FACULTY OF SCIENCE AND TECHNOLOGY

DEPARTMRNT OF FOOD SCIENCE AND NUTRITION

GETRUDE N NDONDE

R0433627

FSN108: FOOD ENGINEERING OPERATIONS

PROJECT PROPOSAL

SUBMITTED IN PARTIAL FUFILLMENT OF FSN108:GUAVA NECTAR PROCESSING PLANT AT

RAMGATE JUICING ESTATES

Guava Nectar processing at Ramgate Juicing Estate

Ramgate Juicing Estate was offered to Miss Bayayi under the land reform program. Miss Bayayi formed Ramgate Juicing Estate to allow the professional management of the juicing business. Mr. Bayayi has since identified a qualified Manager to maintain productivity at Ramgate Juicing Estate. There is potential amount of land to setup a small scale guava nectar processing plant and will ensure 100% capacity utilization.

Project Location

The project is located in Concession, MashonalandWestProvince, 25 km off Harare-Bindura road.

Details of Estate Management and Ownership.

The project is wholly owned by Miss. Bayayi who is director of the company. Due to the small scale nature of the project a qualified and experienced Manager is required, thus Mr. Babayi is managing the project to ensure total viability of the project.

Security

To Show project commitment, the company will Surrender Title deeds for a property in Harare as security to the Lending bank. The current valuation certificate values the property is ZWD20 Billion Value of the property is open for verification by the lending bank.

Guava processing

Introduction

Guava (Psidium guajava L.), which belongs to the Myrtaceae family, is a native of tropical

America and grows well in tropical and subtropical regions. Guava fruit has a characteristic flavor, to which its acidity (pH 4.0 to 5.2) contributes (Jagtiani et al. 1988). It is a rich source of ascorbic acid, containing over 100-mg/100 g (Wenkam and Miller 1965). Most of the guava produced around the world is consumed fresh. Over the past several decades there has been a growing trend toward adding value to raw agricultural products. As populations have become more urban, this trend has accelerated. The need for stable, convenient foods has increased along with the demand for exotic products for international cuisine. Within the globalization of the food industry, the demand for quality juice and juice type beverages has markedly expanded. Traditionally, only a handful of fruit and vegetable juices have served this market as large multinational companies or their affiliates, have captured the majority of national and international juice trade. Both major and minor fruits were be covered with emphasis upon limited-resource producers for local markets. This project will provide adequate details so interested parties can fund the project so as to develop a new processing establishment.

Historical background

The manufacture of guava juices from fruits and vegetables is as old (or older) than agriculture. During the ripening process most fruits soften to the point where simply handling or transporting them yields more juice than flesh, albeit often partially fermented. The resulting pulpy fluid, easily separated from seed and skin, is generally more flavorful than the more solid portion. Hunter-gatherers could either consume quasi juices directly or collect the soft fruit in reasonably leak-free containers for later use. Except for cool temperature climates, storage life was limited to mere hours before incipient fermentation modified the character of the juice appreciably.

Through trial and error humans learned practical ways of extracting juice from various sources and, most importantly, which attractive but toxic fruits to avoid (Kimball,1998). Tool making skills fostered the manufacture of devices for macerating fruits and extracting juices. Containers for storing foods, including receptacles for fluids were also devised from local resources, i.e. woven plant fiber and wood, clay soils and animal skin/intestine. Such methods and equipment can still be found in isolated pre-industrialized regions. Otherwise they are seen only in museums as prehistoric or early artifacts of extinct civilizations. Until fairly recently, liquid containers were quite primitive compared to those of the 20th century. The perishable nature of juices dictated immediate consumption within less than 24 hours in warm climates and extended but still limited time in cooler environs. Natural chilling or freezing was the only alternative to microbial modification of the juice. It was found that the juice, after bubbling mysteriously, has a distinctly different character and affect on those consuming the product. Also, the material stored several days longer slowly turned harshly acidic or developed an even more unpalatable surface growth and taste. This early vinegar was used as a preservative for other fruits and vegetables. Nagy et al(1993) states that, “With the development of agriculture over the last 10 millennia, the cultivation of crops provided a fairly reliable source of food, including fruits appropriate for juice and beverage use. Unless the juice was consumed fresh, soon after pressing, fermentation was the likely, often desired consequence until preservation techniques were developed”. In fact, the concept of maintaining a fruit destined for juicing in its whole, intact form until the juice is needed continues to be a sound principle. Even today, maintaining the fruit intact is one of the easiest ways of preserving juice quality.

Justification

The purpose of this project is to present technical and business information designed to address the processing operations involved in the manufacture of guava nectar. The project aims to add value to local agricultural products, provide employment, augmenting the quality, safety, economy and diversity of the local food supply. To reduce greatly the vast heaps of guava fruits in our country going to waste due to lack of markets or processing outlets thus to develop a local juice processing industry. Despite the more perishable nature of juices, there are practical reasons for their manufacture and processing:

  • The more delicate, soft fruits cannot be kept intact over long periods and tend to

Spoil. Juicing is the logical alternative,

  • The very young, elderly and infirm may have problems eating, let alone peeling certain fruits. Drinking juice is an effective, nutritious alternative,
  • In addition to the nutritive value of juices and the additional health benefits from phytochemicals, recently recognized components of many fruit juices will provide
  • Even flavorful juices, that may not be balanced nutritionally or which lack

nutrients or phytochemicals, can be blended or act as effective carriers for other natural or synthetic nutrients such as vitamins, and minerals

  • Fluid food products, including juices are easier to process, to heat, cool, freeze, standardize, transport, etc., than solid foods or fluids containing particulate. Thus processing efficiency, safety and quality norms are easier to meet,
  • Modern processing, packaging, ingredient technology and distribution systems insure safe, stable and appealing juice and beverage products in a convenient, economical form far from the raw material source or season.

Objectives

To enhance food security

To save foreign currency through reduced fruit juice imports.

To increase juice variety to meet the high demand on the market

To economically empower the members of the community

To provide high quality and reasonably priced juice to consumers.

Null hypothesis

Null hypothesis: there is sufficient evidence that the guava nectar produced is of high ascorbic value and has shelf life of more than three months

Literature review

Guava fruits are used for both, fresh consumption and processing. It excels most other fruit trees in productivity, hardiness, adaptability and vitamin-C content. Besides its high nutritive value, it bears heavy crop every year and gives good economic return involving very little input. This has prompted the researcher to take up guava cultivation on a small scale.Nectar It is the product of blending juice with a certain amount of solids from the pulp containing the same amount of °Brix as the original fruit. Normally, nectars are prepared by diluting fruit pulp to 30 °Brix.

Harvesting and Post-production operations

Harvesting and transporting

Transporting guavas from the production field to the packing location is made by tows, trucks or specially-designed vehicles. Availability of a double roof, thermal insulation and sliding curtains help keep the storage temperature of the fruit during loading and unloading. The equipment must be kept clean and disinfected and fitted with good suspension, low-pressure tires and even and smooth floor surface, such that the packing units can be easily handled. Bulk transportation the use of vegetative material is placed on the vehicle platform to avoid extreme temperatures and to act as cushion against mechanical collisions during transport (Colfruits, 2004). Bruising or puncturing caused by poor handling, dropping or abrasion, will result in localized areas of softening and development of secondary microbial infection (Foodmarketexchange, 2004).

Washing

Washing is an operation that generally is the point of departure of any fruit and vegetable production process. In a small-scale operation, this activity is normally carried out in basins with recirculating water, or simply with still water that is continuously replaced.

The operation consists of eliminating the dirt sticking to the material before it enters the processing line, thus avoiding complications deriving from the possible contamination of the raw material. The washing must be performed using clean water, which should be as pure as possible, and if necessary should be made potable by adding sodium hypochlorite, 10 ml of 10%, solution for every 100 litres of water

Grading

grading, is done after washing, waxing, and fungicide treatment, the guavas are left to dry and then are graded for packing. Graders remove any fruit that shows signs of fresh mechanical damage or any of the conditions that qualify the fruit for rejection in the grading stage. the selection is carried out on a table suitable for this process or on a conveyor belt. Such a process (grading) will entail the removal of all of the fruit and vegetables that do not have uniform characteristics compared to the rest of the lot, in terms of ripeness, colour, shape and size, or which present mechanical or microbiological damage.

Processing

Juice exraction and finishing

The washed sound fruit is first passed through a chopper or slicer to break up the fruit and this material is fed into a fruit pulper(Browns machine 1 and 2). The pulper will remove the seeds and fibrous pieces of tissue and force the reminder of the product through a perforated stainless steel screen. The holes in the screen should be between 0.033 and 0.045mm in diameter can effectively clean up the juice and often yeidl a usable thick pulpy by-product.

. The machine should be fed at a constant rate to ensure efficient operation.

As shown in figure 1 are (a)fruit pulper and (b)finisher(BD 75).Extracted from (

The puréed material coming from the pulper is next passed through a finisher (BD 75). The finisher is equipped with a screen containing holes of approximately 0.020 in diameter. The finisher will remove the stone cells by use of a hydraulic hand pump and pressure gradient of 250 psi. Feed material was recirculated through the system from the fruit and provide the optimum consistency to the product and a reduced pulp concentration of 12 – 13%. Even without macerating enzyme addition, heating to ~70ºC softens the fruit, inactivates native enzymes, reduces microbial load and affects an increase in juice yield. However, delicate flavours can be destroyed and unacceptable darkening due to enzymatic and non-enzymatic browning can occur. Rapid heating and cooling prior to juicing can overcome some of these quality problems. Traditionally mashed fruit and purees were batch heated to optimum macerating enzyme temperature (~55 to 60ºC) in open steam-jacketed kettles with stirring. This step and subsequent cooling can be accomplished by swept surface heat exchangers or thermal screws (a hollow steam-heated auger in a steam-jacketed trough). Steam or cooling fluid flowing through both auger and trough effectively and continuously heats or cools the material. Pulpy, viscous puree cannot be passed through a plate or tube heat exchanger due to clogging problems, although, after solids reduction, these units are appropriate.

Pasteurization

The application of this method is crucial to the product.Pasteurization consists of a thermal treatment that is less drastic than sterilization, but sufficient to inactivate the disease-causing micro-organisms present in the foods. Pasteurization inactivates most of the vegetative micro-organism forms but not the spore-bearing forms, thus it is suitable for short-term preservation. Furthermore, pasteurization fosters the inactivation of enzymes that may cause the deteriorate. As with sterilization, pasteurization is performed according to an appropriate combination in this case its done at a temperature 93 degrees Celsius and held for 48 seconds .The process in guava fruits into juices extends their storage life. This is made possible by pasteurization, which considerably reduces the number of fermentative micro-organisms that contribute to the acidification of juice, at the expense of sugars.

The pasteurization of fruit purees’, provides for their stabilization so that they can be preserved in combination with other methods like chilling or freezing. All of these procedures will contribute to guaranteeing the quality and shelf life of the product over time.

Storage and preservation

The product is then passed to the storage tanks where preservative is added(sodium metabisulphite) and puree the used to process nectar. The processed puree’ is then used as a base in the production of guava nectar. Building on the hurdle principle, antimicrobials can effectively extend shelf life. Sulphur dioxide is quite effective in inhibiting both microbial growth and enzymatic and non-enzymatic browning and is standard practice in most wine making. A small number of individuals are quite sensitive to SO2, so correct labelling and minimum levels are required. SO2 is delivered as the gas or in the less noxious and more easily controlled form as potassium metabisulphite with about 60 percent by weight as SO2. Dosage is reasonably self-limiting, since too little is ineffective and too much gives an unpleasant, pungent aroma. The preservative action is due to the undissociated H2SO3 molecule (formed when SO2 or bisulphites are dissolved in water), so lower pH favours its use. Levels of 30 to 100 ppms, at a pH below 4.0 are effective. However, some asthmatics are so sensitive that simply being near SO2 solutions is enough to trigger an adverse reaction, so caution is advised in use and labelling in foods if over 10 ppms is mandatory.

General outline of guava nectar production from the by-product of guava puree’

1.Weighing2.Mixing1.Weighing

  • sugar-mixing tank-puree’
  • citric acid

1.Water

3.Preservation

-potassium/sodium sorbate

-potassium/sodium benzoate

Containers4.Bottlingcaps

-washing-washing

-steam-steam

-hot water-hot water

5. Storage And Or Transport

Materials And Equipment

The following raw materials are equipment used in the processing of guava nectar

To make one batch of guava nectar with weight of 210kg needs :

Raw material / Quantity (kg)
Guava puree / 60
Citric acid / 21
Potassium sorbate / 0.5
Sugar / 0.053
Water
Total / 210

Raw material

-Mature guavas

-guava puree’

-Sugar

- citric acid

-Water

- potassium/sodium sorbate

- potassium/sodium benzoate

Materials and equipment

- chopper or slicer

-Pulper, Browns machine 1 and 2

-BD75

-plate heat exchanger

-storage tank

- Capper.

-plastic bottles

-filler

Infrastructure:

Plant layout:

- processing room.

- boiler room.

- storeroom for goods and finished product.

- toilets and dressing rooms.

- quality control laboratory.

- area destined for the reception of raw materials.

Indirect or nondepreciable costs.

Plan and technical consultancy:

- Electrical installation.

- Installation of pipes for the supply of drinking water.

- Installation of pipes for the supply of steam.

- Installation of septic tank, septic pit and toilets.

- Installation of pipes for the disposal of waste waters.

-Installation of equipment in the plant.

Estimated Cost Of Supplies And Services Rendered In Establishing Juicing Plant
Supplies and services rendered / Unit price / Quantity / Total
1. OPERATING COSTS
1. Fixed operating costs
a)Quality control supervisor / $2,000,000.00 / 2 / $4,000,000.00
b)Processing plant workers. / $1,000,000.00 / 15 / $15,000,000.00
c)Boiler room operator. / $1,000,000.00 / 2 / $2,000,000.00
d)Plant cleaning staff / $600,000.00 / 5 / $3,000,000.00
Unit price sub-total / $4,600,000.00 / $24,000,000.00
2. SERVICES AND EQUIPMENT
1.lngriedients
a)Guava puree / $130,000.00 / 60 / $7,800,000.00
b)Sugar / $37,000.00 / 21 / $777,000.00
c)Citric acid / $205,000.00 / 0.5 / $102,500.00
d)Potassium sorbate / $754,716.98 / 0.05 / $40,000.00
e)Sodium metabisuphite / $200,000.00 / 2 / $400,000.00
$1,326,716.98 / $9,119,500.00
2.Post-harvest or food processing equipment
a)Brown Machine / $100,000,000.00 / 2 / $200,000,000.00
b)BD 75 / $50,000,000.00 / 2 / $100,000,000.00
c)Chopper / $25,000,000.00 / 1 / $25,000,000.00
d)Plate Heat Exchanger / $80,000,000.00 / 1 / $80,000,000.00
e)Storage tanks / $45,000,000.00 / 5 / $225,000,000.00
f)Connecting pipes / $3,000,000.00 / 10 / $30,000,000.00
g)Fillers / $2,500,000.00 / 7 / $17,500,000.00
g)Sorting belt / $10,000,000.00 / 1 / $10,000,000.00
$315,500,000.00 / $687,500,000.00
3. Travel transport
a)Fuel / $300,000.00 / 1000 / $300,000,000.00
b)Contracted haulage company / $10,000,000.00 / 1 / $10,000,000.00
$10,300,000.00 / $31,000,000.00
4. Outside experts
a)Consultant / $20,000,000.00 / 1 / $20,000,000.00
Cost-price sub-total / $347,126,716.98 / $747,619,500.00
3. AT ALL INCLUSIVE PRICE
1. Maintenance
a)Plant cleaning and disinfection. / $500,000.00 / 20 / $10,000,000.00
b)Equipment repair. / $250,000.00 / 20 / $5,000,000.00
$750,000.00 / $15,000,000.00
2. Insurance
a)Variable operating costs / $50,000,000.00 / 1 / $50,000,000.00
3.Products
a)Detergents / $200,000.00 / 20 / $4,000,000.00
b) Chemical disinfectants / $500,000.00 / 20 / $10,000,000.00
c)Packages / $400,000.00 / 1000 / $400,000,000.00
d) Cleaning materials / $200,000.00 / 100 / $20,000,000.00
$1,300,000.00 / $434,000,000.00
4.Indirect or nondepreciable costs
a)Electrical installation. / $6,000,000.00 / 1 / $6,000,000.00
b) Pipe Installation / $7,000,000.00 / 1 / $7,000,000.00
c)Installation of septic tank / $5,000,000.00 / 1 / $5,000,000.00
d)Equipment Installation in the plant / $10,000,000.00 / 1 / $10,000,000.00
$28,000,000.00 / $28,000,000.00
Cost price sub-total / $80,050,000.00 / $527,000,000.00
GRAND TOTAL / $ 1,298,619,500.00

Weaknesses.

Lack of liquid capital to fund capital and working capital requirements. This can be however, be countered by the availability of ASPEF(Agricultural Sector Productivity Enhancement Facility) funds from the Reserve Bank of Zimbabwe, which can be accessed at a concessionary rate of 50% as in Part 8.1 of ASPEF(Operational Guidelines And Disbursement Modalities).

Opportunities

The availability of the Agricultural Productivity Enhancement Facility (ASPEF) at 50% that can be utilized to enhance productivity.

A ready Market for all products to be produced on the Estate.

Support from monetary authorities supporting juice production.