FRUITS PROCESSING PLANT – 10 Ton/DAY FRUITS INPU

PROCESS DESCRIPTION

The fruit & tomato processing plant will be a unit where fresh fruits will be processed to manufacture ready to drink fruit juice (RTD juice) , juice concentrate, tomato ketchup and tomato paste (22 Brix).

Fresh fruits would be received at reception section and passed on to the fruit washing and grading section. Fruits from reception will be washed in washing section to remove outer dirt and foreign matter from the fruit skin. Washed fruits would be fed to the inspection cum sorting conveyor where unwanted, damaged fruits would be separated out manually.

Washed & graded fruits would be passed on to the fruit juice extraction and processing unit. From fresh fruits the juice will be extracted out in juice extraction system. The outer skin, seed and fiber pomace of fruits would be separated out from extraction machine and then disposed manually. Extracted juice is passed to the heat treatment to avoid the quality degradation. Again it is fine pulped in pulper cum finisher to get fine juice. This juice will go for clarification in the juice clarifier. Clarified juice is used for to further processing to manufacture ready to drink juice or juice concentrate.

In juice concentration section, fruit juice with 10-12 brix would be concentrated to 65brix in multiple effect vacuum evaporators. This will be two effect rising film type evaporation plant.  Feed is received in a level controlled balance tank and fed to the 1st effect calandria for evaporation. Calandrias are shell and tube type vertically arranged heat exchangers. Preheated fruit juice is pumped by recirculation pump through the bottom of the calandria tubes with high velocity from down to upward. Dry saturated steam/vapour is supplied as heating medium in the jacket which causes high heating of juice through the tubes. The high heated juice enters the Vapour liquid separator located at the side top of calandria. Vapour separator unit is maintained under vacuum conditions so as to evaporate water by flash evaporation in vapor separator. Vapors generated are separated in 1st vapour separator and passed in the jacket of 2nd calandria as heating medium. Part of vapors would be used as heating medium for the attached pre-heater. Concentrated product from 1st effect is fed to inlet of calandria of 2nd effect. It then it passes through all the effect to meet its final required concentration. Product with desired solid content from last effect is taken out. Vapours from last effect are condensed in surface condenser. All the evaporation effects operate under vacuum maintained by vacuum pump/system.

The concentrated product ( juice concentrate ) at the desired concentration is continuously taken out from the plant by product discharge pump.

Final concentrated juice would be collected through last effect. Collected juice concentrated juice would be pasteurized and packed in cans in canning line.

In ready to drink juice /Tomato ketchup section, the juice after heat treatment would be used at formulation and blending section. The other supporting formulating ingredients like sugar, citric acid, etc would be made ready for the formation. As required, formulation of RTD would be done in formulation and blending tanks. Formulated RTD /ketchup juice would be pasteurized and packed in glass bottles.

For ketch up, the juice is concentrated to 12-14% TS and then it is mixed with sugar solution and all spices. Then the ketch up is pasteurized and then allowed for packing.

SCOPE OF SUPPLY FOR FRUITS & TOMATO PROCESSING PLANT  - 500 KG/H ( 10 TON/DAY)

01- FRUIT RECEPTION SECTION:

1.1     In Feed Conveyor

          Capacity     :         500 kg/h
          Quantity      :         1 No.

1.2     Fruit/Tomato Washer

          Capacity     :         500 kg/h
          Quantity     :         1 No.

It will be fitted with a conveyor belt, which is driven by a gearbox and jets.  It has a blower, which agitates the water. Raw fruits passing through it will be thoroughly washed by fresh water jet to remove the sticking dirt, dust, sand, etc. It will be a complete unit ready for electrical connections.

1.3     Sorting/Inspection Conveyor

          Capacity     :         6 M Long
          Quantity      :         1 No.

02- PROCESSING AND JUICE EXTRACTION SECTION

2.1     MANGO PROCESSING

2.1.1 Screw Feeder cum Steam Blancher

         Quantity     :         1 No.
         Capacity     :         500 kg/h
         MOC          :         SS 304

This will be a screw type conveyor for transferring the peeled mangoes and then discharging it to the super pulper. (This will have arrangement for pre-heating of mangoes by steam). 

2.1.2 Super Pulper/Destoner

         Quantity     :         1 No.
         Capacity     :         500 kg/h
         MOC          :         SS 304

With carborundum scrapers which results in faster peeling and greater output. The mangoes are fed into top of the chamber. It is driven by a motor of suitable capacity.  

2.1.3  Receiving Tank

         Capacity     :         200 L
         Quantity     :         1 No.
To collect the juice from the juice extraction section before to transfer the juice to the pulp processing section.

2.2     EQUIPMENT FOR PINEAPPLE & TOMATO PROCESSING

2.2.1  Pineapple Stripper

          Quantity     :         1 Set
          Capacity     :         500 kg/h
          MOC          :         SS 304

Made of stainless steel contact parts, complete with spiked drum assembly, cutting knives, feed and discharge chutes, guard drive unit. The unit is suitable for removing flesh from pineapple skins.

2.2.2  Pineapple Sizer cum Corer

           Quantity     :         1 Set
           Capacity     :         500 kg/h
           MOC          :         SS 304

This machine has stainless steel contact parts complete with coring and sizing cutter tube assembly with peeling knives, brackets. Frame is made of mild steel. It is driven
by an assembly guard, discharge chute etc. The unit is suitable for coring and sizing of pineapples, it is operated pneumatically. Supplied with two different sizes of cutter cylinders.

2.2.3  Pineapple Slicer

          Quantity     :         1 Set
          Capacity     :         500 kg/h
          MOC          :         SS 304

This will be used for cutting pineapple in form of slices of different thickness.

2.2.4  Fruit Mill ( Common for pineapple and Tomato)

         Quantity     :         1 No.
         Capacity     :         500 kg/h
         MOC          :         SS 304     

It is high speed continuous fruit crushing mill having all stainless steel contact parts and construction to crush fruits such as pineapple. 

2.2.5  Receiving Tank( Common for pineapple and Tomato)

          Capacity     :         200 L
          Quantity     :         1 Set

To collect the juice from the juice extraction section before to transfer the juice to the pulp processing section

2.3     EQUIPMENT FOR APPLE PROCESSING

2.3.1  Hydraulic Press

          Capacity     :         500kg/h
          Quantity     :         1 Set

This will be a total closed press system with integrated drainage/filter elements. This will be hygienic in operation. This will be consisting of rotor, integrated dejuicing system, hydraulic unit, base frame, electrical controls.

2.3.2  Solid Waste Conveyer

          Capacity     :         Matching
          Quantity     :         1 No.
          MOC          :         Mild Steel

This conveyer will be used to transfer the waste solid particles out of the processing system. Supply will be complete with motor and gear box.

2.3.3  Pulp Receiving Tank

         Capacity     :         200 L
         Quantity     :         1 No.

3.0     JUICE PROCESSING SECTION

3.1     Juice Transfer Pump
         Capacity     :         500 LPH
         Quantity      :         3 No.
         Type           :         centrifugal
          MOC          :         SS 304

This will be used for each section to transfer the juice for processing section. This will be a heavy-duty pump coupled with suitable HP motor.

3.2     Pulp Pre-heater

          Capacity     :         500 kg/h
          Quantity     :         1 Set
          Type           :         Shell and tube type
          Inlet temp.  :         30oC
          Outlet temp.         :         65oC

To heat pulp up to the desired temperature for inactivation of enzyme

3.3     Pulper cum Finisher  

          Capacity     :         500 kg/h
          Quantity     :         1 No.
          MOC          :         SS 304

Two stage pulping unit for fine pulping of crushed pre-heated mango pulp.

3.4     Juice Clarifier

          Capacity     :         500 L
          Quantity     :         1 No.
          MOC          :         SS 304

It will be used for solid liquid separation from juice so that clear juice will be used for ready to drink juice preparation.

3.5     Receiving Tank

          Capacity     :         200 L
          Quantity      :         1 No.
          MOC          :         SS 304

3.6     Transfer Pump

          Capacity     :         500 LPH
          Quantity      :         1 No.
          Type           :         Centrifugal

This will be a heavy-duty pump coupled with suitable HP motor.

1. 3.7     Intermediate Juice Storage Tank
2.  
3.                    Quantity     :         1 No.
4.                    Capacity     :         500 L
5.                     MOC          :         SS 304
6.  
7. To store the fruit pulp that is being finely pulped from the finisher. Inlet and outlet valves will be provided. The tanks will have smooth surface and finely ground weld seams and mirror polished from inside. It will be complete with agitator blades coupled to a suitable HP geared motor. There will be a SS 304 half hinged lid.

3.8     Inter connecting Pipes and Fittings:

This will be used for interconnecting various equipments for the entire plant. All SS 304 pipes will be welded and polished.

4.       EVAPORATION SECTION ( JUICE CONCENTRATION)
       
Type                    :        2 Effect Forced Circulation Evaporator

Product                :        Tomato juice / fruit juice

Capacity              :        347 kg/h water evaporation   

Tolerance:

All performance figures ± 5%

Scope of Supply for Evaporation Section:
 

• Balance Tank

       
           Capacity               :        50 L
           Quantity               :        1 No.
           MOC                    :        SS 304
       
It will be fitted with feed inlet connection along with a float-operated valve to maintain the liquid level in the tank and outlet connection. The SS Balance tank will be provided with SS legs fitted with SS ball feet for height adjustment.

• Graduated Flow Control Valve

        
            Quantity              :      1 No.
            MOC                   :      SS 304
       
This will be used for accurate control of the feed rate.   The valve will be complete with SS union connections, conforming to DIN standard.

• Feed pump

           Quantity     :         1 No.
           MOC          :         SS 304
           Type           :         Centrifugal

This is a centrifugal pump with sanitary design and SS mechanical shaft seal capable of pumping the required feed rate. The pump will have sealing arrangement and will be coupled to an electric motor of suitable horsepower rating. The pump will be complete with SS shroud and SS inlet/outlet ending in SS union of DIN standard.

• Calandria

     
           Quantity               :         2 Nos.            
           MOC                    :         Shell  : SS 304, Tube : SS 304

Calandria will have bunch of tubes welded or expanded to the tube plates in a vertical shell. The bottom of the calandria will be made as a container to receive the concentrate and a connection for vapour duct leading to vapour separator.

Calandria will be provided with quick detachable top and bottom covers for visual inspection/manual cleaning, a SS sight glass (fitted with toughened glass) at the bottom of the jacket to monitor the condensate level and necessary connections for steam vapour condensate,  non-condensable, air vent,  product  inlet, concentrate outlet, etc.    

• Vapour Separator

       
           Capacity    :      As per specified evaporation rate
           Quantity    :         2 Nos.
           MOC         :         SS 304
Vapour separators, separate the vapour from concentrate and normally placed in front of the calandrias. These are connected to the calandrias through the duct. The separator will be complete with the following fittings and accessories:

• 1 No. SS quick openable manway/hand hole located on the vertical portion of the shell.
• 1 No. Sight glass
• 1 No. Light glass
• 1 Set connections for temperature sensors and vacuum gauge.
• 1 No. SS Concentrate outlet at the bottom, ending in SS union.

• Condenser 

       
           Capacity        :      As per specified evaporation rate
           Quantity        :      1 No.
           Type             :        Surface type (Shell and Tube)
           MOC             :        Shell SS 304 , Tube SS 304

This will have a bunch of SS tubes mounted in a vertical shell. The water is circulated in the tubes and vapour gets condensed on the shell side. All product contact parts shall be of SS 304.       

The condenser will be complete with following fittings and accessories:

• Water inlet and outlet connection with  matching  flanges
• Vacuum connection
• 1 No. connection for Vacuum Gauge
• 1 No. Sight glass
• Recirculation  Pumps

         Quantity     :         2 Nos.
         MOC          :         SS 304
         Type           :         Centrifugal

These pumps will be provided for recirculation of juice through the forced circulation type bottom to top of the tubes of the calandrias. These pumps will have adequate capacity to pump the juice through the calandrias at required rate. The pumps will be supplied with suitable horse power rating motors. The concentrate pumps will have the description as that of feed pump.

• Transfer Pump

             Quantity     :         1 No.
             MOC          :         SS 304
             Type           :         Centrifugal Type
       
This pump is used for transfer of calculated amount of pre-concentrate from the vapour separator of next effect. This pump will have adequate capacity to pump the concentrate product from effect.

• Product Pump ( product Discharge )

          Quantity     :         1 No.
          MOC          :         SS 304
          Type           :         Lobe type

This pump is used for extracting final concentrated product from the last effect. This pump will have adequate capacity to pump the concentrate product from effect.

• Process Condensate Pump

       
          Quantity      :         1 No.
          MOC           :         SS 304
          Type            :         Centrifugal
       
This will be provided for extracting out process condensate from last two effect of evaporator. This is a centrifugal pump with sanitary design and mechanical shaft seal capable of pumping the required feed rate from balance tank to calandria. The pump will have sealing arrangement and coupled to an electric motor of suitable horsepower rating.  The pump will be complete with SS shroud and SS inlet/outlet ending in SS union of DIN standard.

• Steam Condensate Pump

       
           Quantity       :         1 No.
           MOC           :         SS 304
           Type           :         Centrifugal
        
This will be provided for extracting out steam condensate from 1st effect of the evaporator. This is a centrifugal pump with sanitary design and mechanical shaft seal capable of pumping the required feed rate from balance tank to calandria. The pump will have sealing arrangement and coupled to an electric motor of suitable horsepower rating.  The pump will be complete with SS shroud and SS inlet/outlet ending in SS union of DIN standard.

• Vacuum Pump

       
           Quantity             :        1 No.
           Type                  :         Water ring vacuum pump
           MOC                 :         Casing                  :         CI with SS sleeves
           Cover                 :         CI, Rotor :            SS304
       
This will be of liquid ring water sealed type coupled to an electric motor of suitable rating through a flexible coupling. The pump will have sufficient capacity to achieve the required vacuum in the plant.       

• Vapour Duct

       
           Quantity    :      1 Set
           MOC         :         SS 304

This will be made of suitable thickness stainless steel for interconnecting the thermal vapour re-compressor, calandrias, vapour separators and condenser.

• SS Pipes and Fittings

       
           Quantity   :         1 Lot
           MOC        :         SS 304

Complete with necessary pipes, unions, bends, tees, valves, pipe supports, etc. for interconnecting various components of the plant based on a compact layout.  Apart from product lines, SS piping will be laid for condensate lines, vent lines for non condensable gases, etc.

• Seal Water Tank

          Capacity     :         50 L
          Quantity     :         1 No.
          MOC          :         SS 304
       
This will be provided along with water inlet connection with float valve and outlet connection with valve. The function is to supply seal water for all SS pumps.

• Control panel

       
           Quantity     :         1 Set        
           MOC          :        SS 304
     
With SS housing, duly polished in which the coloured flow sheet (Mimic diagram) of the plant will be depicted. The panel will have one set push buttons for ON-OFF of all the electric motors in the plant with corresponding indication lamp for operation placed on the flow sheet. The panel will be of damp-proof construction. The instrument panel will be pre-wired to terminal connections.

• Instruments and Controls:

• 1 set Pressure Controller to control steam pressure at the inlet of 1st calandria.

       
(a)     Digital type Temperature indicators with PT-100 sensors for:

• Boiling temperatures in all the effects.
• Temperature in the steam jacket of first calandria.

(b)     Local Mountings:

• 1 Set Pressure gauge for indication of the steam  pressure before the 1st calandria
• 1 Set Dial type vacuum gauges for indication of vacuum in all effects and condenser.
• 1 Set Dial type temperature gauges for indication of boiling temperatures in all effects.

• Steam Supply System

            Quantity            :           1 Set
                  
The system will comprise a main header with individual branch connections for the various equipment and an incoming steam supply line about 200 mm long ending in a flange. Each of the connections will be provided with a steam valve. The header will be complete with condensate drain line equipped with steam trap assembly.

• Service Water Line

Steam and water should be supplied at one point within the plant by client. The distribution of such line to various utility points will be done by SSP.             

• Control panel

       
           Quantity     :         1 Set        
           MOC          :         SS 304

With SS housing, duly polished in which the coloured flow sheet (Mimic diagram) of the plant will be depicted.  The panel will have one set push buttons for ON-OFF of all the electric motors in the plant with corresponding indication lamp for operation placed on the flow sheet. The panel will be of damp-proof construction. The instrument panel will be pre-wired to terminal connections.

Instruments:

• 1 Set Pressure Controller to control steam pressure at the inlet of 1st calandria.
• 1 No. metal tube rotameter to measure the feed input to the evaporator.

       
Digital type Temperature indicators with PT-100 sensors for

• Boiling temperatures in all the effects.
• Temperature in the steam jacket of first calandria.

Local Mountings:

• Pressure gauge for indication of the steam  pressure before the 1st calandria
• 1 Set dial type vacuum gauges for indication of vacuum in all effects.

06- PACKING SECTION

CANNING LINE  FOR JUICE CONCENTRATE /TOMATO PASTE: 

          Capacity    :        10 – 15 Cans/min.
          Quantity    :        1 Set

Can packaging line will consist of :

• Screw Pump :  One No. screw type transfer pump.

• Can Washer :  Manufactured in SS 304.  It is horizontal rotary type washer for removing dirt and accumulated dust on cans seams during manufacture storage. It is suitable for washing 10 to 15 cans per minute.  The steam and water spray jets are properly located and anchored rigidly to the frame work, so that no can goes unwashed.  It is fitted with a suitable HP motor and reduction gear box.

• Unscrambler: This will be of SS 304 construction. It will unscrambler the cans from the can washer and pass it on the inlet conveyor. It is fitted with a suitable HP motor and reduction gear box.

• Feed in conveyor : This will be of SS 304 construction. It is fitted with a suitable HP motor and reduction gear box.

• Rotary Can Filler: It is fitted with a suitable HP motor complete with changed for handling different sizes of cans.

            Filling range          :        A202/A301/A401 size cans
            Output                    :        10 – 12 fills/min.

• Quantity                   :        1 No.

• Discharge Conveyor: It is driven by a suitable HP motor and gear box. This will be having a wire mesh honey comb for automatic discharge of filled cans.

• Can Seamer : Two Nos. for top and bottom can seamer will be supplied.

• Canning Retorts :

           Quantity              :        1 No.

Canning retort of mild steel 6 mm thickness electrically welded and tested to 50 lbs hydraulic pressure. The retorts are fitted with a dial thermometer, pressure gauge, safety valve, petcock, wing nuts clamp, packing gland, etc.  4 Nos. crates for the above retorts will be supplied.

• Can Body Reformer : Can body Can body reformer machine mounted on tubular stand, complete with fixed roll shaft, Idler roll and driving roll to suit can Dia 301, 401 machine supplied with complete electrical.

• Hand Flanger:  Hand flanger machine suitable for flanging 301, 401 Dia cans machine supplied with flanging dies and tools.

• Lid Embossing Machine : Machine supplied with double row die holder with max. 8 letters.  Metal type will be extra as per your requirement.

• Flange Rectifier : Machine supplied with double row die holder with max. 8 letters. Metal type will be extra as per your requirement.

07- UTILITY SECTION

7.1     Steam Boiler with Water softener

          Capacity               :         500 kg/h
Working pressure :         10.5 kg/cm2–g

Energy efficient boilers suitable for oil firing will be provided to cater the steam requirement of the entire plant.  Boilers and steam distribution system are as per prevailing standards. Condensate of acceptable standard will be utilized as boiler feed water. The boiler is capable of giving steam at a working pressure of 10.5 kg/cm2, complete with refractory, heat recovery unit and other standard accessories.

7.2     Cooling Tower

          Capacity               :         50 TR
          Quantity               :         1 No.

For cooling the water from 38oC to 30oC. The scope includes pump also.

7.3     Air compressor

          Capacity               :         30 nm3/h
          Quantity               :         1 No.

Air compressor will be supplied for a continuous compressed air free from moisture and oil. It will be consisting of an air receiver, with manhole, filters, pressure gauges, valves and fittings, automatic pressure cut off switches, air filter cum regulator unit, electric motor with "V" belts, drive pulleys, safety valve, air delivery valve, non return valve. The unit will be suitable for floor mounting and developing a pressure of 6 kg/cm2

7.4     SS Pipes and Fittings:  1 Lot SS Pipes and fittings will be provided for product line.

7.5      MS Pipes and fittings: 1 Lot MS Pipes and fittings will be provided for service / utility line.

7.6      Structural supports of the plant.

7.7      Insulation and Cladding for the Steam Lines.

7.8      MCC and Control Cabling.

SERVICES TO BE MADE AVAILABLE BY CLIENT (BATTERY LIMITS)

• Fresh tomatoes/fruits to be made available near by the feed conveyor.
• Water : To be made available at balance tank
• Electrical power - To be made available at the control panel (440V,50 Hz, 3 phase)

EXCLUSIONS

• Civil/Structural work, foundation, etc.
• Other services like water, electricity, etc.
• Effluent Treatment Plant
• All Service Pipelines
• DG SET (150 KVA)
• Glass Bottle Packing Line
• Boiler Chimney
• Any other item not given in scope of supply