Integrated Pack House Sample DPR
Integrated Pack House Sample DPR
ON
OFFICE ADDRESS :
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Project At A Glance
Constitution
Office
Unit Location
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Cost of Project (Rs in Lakhs):
(c) Insulation
Sub Total
Total
Means of Finance:
Sl Item Ripening Integrated Functional
No Chambers Pack House Infrastructure
Total
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1. INTRODUCTION
The Government of India has been providing support for the holistic development of horticulture
through various schemes such as National Horticulture Mission (NHM), Horticulture Mission for
North East and Himalyan States (HMNEH), National Horticulture Board (NHB) and Coconut
Development Board (CDB).
India is the second largest producer of fruits and vegetables in the world with production of
81.3 million MT and 162.2 million MT respectively but its share in global export of fruits and
vegetables is around 1.4% only. Approximately 20 - 25% of fruits and vegetables get
wasted in the country. This is mainly caused due to lack of cold chain infrastructure which
includes both storage and transportation facilities.
Ripening chambers play a vital role in extending the shelf life and period of marketing, avoiding
glut and post-harvest losses reducing transport bottlenecks during peak period of production
and maintenance of quality of produce. Hence, the development of ripening chambers in the
country has an important role in reducing the wastages of the perishable commodities and
providing remunerative prices to the growers and to make available farm products to the
consumers at competitive and affordable prices.
The cold chain industry in India is still at a budding stage and despite large production of
perishables, the cold chain potential still remain untapped due to high share of single
commodity cold storage, high initial investment (for refrigerator units and land), lack of enabling
infrastructure like power & roads, lack of awareness for handling perishable
produce and lapse of service either by the storage provider or the transporter is leading to
poor quality of produce.
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However, increasing urbanization and growth of organized retail, food servicing and food
processing sector are boosting the growth of cold chain industry in India. The trend is
shifting towards establishing multipurpose cold storages, ripening chambers, pack houses
and providing end to end services to control parameters throughout the value chain.
Mango is the national fruit of India, known as the 'King of Fruits'. It is one of the most
important and popular Asian fruits. The fruit is very popular with the masses due to its wide
range of adaptability, high nutritive value, and richness in variety, delicious taste and
excellent flavour. The fruit is consumed in both forms raw and ripe.
Mango is grown in India in tropical and subtropical regions from sea to an altitude of 1500
meters. It is grown almost in all states of India. However, it is mainly cultivated in, Andhra
Pradesh, Bihar, Gujarat, Karnataka, Kerala, Maharashtra, Orissa, Tamil Nadu, Uttar
Pradesh and West Bengal.
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3. HORTICULTURE SCENARIO in Andhra Pradesh
Andhra Pradesh produces about 23.32 m. MT of horticulture produce from an area of 1.9
m. ha, accounting for 9.70% of total horticulture production in the country.
Andhra Pradesh is the third leading fruit producing state in the country after Tamil Nadu
and Maharashtra and its share accounts for 12.6% of the total production of fruits in the
country. The main fruits are Mango, Banana, Citrus, Papaya, Guava and Sapota.
Andhra Pradesh is the second largest producer of Mango in the country after Uttar
Pradesh. With a production of 3.36 m. MT tonnes from an area of 0.39 m. ha, Andhra
Pradesh produces about 22% of the mango in the country. The major mango producing
belts are Krishna, East & West Godavari, Khammam and Vijayanagaram. The commercial
mango varieties grown are Bangnapalli, Suvarnarekha, Neelum and Totapuri, of which
Bangnapalli is an early variety. The productivity of mango is 8.6 t/ha. A large number of
processing units have been set up in the Chittoor belt, mainly processing for Totapuri
variety for pulp, which is being exported.
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4. POST-HARVEST MANAGEMENT
In order to deliver a quality product to the market and ultimately to the consumer to
command buyer attention and gives the grower a competitive edge, proper post-harvest
management is the need of the hour.
Nearly, 20-25 per cent of fruits are wasted due to faulty Post-harvest practices during
harvesting packaging, storage, grading etc. This wastage can be reduced to some extent
through proper and scientific methods.
Post-harvest management can be considered as second production operation to add
values to the products and the basic means for effective marketing. Post-harvest
management operations are quite diversified, consisting of collection, curing, pretreatment,
grading, packaging, pre-cooling, low temperature storage, pallet loading, transporting, and
depending upon various crops.
Normally, Mangoes do not need any post-harvest treatment for marketing in local markets,
except simple washing with water to remove the latex and dust. On a commercial scale or
for export purpose, they are sometimes dipped in hot water, containing fungicide for the
control of diseases. However, hot water treatment (HWT) is an effective post-harvest
treatment for Mangoes. Dipping newly harvested fruits in hot water minimizes fruit fly
damage, anthracnose, and stem-end rot infections.
Curing is necessary when fruits are to be stored for long periods to extend the shelf life.
The fruits are usually spread on the floor in the orchard’s yard, having the cushion of paddy
straw or simple straw for nearly 24 hrs and then washed to remove the dirt. Post-harvest
cooling rapidly removes field heat from freshly harvested fruits, which helps in stabilizing
the metabolic process. Post-harvest cooling can:
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4.2.1 Grading
The fruits graded according to their size, weight, colour and maturity benefits both the
producer and consumer. It has been observed that bigger size fruits take 2-4 days more
time in ripening than smaller ones and hinder to achieve uniform ripening. Therefore,
grading according to size play an important role in packaging of the fruits. During grading,
the immature, overripe, damaged and diseased fruits should be discarded.
4.2.3 Ripening
In India, 99% of the Mangoes are ripened by using Calcium Carbide, which is a toxic
chemical and extremely hazardous. It is the most economical way to ripen a mango, but a
banned chemical, and should not be used for ripening of fruits. Such fruits do not ripe
uniformly and quality of fruits remains inferior.
It would be better to treat the fruits with ethylene gas (100 ppm) in airtight room by
exposing them for 24 – 48 hrs under controlled conditions of temperature and humidity, for
ripening purpose. These treatments ripen the fruits uniformly with attractive colour.
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4.2.4 Uniformity
The contents of each package must be uniform and contain only mangoes of the same
origin, variety, quality and size. The visible part of the contents of the package must be
representative of the entire.
4.2.5 Packaging
Mangoes must be packed in such a way as to protect the produce properly. The materials
used inside the package must be new1, clean, and of a quality such as to avoid causing
any external or internal damage to the produce. The use of materials, particularly of paper
or stamps bearing trade specifications is allowed, provided the printing or labeling has been
done with non-toxic ink or glue. Mangoes shall be packed in each container in compliance
with the Recommended International Code of Practice for Packaging and Transport of
Fresh Fruits and Vegetables (CAC/RCP 44-1995, Amd. 1-2004).
4.2.6 Storage
Storage is essential for extending the consumption period of fruits, regulating their supply to
the market and for transportation to long distances. Storage of fruits is also important due
to reason that their production is seasonal, but demand remains for a longer period.
Storage at 10 to 13 °C (50 to 55 °F) with 85 to 90% RH, give a shelf life of 14 to 28 days for
mature green fruit, depending upon variety. Ripe fruits can be stored at 7 to 8 °C (44.6 to
46.4 °F). Mature green fruits can be stored at room temperature for about 4-10 days,
depending upon variety. When fruits are treated chemically and precooled to 10-12 oC
before storing them at an appropriate temperature, their shelf life is enhanced. Central
Institute for Subtropical Horticulture, Lucknow has suggested to store Dashehari and
Mallika at 12 °C, Langra at 15 °C, Chousa at 10 °C to enhance the shelf life to 2 to 3
weeks. It is better if fruits are precooled before keeping them at low temperature.
4.2.7 Transportation
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4.2.8 Important Assembling markets in Andhra Pradesh
Calcium Carbide is being used for ripening of fruits like banana, mango etc., which emits
harmful fumes and affects the health of the consumers. Calcium carbide is used in some
countries as source of acetylene gas, which is an artificial ripening agent. However,
acetylene is not nearly as effective for ripening as is ethylene, and acetylene is not a
natural plant hormone like ethylene. Calcium carbide may contain traces of arsenic and
phosphorous, both are highly toxic to humans and the use of this chemical for ripening is
illegal in most countries. The usage of Calcium carbide is banned in our country also.
When used in accordance with good manufacturing practice, USFDA recognized ethylene
as safe (GRAS).
Ethylene has been found not harmful or toxic to humans when used in the recommended
concentrations in ripening rooms. In fact, ethylene was used medically as an anesthetic in
concentration significantly greater than that found in ripening room. However, ethylene is
often targeted as the reason for difficulty in breathing in ripening rooms.
High humidity forced ripening chambers are normally used for fruit ripening. These
specially built gas tight rooms have systems for controlling temperature, humidity and
concentration of Ethylene and CO2 levels. The chambers have a 5 day cycle period.
Ripening of fruits is possible through two methods. (1) by using portable ethylene
generators and (2) by using fully automated centralized ripening system with ethylene gas
cylinder.
Pressurized ethylene gas is released at very slow rate by using a double stage gas
regulator and solenoid valves into the ripening chambers loaded with fruits until the
desired concentration is achieved and maintained.
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6.2 System required for ethylene gas supply
1. CO2 Analyzer
2. Ethylene analyzer with concentration controller
3. Doping ethylene gas cylinder
4. Double stage gas regulator
5. Gas control system with fully automated concentration controller with solenoid
valves and dispensing pipeline.
6.4 Desired Storage Environment of Fruits and Vegetables in the cold chambers
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7. Present Project
The important post-harvest operations of fruits are curing, washing, grading, packaging,
storage, transportation, processing and marketing etc. The promoter intend to use
contemporary technology for cleaning, grading, ripening and packing mangos using
hygienic and natural processes. __________________ is an integrated unit for post
harvest management of mangos and other fruits. The unit includes integrated pack house,
ripening chambers and functional infrastructure.
The proposed unit is at a distance of _______ from _______________. This will not only
reduce the transportation delay, but also reduce the cost of transportation. The present
location has got the direct transport facilities to Hyderabad and Amaravathi, the proposed
capital city of the new Andhra Pradesh state.
ideally situated near to Mango and other fruits and Vegetable cultivating areas.
The project is ideally situated in the area very near to Mango and other Fruit & Vegetable
Markets.
The proposed area is well known for commercial crops like Vegetables, and fruits like
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Mango, Guava, Banana and other fruits. The integrated pack house and ripening facilities.
in the proposed area will facilitate the economic development of farmers and help in
regularize marketing system.
The traditional way of ripening the fruits is outdated considering the deterioration, damage
like color changing and loss of weight. Due to the technological development in the area of
ripening and storage facilities, it is available to the common man.
The setting up of a research center on Mango near _________ in the district is expected to
give a boost to mango production.
Considering all the above facts and considerations, the proposed unit will have advantage
and can easily be managed successfully.
7.2 Marketing
Mango is the major fruit crop in ____________district. It covers an area of _______ ha,
which is mainly concentrated in _________ mandals. Various other fruits like banana,
sapota, guava, papaya and pomegranate and vegetables are being exported to other
districts and states in India. Fruits like mango, Sapota and vegetables like cabbage,
tomato, green peas can fetch good market throughout the year by storing them under
controlled temperatures. It is therefore felt that a tremendous requirement for controlled
temperature storage facility for different commodities thought the year can only be met by
construction of the ripening chambers.
The unit is being is promoted by the persons who is having good relations with other
Traders and Farmers in the district and it is well connected to rest of the Andhra Pradesh
and Telangana state. The promoter of the firm has been involved in fruit business, due to
which the promoters are having good contacts with the farming community in the district.
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7.4 Incentives
The unit is eligible for the following incentives from the central and state governments.
2. Concession on power tariff @ Rs.1.00/- per unit of Electricity Consumption for the
First 5 Years from the State Government.
7.5 Backward Linkage with farmers with reference to either providing services or
purchase of raw material:
The area where the unit is located has lot of farmers who are growing mangos and other
horticulture crops and vegetables. The promoter’s _ _ _ _ _ _ _ _ _ _ _ has excellent
contacts and tie ups with mango, banana and sweet orange farmers and traders. He is
planning to store the Apples as well in the ripening chambers during off season. They
provide infrastructure and marketing support to these farmers to get their horticulture
produce and clean, grade, sort, ripen and pack it in their unit and provide the export
facilities.
The promoters have good contacts with these farmers and traders and provide marketing
support to these farmers by way of storing the material in their unit, and inviting the
corporate retailers to purchase the material. Moreover, number of other farmers willing to
provide their raw materials for ripening and storage.
7.6 Forward Linkages- Analysis of domestic and export markets, tie up made for
sale of Produce and branding aspect:
Being in the fruit trading business for ___ years, the promoters have established excellent
contacts and relations with the traders and retailers of horticulture commodities like fruits
and vegetables. They will provide transportation support and marketing support to the
farmers who use their infrastructure facilities and the ripening chambers. They also invite
the corporate retailers to purchase the material. They have export tie ups with ________,
___________________________________ and __________________ states.
Being in the public service for long time, the promoters have good contacts with the traders
and retailers of commodities, fruits and vegetables. They will provide marketing support to
the farmers who store with them. They will have tie ups with the collateral management
companies and bankers to provide loan on the produce.
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Due to the shortages of storage capacity in the area, the farmers have to go faraway places
for storages of their produce. Thus there is ample of potential for establishing more modern
technology based cold storage units in this area.
Strength:
Weakness:
Un-expected or un-timely rains or cyclones would affect the crop production which
in turn effects the capacity utilization
Inefficient supply chain due to a large number of intermediaries
Seasonality of raw material
Opportunity:
Threat:
Any change in the Government policies can severely impact the performance of the
industry as a whole.
Natural Calamity.
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7.8 Infrastructure
7.8.1 Power
The required power will be drawn from APSPDCL. To meet the demand during power cut
period and for continuous supply, the company has made alternative and stand by
arrangements with Diesel Generators.
7.8.2 Fuel
The unit requires Diesel Oil for operating the Generator in case of power failures. The
required Diesel Oil can be procured locally.
7.8.3 Water
The total water requirement for the plant can be drawn from the bore well.
7.8.4 Effluents
Since it is a washing, grading, ripening and packing unit, no harmful effluents will be
generated in the process. Hence the question of disposal of effluents does not arise.
The unit requires 2 machine operators, 3 skilled workers and 3 unskilled workers and 2
helpers for operating the unit. One Manager cum Accountant, one Clerk cum typist , one
Office Boy and 1 Watchmen are required for administration. This unit provides
employment opportunity to 13 members directly and about 50 unskilled labor for loading
and unloading and packing the fruits. The project does not require any labour for day to
day operations except for commodity handling. The loading and unloading charges will be
borne by the customers.
The promoters have own land Boddanapalli village, Agiripalli Mandal in Krishna District
where the project is set up.
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7.8.7 Buildings and Civil Works
The machinery will be housed in 9 ripening chambers and integrated pack house. The
building is a GI Roof shed which is constructed to meet the present requirement. The promoters
have received the required permissions for setting up the unit.
The project mainly requires construction of adequate buildings for the ripening chambers,
machinery and administrative buildings like office, toilets, water supply facilities, parking facilities
etc.
The plant & machinery is required for the refrigeration of the ripening plant. The promoters have
already identified the established & reputed machinery suppliers.
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1. Project Cost - ________________________ - Ripening Chambers
Civil (Iron Pillars, Beams and Iron
CIVIL Angulars and Iron wire mesh for
shed and Mezannaine floors)
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2. Project Cost - ______________________- Integrated Pack House
Civil for Shed (Iron, Roof sheets for pillars, truss
CIVIL and purlin)
Concrete Flooring
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3. Project Cost - _____________________ - Functional Infrastructure
Civil for Shed (Iron, Roof sheets for pillars, truss and 13,50,000
purlin)
Concrete Flooring 2,00,000
CIVIL 21,81,000
Development cost of Parking Area 1,00,000
Office, Guest Rooms & Canteen building and 5,31,000
furniture
Crates (4000 Nos * Rs 210/-) 8,40,000
Plant &
De-sapping tables 9,000 8,69,000
Machinery
Weighing Machine 20,000
Fire Safety Equipment 50,000
Bus Bars (Electrical Panel Board) 1,05,000
Electrical 4,25,000
Electrical 20 mm 4 core cables 1,20,000
Lights, wiring etc 1,50,000
Working Capital Margin 3,00,000 3,00,000
37,75,000 37,75,000
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