs.) 18000 Size of SKU’s (in kg) 0.5 to 1 Total expenditure or investment (in Rs.) 66000 MRP for SKU per kg (in Rs.) 400 Total earnings in Rs. 240000 Net Profit (in Rs.) 174000** B:C ratio 3.63:1 Daily income per each member 500/- ***Profit Sharing: 25% depositing in the name of society 15% bonus for active members and remaining will be the operational cost Bheem bai Adivasi Mahila Sakara Sangam, Utnoor
  • 104.
  • 105. Survey and Consensus Building INTERVENTIONS Established 17 Multipurpose processing mills at 17 remote tribal hamlets Number of House holds in tribal hamlet: 50- 80 Benefiting over 5200 tribal household members @ a project cost of Rs 5.2 lakhs (TSP) One Woman farmer is managing the unit in each village Earning an amount of Rs. 3200 to 3800 per month apart from regular farm income
  • 106. Off and On Campus Trainings
  • 107. Establishment of multipurpose processing mills
  • 108. Advantages of multi-processing units in remote tribal Hamlets  Process locally grown sorghum, millets, wheat, pulses and other foods for their household consumption  Benefiting over 1000 households or 5000 household members.  Reduce the gaps in primary processing infrastructure for sorghum, millets, soybean, red gram, Bengal gram and spices for domestic consumption  Tribal families need not to go to mandal headquarters or major villages for flour milling or grinding spices like chili and turmeric  Preparation of varied diets from locally grown foods helped reduce nutritional deficiencies among children and adolescent girls  Tribal women were trained to produce malted foods, dhal milling and spice powders for income generation.
  • 110. Impact  Paved the way for the production of diverse balanced diet from locally grown foods with minimum expenditure or no cost.
  • 111.
  • 112.  To reap benefit of scale in terms of procurement of inputs, availing common services and marketing of products.  The States would identify food product for a district keeping in view the existing clusters and availability of raw material. ONE District ONE Product (ODOP)
  • 113. Up gradation of Individual Micro Food Processing Units A Unit can avail credit-linked capital subsidy @35% of the eligible project cost with a maximum ceiling of Rs.10 lakh per unit. The beneficiary contribution should be minimum 10% and the balance should be loan from a Bank.
  • 114. Support to FPOs / SHGs / Cooperatives The scheme would provide support t o F P O s/ S H G s/ P r o d u c e r Cooperatives for capital investment along the entire value chain with credit linked grant @ 35%.
  • 115. Seed Capital to SHG  Seed capital @ Rs. 40,000/- per SHG member would be provided to those engaged in food processing for working capital and purchase of small tools.  Seed capital as grant would be provided to the SHG federation which, in turn, would be extended to members as loan through the SHGs.
  • 116. Common Infrastructure Credit linked grant @35% would be provided to FPOs, SHGs, cooperatives, State owned agencies and private entrepreneurs for development of common infrastructure.
  • 117. Conclusion  India’s large market size with growing incomes and changing life styles also creates incredible market opportunities for food producers, food processors, machinery makers, food technologists and service providers in this sector.  Poor agricultural performance can lead to inflation, farmer distress and unrest and larger political and social disaffection— all of which can hold back the economy.”
  • 118. References/Acknowledgement • MOFPI, GOI, • Olamspice International • ICAR-IVRI, Izatnagar • I D fresh/JOVAKI AGROFOOD INDIA PVT LTD • Neni Food Products • Frubites products, Livoil, • Source trace, • Prajamitha Co-operative society, Utnoor • American Soybean Association, Institute of Food Technology (IFT) • Synthite Industries