Upload
msmsindia
View
82
Download
0
Embed Size (px)
DESCRIPTION
Onions are undeniably the single most important foo preparation ingredient. Its availability around the year is the obvious most sought after scenario around the world. Frozen chopped IQF frozen onions is the clear answer. MAZDA are in the forefront in this discipline of the Food Processing Sector, with complete plants from conceptualization to location-specific project design and implementation. More about us at www.mazmach.com
Citation preview
Project code: MAZDA N-106
ONIONS IQF PLANT-FROZEN PRODUCTS
NOTESIndividually Quick Frozen (IQF) products are value added preserved food products. Onions, various fruits and vegetables, meats, sea food are thus preserved and marketed. p
White onions are preferred. General diced, sliced onions are processed into IQF varieties.
Recommended Sizes
1/4" 3/8" 1/2" 3/4" 1"
Diced
Strips
Mazda Speciality Machine Systems,Scale NTS
PackagingSeveral different packaging options are offered. Standard sizes range from a 40 lb box to a 1,300 lb industrial reefer cargo totes.
INDIA
SHEET # 2011.N 106.01
Scale NTS
DSN
Onions are fed in manually. A transport system leads the onions continuously through the blades. The blades are positioned so that they adjust to the size of the onions largely independently of each other.
The design of the probe / scanner that determines the position of the blades ensures that, as far as possible, only what is necessary is cut off the onions. Precision ensures less unnecessary waste!
After inserting the onions into the transport facility, it holds them so tightly that they cannot shift around any more. This means that the g y a ey ca o s a ou d a y o e s ea s a eleaves and roots are normally cut off with great accuracy by blades.
This precision cutting saves on a lot of subsequent manual work at the inspection bench. – The onions and their tops and tails are ejected separately from the machines.
Sliced IQF Onion:2-4 mm3-5 mm Green Spring 3-5 mm4-6 mm5-7 mm
G ee Sp gOnions- diced IQF
Diced IQF Onion:4 mm6 mm10 mm
Mazda Speciality Machine Systems INDIAScale NTS
10 mm20 mm
Mazda Speciality Machine Systems, INDIA
SHEET # 2011.N 106.11
Scale NTS
DSN
Notes:Notes:
CUTTING
Mazda Speciality Machine Systems
Data Sheet # 2013.156
NOTES
The onions are stored in boxes at temperatures of 33º-34º until further processed.34 until further processed.
Onions are topped and peeled then diced to meet customer’s specifications.
After the onions are diced they are blanched and individuallyare blanched and individually quick frozen.
Mazda Speciality Machine Systems,Scale NTSINDIA
SHEET # 2011.N 106.04
Scale NTS
DSN
Fresh produce handling equipment
IQF Freezing methodologyIQF Freezing methodology
Mazda Speciality Machine Systems INDIAScale NTS Mazda Speciality Machine Systems, INDIA
SHEET # 2011.N 106.06
Scale NTS
DSN
Mazda Speciality Machine Systems INDIAScale NTS Mazda Speciality Machine Systems, INDIA
SHEET # 2011.N 106.15
Scale NTS
DSN
Extremely quick freezing of the surface on first bed reduces de-hydration to a y q g yminimum. Low or zero lumps keep yield to a maximum.
Mazda Speciality Machine Systems,Scale NTSINDIA
SHEET # 2011. N 106.07
Scale NTS
DSN
BLAST FREEZING IS A LOWER COST OPTION
Notes:Notes:
FREEZING
VACUUM-PACKAGING
Mazda Speciality Machine Systems
Data Sheet # 2013.157
PRECONDITION FOR SELECTION OF TECHNOLOGY1.1 ProductVarious fruits, vegetables, meat, poultry and dairy
d t
Frozen Options------------------
-IQF Diced Product: 1/4"products
Nominal capacity1200 kg per hourIn feed temperature +5 COut feed temperature -18 C (levelled out)
1/4 3/8" 1/2" 3/4"
------------------- IQF Onion Strips:
SLICED IQF
(levelled out)1.2 Logistic dataFed from conveying elevator via in feed distribution shaker.Even feeding rate ± 5 %.
Q p3/8" 1/2" 3/4"
------------------- Onion Fines
Wet products shall be well dewatered.1.3 Production processFreezing IQF
------------------- Custom Cuts------------------
- Blanched ------------------ DICED IQF
Mazda Speciality Machine Systems,Scale NTSINDIA
SHEET # 2011.N 106.09
Scale NTS
DSN
Packaging OptionsPackaging Options
IQF diced onions are packaged in plastic film pouches, bags ( even gas flushed), or in corrugated cartons with a plastic bag lining.
Options range from Automated FFS machines with weigh fillers to very simple pouch filling and sealing machines ( As shown)
Mazda Speciality Machine Systems,Scale NTSINDIA
SHEET # 2011.N 106.10
Scale NTS
DSN
A By Product:
A frozen onion food product is prepared by a process which includes the steps of peeling and slicing fresh uncooked onions, cutting the resulting onion slabs into pieces most of which are composed of two or more lengths of onion scales in side-by-side relationship, separating each piece into its individual
l t ti th t d t ith b tt i t dscales or nuggets, coating the separated nuggets with a batter mixture and quick-freezing.
The separating operation includes the use of hydro, mechanical and vibratory forces to produce a continuous supply of separated nuggets ready for the coating operation If desired the coated cubes can be partially fried beforecoating operation. If desired the coated cubes can be partially fried before freezing.
Mazda Speciality Machine Systems INDIAScale NTS Mazda Speciality Machine Systems, INDIA
SHEET # 2011.N 106.12
Scale NTS
DSN
PROJECT REQUISITESPROJECT REQUISITES:
Plant Capacity: 2.20 tonnes per hour fresh onions
Plant Area: 1000 sq. mtrs
Electric Power: 175 KW
Steam: 0 5 tph at 10 kg/sq cmSteam: 0.5 tph at 10.kg/sq.cm
Water: 2500 lph
Compressed air: 100 lpm at 7 bar
Others: A Cold Store
Sensitivity factors:
Mazda Speciality Machine Systems INDIAScale NTS Mazda Speciality Machine Systems, INDIA
SHEET # 2011.N 106.17
Scale NTS
DSN
Y
SU
E
$
PROFIT AREA
BREAK EVEN POINT
B
OS
T A
ND
RE
VE
N
LOSS
FIXED COST LINE
CO
BREAK EVEN VOLUME
AREA
0 P Break Even Point
Mazda Speciality Machine Systems INDIAScale NTS
ANNUAL PRODUCTION (Units)0X 100
= Annual Fixed Cost -----------------------------------Annual Fixed Cost + Profit
Mazda Speciality Machine Systems, INDIA
SHEET # 2011.N 106 . 18
Scale NTS
DSN
NOTESFinancial InvolvementsFinancial Involvements
Land and Building As recommended in the PDD
Plant Equipment. USD 400,000.- to 500,000.-
-depending on freezer option chosen
Production of IQF Onion products venture beyond a-
Break Even Volume of: 1000 Kgs per hour -diced frozen onions
And economically sustainable: at 20 percent enhanced production.
A plant capacity of: 2200 Kgs per hour -Fresh onions.A plant capacity of: 2200 Kgs per hour Fresh onions.
Pay back period under normal conditions: 2 Years
.
Mazda Speciality Machine Systems,Scale NTSINDIA
SHEET # 2011. N 106. 19
Scale NTS
DSN
Produce that can also be processed at the facility.
Potato cubes and Green Spring Onions- diced
Produce that can also be processed at the facility…Mixed vegetables, peas, with minor additions of equipment