Potato Powder and Flakes
Indian vegetable basket is incomplete without mentioning the king of vegetables-potato-a sustaining force and a culinary delight. The power of potato is known for sustaining millions of lives by providing food and nutrition during distress times. Its high production potential per unit area, high nutritional value and great taste makes potato one of the most important food crops in the world. Classified as a vegetable, potatoes help contribute to the minimum goal of eating five servings of fruits and vegetables per day. One serving-a 5.3 ounce, medium potato-provides:
- 45 percent of the daily value for vitamin C.
• 21 percent of the daily value for potassium.
• Three grams of fiber.
• Only 100 calories.
The tantalizing taste of nutrient-rich potatoes makes it an essential part of every breakfast, lunch and dinner worldwide. An array of dishes created by potato speaks volumes about the variety that it offers to the palate. India produces around 15 varieties of potatoes that come in different shapes, sizes, skin colour and flavour. Kufri Jyoti, Kufri lauvkar, kufri swarna, Kufri lalima and kufri giriraj are some of the varieties that form a part of Indian potato portfolio, powered with energy.
• In India, potato es are grown in winter under short-day conditions and harvested from January to march when there is no fresh harvest of potato in most parts of northern hemisphere making it a strategic crop from export point of view.
• India produces about 28 million tonnes of potato and the productivity of potato in India is 19t/ha, which is higher than the world average of 16.5t/ha.
• The Indian potato is cultivated in sandy loam soils resulting in good shape and luster to the tubers.
• Preferred worldwide for its taste, Indian potato meets the international quality standards in terms of freedom from prohibited diseases, shape, size, skin colour, flesh and dry matter content.
• Over the years India has developed indigenous technologies including development of suitable varieties, seed production technology, agro techniques and post-harvest technologies, offering world a quality product.
• The pride of Indian potato industry are the four agri export zones that have been set up by the government of India in Punjab, Uttar Pradesh, West Bengal and Madhya Pradesh for further value addition.
Potato powder and flakes are processed potatoes. It will help to increase the shelf life of potatoes. There are various machines required for the processing of potatoes. Most of the machines are indigenously available; very few of them may be imported. There are plenty of well varieties of potato available for processing. As a whole the products have fair market demand. There is scope for new entrepreneurs. Environmental pollution problem is there, which can be solved by proper treatment.
1. It is generally blow to mesh size free flowing powder.
2. It is tasty and mostly white to pale yellow coloured powder.
3. It absorbs moisture from air when it is kept in open air.
4. It can be preserved for more than one year when it is vacuum packed with nitrogen flash.
1. It is crispy and very lightweight product.
2. It also absorbs moisture from air and become soft.
USES OF POTATO POWDER
It is used for making allu bhujia. It is used to make soup concentrate.
USES OF POTATO FLAKES
It is used as breakfast or snack food.
DESCRIPTION OF RAW MATERIALS
The basic raw materials required are:
1. Potatoes-of very good varieties
The potatoes required for processing dehydrated potato products are of very good quality. The kufri variety is generally used for processing. The only edible part of potato is tuber. It can grow in a wide range of climatic cycle. The growing cycle is 90-140 days.
With high percentage of water content, its quality is adversely affected with the passage of time. Potatoes chosen are free of sprouts, green skin, or spots. To prevent potatoes from greening, spoiling, they are stored in cold storage facilities that are well ventilated and under regulated temperatures. This prevents development of sugar in potatoes and these potatoes are commonly called Low Sugar Potatoes. Evening
2. Additives & Preservatives
The potato processing additives and their functions are:
Mono & Diglycerides - This reduces stickiness and is a required additive.
Sodium Bisulfite - inhibits browning.
Sodium Acid Pyrophosphate (SAPP) - inhibits greying, colour control.
Citric Acid - Processing aid for emulsions stability.
BHA, BHT - to inhibit oxidation - for preserving flavour.
Colour, Spice and Vitamins - added as required.
PACKING AND MARKING
1. PACKING - Dehydrated potatoes shall be packed in clean, sound, moisture proof containers made of tin-plate, laminated foils or any suitable material which would prevent the intake of moisture.
2. MARKING - Each container shall be marked or labelled with the following particulars:
a) Name and type of the material,
b) Name and address of the manufacturer,
c) Net mass,
d) Declaration to the effect that permitted preservatives have been used,
e) Batch or code number indicating the date of manufacture, and
f) Manufacturer's license number.
g) Each container may also be marked with the ISI Certification Mark.
Basic Raw Material Required
(1) Potato (Kufri Chandramukhi variety)
(2) Sodium Metabisulphite
(3) Salt (Sodium chloride) Mixed Spices.
Basic Plant & Machines Required
(2) Paste maker
(3) Slurry making tank
(4) Sifter sieve
(5) Spray drier
(7) Automatic filling weighing and sealing machine
(10) Storage tank
(11) Washing trap
(12) Digital Balance.
Take potatoes by bucket elevator to the pressure vessels heat it at 110°C for 15 - 20 minutes. Boiled potatoes are passed through washing machine. Washed and boiled potatoes are put in the pulping machine where the potatoes are deskinned and deskinned potatoes are feed in the automatic paste making machine. Potato paste is formed and put it in the slurry making machine, formed slurry of 30% concentrate is feed into the spray drier to form potato powder.
Entry temperature of the slurry is 80°C and spray drier steam temperature 125°C - 130°C. Potato powder formed which is collected in the holding drum and then packs it by automatic weighing and sealing machine.
Keep the pack product at room temperature and market the product. Check the quality of the product before marketing.
Make potato slurry of 30% and feed it into the flaker at 125°C-130°C to form potato flakes. Flakes rolls speed 3-4 minutes per revolutions.
Check the quality of the flakes and then pack it in 500 gm. 1 kg pack. Store the product at room temperature.
Rated Plant capacity = 6.00 MT/day
= 1800.00 MT/annum
POTATO POWDER & FLAKES
No. of working days = 25 days/month
= 300 days/annum
No. of shifts = 2 per day
One shift = 8 hours
5 MT POTATO POWDER/DAY
1 MT POTATO FLAKES/DAY
Currency - Rs.
LAND & BUILDING Cost Rs. 129 Lakh
PLANT & MACHINERY
1. Spray Drier
2. Washing Tank
4. Jacketed Pressure Vessel
5. Bucket Elevator
6. Jacketed Slurry Making Tank
7. Holding Tank 5000 ltrs.
8. Boiler steam producing
9. Automatic Fill, Weighing & Packing Machine
10. Digital Balance
11. Paste Making Machine made by SS 304
12. Maintenance Equipments
13. Potato Pulping Machine
15. Material Handling Equipments
16. Laboratory Equipments
17. Miscellaneous Machine like pipeline
valves, motor etc. TOTAL Rs. 133.25 Lakh
1. LAND & BUILDING Rs. 129 Lakh
2. PLANT & MACHINERY Rs. 133.25 Lakh
3. OTHER FIXED ASSETS Rs. 67.5 Lakh
TOTAL Rs. 329.75 Lakh
WORKING CAPITAL REQUIREMENT/MONTH
1. Potato (Kufri Chandra Mukhi)
2. Lab Chemicals
3. Printed Packing Material TOTAL Rs. 45.83 Lakh
TOTAL WORKING CAPITAL/MONTH
1. RAW MATERIAL Rs. 45.83 Lakh
2. SALARY & WAGES Rs. 6.86 Lakh
3. UTILITIES & OVERHEADS Rs. 8.38 Lakh
TOTAL Rs. 61.07 Lakh
COST OF PROJECT
TOTAL FIXED CAPITAL Rs. 329.75 Lakh
MARGIN MONEY Rs. 45.8 Lakh
TOTAL Rs. 375.55 Lakh
TOTAL CAPITAL INVESTMENT
TOTAL FIXED CAPITAL Rs. 329.75 Lakh
TOTAL WORKING CAPITAL FOR 3 MONTHS Rs. 183.19 Lakh
TOTAL Rs. 512.94 Lakh
TURN OVER/ANNUM = Rs. 1032 Lakh
PROFIT SALES RATIO = 20.46%
RATE OF RETURN = 41.16%
BREAK EVEN POINT (B.E.P) = 43.31%