Mr. Rahul Paharia, Director, Jwala Techno Engineering Pvt Ltd, Mumbai, Maharashtra, talks about how to set up mango pulp processing unit.
Mangoes are of special interest for anybody interested to set up a fruit processing plant. Amongst all the fruits exported from India, mangoes are exported the most. There is high demand for various forms of processed mangoes like mango pulp, mango juice, mango dices etc. Amongst these mango pulp is the most important one and is exported in large quantities from India in aseptic, canned and frozen form. The other popular forms in which mango is processed are mango juice, frozen mango dices, concentrated mango pulp etc.
Mango Pulp Processing
In a mango pulp processing unit, we have machineries involved in series of operations such as washing, sorting, pulping, standardising, pasteurising, packing etc. The mangoes are first washed in the Washer machine where the cleaning happens by dipping mangoes in a tank filled with water that is agitated with the help of a blower. After washing the mangoes are taken to a sorting belt where the mangoes are sliced and inspected. They are then transferred by a conveyor belt to the pulper machine. In the pulper machine the pulp from the mangoes is extracted and the stone and the skin are separated. The pulp is taken to a standardisation tank for standardising the quality of the pulp. The pulp is then pasteurised by heating it to a temperature of 90 deg. C. After pasteurisation the mango pulp is taken for packing.
Canned Mango Pulp
In the case of canning the pulp is filled in sterilised tin cans. The tin cans are then placed in a retort filled with boiling hot water. The tin cans are then cooled and are ready for storage. No preservatives are needed to be added to the pulp in canned form. You can place the cans in room temperature and it does not require any form of controlled atmosphere storage when canned. There is high demand for canned mango pulp from India.
Aseptic Mango Pulp
In aseptic packing the pulp is filled in 200 liters bag in drums. The pulp is sterilised and filled using a aseptic filling machine in 200 liters bags that are placed in drums. You do not need to add any preservative in the case of aseptically packed pulp. Aseptic pulp has the highest demand amongst all forms of processed mango pulp.
Mango Juice
The mango juice is a commonly produced product. It is processed from mango pulp. Very rarely is the mango juice is produced from the fruit directly. Sugar syrup is added to the pulp to prepare mango juice. The sugar syrup is prepared by mixing sugar and water, heating it and then passing it through a filter. Once the juice is prepared in kettle, it is transferred through the homogeniser for the uniformity of the product. The juice is then pasteurised by heating at 90 deg. C and then cooling it so that it can be filled in plastic bottles.
Frozen Mango Pulp
Mango pulp is pasteurised and then cooled to 15 deg. C. The cooled mango pulp is filled in pouches and then placed in a blast freezer. The temperature of the pulp is brought down to -18 deg. C. in the blast freezer. The frozen pulp is then stored in a cold storage chamber that maintains the temperature of the pulp at -18 deg. C. Frozen mango pulp demand has shot up in the last few years and is exported in good quantities from India.
Frozen Mango Dices
Mangoes are washed thoroughly, then they are peeled and sliced manually. The sliced mangoes are fed to the dicer machine that cut the mangoes in dices of desired size. The diced mangoes are passed through an IQF or blast freezer to obtain frozen mango dices. Frozen mango dices are then filled in pouches and stored in cold storages that maintain the temperature of -18 deg. C. The demand for frozen mango dices is high in Europe and other western countries.
What are the key regulatory considerations and permits needed to establish mango pulp processing unit? Can you outline essential machinery and equipment for efficient mango pulp processing?
In terms of regulation, you need to have FSSAI certification, and for exporting, there are more guidelines to be met. They would go for inspections before any export is done. While setting the factory, you need the approval from pollution control board, set up ETP line to process the water that is being used in the plant. There could be more guidelines. The essential operations involves mango processing are washing, pulping, and pasteurisation. These operations are carried out in machines like washer, pulper, pasteuriser etc.
How can farmers and processors ensure sustainable and consistent supply of quality mangoes for processing?
The quality of mangoes for processing is important. Often good quality mangoes are normally sold in fresh farm and directly exported. Some varieties are used for processing. Totapuri is a common and popular variety for processing. Alphonso and some more varieties are sold in fresh farm, while some alphonso is used in processing. It all depends on the variety of the mangoes and what the customers are looking for. The best mangoes are not for processing, but lower and medium variety mangoes are used for other processes. When mangoes are not ripened, we have to put them in ripening chamber in order to make them ripe and bring them up to the level for processing. These are the basic factors that need to be taken care of when choosing which type of mangoes are good for processing.
What are the key factors influencing in selecting the optimal location for the mango pulp processing unit?
Many factors are involved, but the biggest one is that the plant should be in an area where the mango is grown in good quantities. Transportation is an important aspect when it comes to processing plants like these. So the plant should be close to the mango growing area. In a belt like Chittoor, we can find several plants for mango pulp processing. Other factors include how near or far the port from where the exports are going to happen is located. Generally we have seen most of the exports are from Mumbai or on the western side of the country. We can find a few plants in Maharashtra near to the coastal belt and Konkan region. Other factors would include the price of land, how close or far it is from the urban kind of setup etc. It also matters how much support the state government is giving for setting up of a plant like this. There are subsidies given by the state government which one has to take into account. To summarise, location, availability of mangoes, distance from the port, government friendly policies, and prices of the land are the main considerations in setting up a processing unit.
How can agriculture entrepreneurs get financial support for mango processing unit?
Central and state government offer subsidies for setting up of mango processing units. One should also approach institutions like NABARD for financial support in setting up of such plants. Since food processing industry falls under priority sector lending, they can approach banks for loans at preferential rates.
When do you provide insights into cost effective waste management for byproducts generated during mango pulp processing? What are the quality control measures to be implemented to ensure high quality mango pulp?
The major waste generated from mangoes are the stone and peels. They are normally sun dried and crushed to bring it in usable form. This waste can then be used for applications such as a input for boiler thereby reducing its running cost.
How can technology be integrated in processing unit for enhanced efficiency and productivity? Are there any training programs and resources available for farmers who want to venture into mango pulp processing, and how can they access the information?
We can go to any level of automation that we want. It depends on the size of plant and amount of capital investment from the entrepreneur. We can have PLC controls in plants so that the operations of quality machines are integrated. We can reduce the labour involved in plants like this. Government institutions like CFTRI that have facilities to which farmers can be exposed. They can understand technologies involved in the mango processing. People can approach consultants and technologists for guidance and information. Companies like ours who are involved in machine manufacturing can offer guidance to farmers as to how they can go about processing of mangoes.
Can you recommend marketing strategies for entrepreneurs for selling mango pulp products?
Mango pulp is sold in bulk to customers it is a B2B industries where we would be selling to corporate than distributors and consumers directly. For the export market, we need to target the bulk buyers in areas like Middle East countries which have big market for Indian mangoes. We have to understand their tastes to cater to their requirement, participate in exhibitions, list in government agencies such as APEDA etc.
Mr Rahul Paharia
Email rahul@jwalaengineering.com
Phone 9820197764
Mangoes are of special interest for anybody interested to set up a fruit processing plant. Amongst all the fruits exported from India, mangoes are exported the most. There is high demand for various forms of processed mangoes like mango pulp, mango juice, mango dices etc. Amongst these mango pulp is the most important one and is exported in large quantities from India in aseptic, canned and frozen form. The other popular forms in which mango is processed are mango juice, frozen mango dices, concentrated mango pulp etc.
Mango Pulp Processing
In a mango pulp processing unit, we have machineries involved in series of operations such as washing, sorting, pulping, standardising, pasteurising, packing etc. The mangoes are first washed in the Washer machine where the cleaning happens by dipping mangoes in a tank filled with water that is agitated with the help of a blower. After washing the mangoes are taken to a sorting belt where the mangoes are sliced and inspected. They are then transferred by a conveyor belt to the pulper machine. In the pulper machine the pulp from the mangoes is extracted and the stone and the skin are separated. The pulp is taken to a standardisation tank for standardising the quality of the pulp. The pulp is then pasteurised by heating it to a temperature of 90 deg. C. After pasteurisation the mango pulp is taken for packing.
Canned Mango Pulp
In the case of canning the pulp is filled in sterilised tin cans. The tin cans are then placed in a retort filled with boiling hot water. The tin cans are then cooled and are ready for storage. No preservatives are needed to be added to the pulp in canned form. You can place the cans in room temperature and it does not require any form of controlled atmosphere storage when canned. There is high demand for canned mango pulp from India.
Aseptic Mango Pulp
In aseptic packing the pulp is filled in 200 liters bag in drums. The pulp is sterilised and filled using a aseptic filling machine in 200 liters bags that are placed in drums. You do not need to add any preservative in the case of aseptically packed pulp. Aseptic pulp has the highest demand amongst all forms of processed mango pulp.
Mango Juice
The mango juice is a commonly produced product. It is processed from mango pulp. Very rarely is the mango juice is produced from the fruit directly. Sugar syrup is added to the pulp to prepare mango juice. The sugar syrup is prepared by mixing sugar and water, heating it and then passing it through a filter. Once the juice is prepared in kettle, it is transferred through the homogeniser for the uniformity of the product. The juice is then pasteurised by heating at 90 deg. C and then cooling it so that it can be filled in plastic bottles.
Frozen Mango Pulp
Mango pulp is pasteurised and then cooled to 15 deg. C. The cooled mango pulp is filled in pouches and then placed in a blast freezer. The temperature of the pulp is brought down to -18 deg. C. in the blast freezer. The frozen pulp is then stored in a cold storage chamber that maintains the temperature of the pulp at -18 deg. C. Frozen mango pulp demand has shot up in the last few years and is exported in good quantities from India.
Frozen Mango Dices
Mangoes are washed thoroughly, then they are peeled and sliced manually. The sliced mangoes are fed to the dicer machine that cut the mangoes in dices of desired size. The diced mangoes are passed through an IQF or blast freezer to obtain frozen mango dices. Frozen mango dices are then filled in pouches and stored in cold storages that maintain the temperature of -18 deg. C. The demand for frozen mango dices is high in Europe and other western countries.
What are the key regulatory considerations and permits needed to establish mango pulp processing unit? Can you outline essential machinery and equipment for efficient mango pulp processing?
In terms of regulation, you need to have FSSAI certification, and for exporting, there are more guidelines to be met. They would go for inspections before any export is done. While setting the factory, you need the approval from pollution control board, set up ETP line to process the water that is being used in the plant. There could be more guidelines. The essential operations involves mango processing are washing, pulping, and pasteurisation. These operations are carried out in machines like washer, pulper, pasteuriser etc.
How can farmers and processors ensure sustainable and consistent supply of quality mangoes for processing?
The quality of mangoes for processing is important. Often good quality mangoes are normally sold in fresh farm and directly exported. Some varieties are used for processing. Totapuri is a common and popular variety for processing. Alphonso and some more varieties are sold in fresh farm, while some alphonso is used in processing. It all depends on the variety of the mangoes and what the customers are looking for. The best mangoes are not for processing, but lower and medium variety mangoes are used for other processes. When mangoes are not ripened, we have to put them in ripening chamber in order to make them ripe and bring them up to the level for processing. These are the basic factors that need to be taken care of when choosing which type of mangoes are good for processing.
What are the key factors influencing in selecting the optimal location for the mango pulp processing unit?
Many factors are involved, but the biggest one is that the plant should be in an area where the mango is grown in good quantities. Transportation is an important aspect when it comes to processing plants like these. So the plant should be close to the mango growing area. In a belt like Chittoor, we can find several plants for mango pulp processing. Other factors include how near or far the port from where the exports are going to happen is located. Generally we have seen most of the exports are from Mumbai or on the western side of the country. We can find a few plants in Maharashtra near to the coastal belt and Konkan region. Other factors would include the price of land, how close or far it is from the urban kind of setup etc. It also matters how much support the state government is giving for setting up of a plant like this. There are subsidies given by the state government which one has to take into account. To summarise, location, availability of mangoes, distance from the port, government friendly policies, and prices of the land are the main considerations in setting up a processing unit.
How can agriculture entrepreneurs get financial support for mango processing unit?
Central and state government offer subsidies for setting up of mango processing units. One should also approach institutions like NABARD for financial support in setting up of such plants. Since food processing industry falls under priority sector lending, they can approach banks for loans at preferential rates.
When do you provide insights into cost effective waste management for byproducts generated during mango pulp processing? What are the quality control measures to be implemented to ensure high quality mango pulp?
The major waste generated from mangoes are the stone and peels. They are normally sun dried and crushed to bring it in usable form. This waste can then be used for applications such as a input for boiler thereby reducing its running cost.
How can technology be integrated in processing unit for enhanced efficiency and productivity? Are there any training programs and resources available for farmers who want to venture into mango pulp processing, and how can they access the information?
We can go to any level of automation that we want. It depends on the size of plant and amount of capital investment from the entrepreneur. We can have PLC controls in plants so that the operations of quality machines are integrated. We can reduce the labour involved in plants like this. Government institutions like CFTRI that have facilities to which farmers can be exposed. They can understand technologies involved in the mango processing. People can approach consultants and technologists for guidance and information. Companies like ours who are involved in machine manufacturing can offer guidance to farmers as to how they can go about processing of mangoes.
Can you recommend marketing strategies for entrepreneurs for selling mango pulp products?
Mango pulp is sold in bulk to customers it is a B2B industries where we would be selling to corporate than distributors and consumers directly. For the export market, we need to target the bulk buyers in areas like Middle East countries which have big market for Indian mangoes. We have to understand their tastes to cater to their requirement, participate in exhibitions, list in government agencies such as APEDA etc.
Mr Rahul Paharia
Email rahul@jwalaengineering.com
Phone 9820197764