Mahaan Foods

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Category Dairy Products

Description Mahaan is a leading supplier of dairy products in India and has been
recipient of several Awards for its export leadership position in India
and also has been the recipient of President's Award for best
enterprise and quality.
Website URL http://www.mahaanfoods.com/
Contact Address 78/3, 2nd Floor
Janpath
New Delhi, DH - 110001
Email : info@mahaanfoods.com
Fax : +91-11-23353191

Mahaan group
 ahaan Foods Ltd. specialises in the
manufacture of Coffee Whiteners / Dairy
Whiteners for food service market as well as
the FMCG market. It makes products in a
multiple stage drying system consisting of
falling film evaporator under vacuum and a
multi stage dryer consisting of nozzles
spraying tower and fluidised bed.

ahaan Dairies Ltd. has two divisions –

one is a division with procurement of milk
and process the same to make pure ghee and
the other is a division that is dedicated
towards making pickles and chutney’s.

ahaan Proteins Ltd. is the only

composite dairy ingredient plant in India
that manufactures edible casein,
pharmaceutical and edible grade lactose,
whey protein concentrate 70% and pure ghee.

Mahaan Proteins Ltd. has been set up with

foreign technical collaboration and has
specialised in manufacturing dairy ingredients
and is currently developing caseinates and
functional WPCs.It has also added a brand
new facility for spray drying specialised
instantly soluble powders for it’s buyers
engaged in the nutraceuctical industry.

ce International. is the
international
merchandising arm of the
Mahaan Group and is the
strategic business unit
dedicated in promoting
international trade ie. both
import and export of dairy
and food products.
About us

Mahaan Group has an annual sales turnover of USD 45 million (INR 200 crores) and is a prominent
manufacturer of:

A. FMCG products :
Coffee Creamers
Dairy Whiteners
Pure ghee
Fruit and Vegetable
Pickles and Chutneys.

B. Dairy Ingredients

Milk Fractions
Edible & Rennet Acid Casein
Pharmaceutical and Edible Lactose
Whey Protein 70, up to 90% Demineralised Whey Powder
Whey Powder and Milk Fat.

Intermediate Customised Composites

Special wet blend as well as dry blend premixes are
manufactured and contract sold as per customer
requirements enabling the customer to formulate his
own products enabling him to reduce his process space,
man and machinery costs.

Mahaan processes up to 700,000 Liters of milk per day

in three plants located in North India and has ongoing
technical support from various leading dairy
technologists form Europe , America and Oceania.

Mahaan has an on going R&D of its own and is

spending as much as 1 % its sales turnover on R&D. It also makes use of an Applications Centre to
develop new application proactively. Mahaan has 600
Distributors for its FMCG sales network in India and is rapidly
increasing it to over 1500 by year 2001. It has parallel
relations with more than 600 food companies Indiawide for
servicing their dairy ingredients requirements.

Mahaan currently procure its milk from more than 30,000

farmer families, having set up its own physical milk
procurement network in over 1000 villages.

Mahaan is a leading supplier of dairy products in India and

has been recipient of several Awards for its export leadership position in India and also has been the
recipient of President's Award for best enterprise and quality.

Mahaan has also a vision of being a leading FMCG producer and provider of ever increasing range of
dairy ingredients for the food industry.

Mahaan always looks for alliance with new associates in India as well as around the globe for furthering
its technical as well as marketing strengths.

Research and development

Mahaan has worked with National Dairy Research Institute, Indian

Institute of Technology, Central Food Technological Institute and has
its own independent research team working towards understanding
processes and improving efficiencies in production and quality
control. Mahaan has initiated the setting up of a very sophisticated
new R & D centre with an estimated investment of US$ 2 million (INR
8 crores). A complete pilot plant involving Ultrafiltration, Nanofiltration,
Microfiltration, Chromatographic Separation, Molecular fractionation,
Evaporation and Spray drying is being set up to develop new
products such as Lactoferrine, Lactose Peroxide, Alfa Lactalbumin,
Beta Lactalbumin, Whey Protein Isolates, Casein fraction, Amino Acid
fraction, Hydrolyzed protein, Functional
Ingredients etc.

All three plants are equipped with a complete on line quality assurance
for ensuring supply of products of a uniform and consistent quality thus
rendering the costly time consuming process of quality testing at the
buyers plant site and ensuring the customer always good value for
money as per his / her perceived expectations. The quality assurance
is built around a system of benchmarking all inputs and outputs in addition to
the on-line quality assurance and in-depth investigated audit is also routinely
made by an independent team of quality auditors in order to ensure the highest productivity while
ensuring constantly highest standard as per the established benchmarks.
A Tasters' Panel with a high sense of objective sensory evaluation perform panel testing on a very
frequent and regular intervals ensuring consistent organoleptic profile of all products.

A team of technicians develop new applications for existing products and develop new products for
existing applications for giving greater value for money and convenience to its buyers as well as to
customizing products as per specific customer requirements in addition to the applications laboratory
where these technicians work in order to service our customers in a more pro-active manner. They also
consistently develop new recipes and new products for the Consumer Sales Division.

Products
The Group manufactures two categories of products :-

A) Industrial products in the form of dairy ingredients

B) FMCG products for household consumption

The Group manufactures special purpose dairy ingredients and

currently sells both in the domestic as well as in the international
market to food/pharmaceutical/nutraceutical companies.

Mahaan Group also manufactures private label dairy products as well

as makes customised agglomerated and instantly soluble dairy
premixes under its contract manufacturing services.

In the FMCG category Mahaan makes pure ghee, dairy whiteners for
sale Indiawide and is currently in the process of initiating international
marketing under its own brand.

In its Fruits & Vegetable Division Mahaan has started manufacturing

pickles and chutney’s and is in the process of developing new products
to increase its FMCG product portfolio.It has plans to emerge as the
leading manufactutrer of Indian food products.

A) Industrial products in the form of dairy ingredients

PROCAS 2100
EDIBLE ACID CASEIN

PROCAS 2200
ACID CASEIN- FIRST INDUSTRIAL GRADE

PROCAS 2300
EDIBLE ACID CASEIN- STANDARD GRADE

PROCAS 2400
ACID CASEIN- INDUSTRIAL GRADE

PROMIL
6800
MILK PROTEIN CONCENTRATE 80%

PROMIL
6600
MILK PROTEIN CONCENTRATE 56%

PROMIL
6400
MILK PROTEIN CONCENTRATE 42%

PROCON 3800
WHEY PROTEIN CONCENTRATE 80%

PROCON 3700
WHEY PROTEIN CONCENTRATE 70%

PROCON 3450
WHEY PROTEIN CONCENTRATE 45%

PROCON 3350
WHEY PROTEIN CONCENTRATE 35%

PROCON 3250
WHEY PROTEIN CONCENTRATE 25%
PROWEP
5000
DEMINERALISED WHEY
POWDER 90%

PROWEP
5100
DEMINERALISED WHEY
POWDER 70%

PROWEP
5200
DEMINERALISED WHEY
POWDER 50%

PROWEP
5500
WHEY POWDER- SPRAY DRIED

PROWEP
5600
NATURAL CALCIUM FULFILLED
WHEY POWDER
MAHAAN
9000
SKIMMED MILK POWDER

MAHAAN
9500
FULL CREAM MILK POWDER

MAHAAN
9600
SPRAY DRIED DAIRY WHITENER

MAHAAN
9900
DEHYDRATED MILK FAT
PROLAC
1100
LACTOSE PHARMACEUTICAL GRADE

PROLAC
1200
EDIBLE GRADE
DAIRY PLUS PROVAL 9800
MILK POWDER REPLACER

DAIRY PLUS PROVAL 9815

MILK POWDER REPLACER

DAIRY PLUS PROVAL 9820

MILK POWDER REPLACER

DAIRY PLUS PROVAL 9825

MILK POWDER REPLACER

DAIRY PLUS PROVAL 9842

MILK POWDER REPLACER

DAIRY PLUS PROVAL 9770

SWEETENED CONDENSED
MILK REPLACER

DAIRY PLUS PROVAL 8333

FUNCTIONAL FOOD PREMIX
 B) FMCG products for household consumption

Cut pieces of select fruits and vegetables are mixed in a

specially prepared spice mix and oil. Fruits and vegetables
are cut, washed and sorted prior to mixing with top grade
spices and oil. The entire process of cutting, washing, sorting,
blending, maturing and container filling is mechanized
ensuring highest product standards. Customer specific ready-
to-eat recipes can be prepared offering a wide variety and
flexibility to cater to the connoisseur's delight.

EXISTING PRODUCT RANGE :

1. Mixed5. Mango Pickle

Pickles
2. Green Chilli6. Mango
Pickle Chunda
3. Mango7. Garlic Pickle
Chutney
4. Mushroom8. Red Chilli
Pickle Stuffed Pickle
9. Lime Pickle 10. Sweet &
Sour Lime
11. Mango
Garlic
Pickle

INGREDIENTS :
Select and sorted fruits and vegetables, salt, sugar, spices, vinegar and oil.

Cut pieces of select fruits are mixed in specially prepared gravy with spices,
sugar and fruit juices. The entire process of making chutneys is automated
ensuring highest hygiene standards.

EXISTING PRODUCT RANGE :

Hot and sweet (sliced)
Chat Pat (hot and sweet sliced)
Khat Mith (Tit – Bits)
Teekhi Meethi (Grated)
INGREDIENTS :
Mango fruit, sugar, salt,spices, condiments and acetic acid.

Ghee (Anhydrous Milk Fat) is a pure, natural, cooked milk

fat, free from any additives. It is obtained by cooking white
butter. White butter is obtained by churning cream which is
separated from pasteurized milk through automatic
centrifugal separators. Ghee has a pleasant aroma and
flavour which imparts an unique speciality to cooked food
and is also used as an ingredient in the preparation of
processed food to impart dairy and creamy flavour.

TYPICAL ANALYSIS :
Milk Fat, %, min. 99.7 Baudian Test Negative
Moisture, max. 0.30 R.M. Value 28 - 35
FFA, max., % 1.5 Polenskey Value, max. 2.0
Antioxidants Nil BR at 40 deg. C 40 - 43

INGREDIENTS :
Pure Ghee is available in 200 ml., 500 ml. 1000 ml., 500 gms, 1 Kg., 2 Kg. and 5 Kg. in refill packs
ie.which are bag in the box mono cartons, HDPE jars and tin containers.

This is a dairy product obtained through a proprietary formulation by blending high quality ingredients and
then spray drying.

TYPICAL ANALYSIS :

Moisture 4%
Fat 18 %
Proteins 18 %
Carbohydrates 56 %
Ash 4%

BRANDS AVAILABLE :
Mahaan Dairy Whitener
Mahaan’s Readymi
Mahaan’s Instamilk
Mahaan’s Amarspray.
INGREDIENTS :
Skimmed milk solids, milk fat, sucrose & maltodextrine.

Contract manufacturing services

Contract manufacturing on Loan License Basis of Dietetic foods including Health Foods, Clinical &
Medical Foods, Nutritional Foods, Baby / Weaning foods infant nutrition, Sport Drinks, Food Premixes &
Desserts etc. with salient features as under:-
ZERO
INVESTEMENT
As most modern
plant & facilities put
up
with up with 20
million US Dollars
investment
available.

ZERO
GESTATION
PERIOD
As all facilites are in
regular production
at present, with
spare capacity 50%
approximately, with
can translate to
over 50 million US
dollars turnover in
near future.

ZERO
QUALITY RISKS
As international
level Hygiens
Standards, Quality
Assurance system,
Qualified Q.C.
personnel
available.

100 %
CAPACITIES &
CAPABILITIES
With regards to
Production
Capacities,
R& D and Product
Development wide
range of process
and production
facilites 100%
Captive Power
Generation Well
Qualified
Professionals
Availability of own
manufactured basic
raw materials Sales
Tax Exemption etc.

100% RELIABILITY
LIQIID MILK PROCESSING 7 LAC LITERS PER DAY

TWO PLANTS AT
KOSI KALAN (U.P).
PAONTA SAHIB (H.P.)

END PRODUCTS
CASEIN
WHEY PROTEINS
MILK PROTEINS
WHEY PROTEINS
LACTOSE
DEMINERLISED WHEY
MILK POWDERS
FAT FILLED MILK POWDERS
DAIRY WHITENERS
NON-DAIRY COFFEE CREAMER
FOOD PREMIXES / BLENDS ETC.

TURNOVER 200 CRORES PLUS.

SPARE CAPACITY 50% APPX. RESERVED FOR SPECIALITY PRODUCTS.

LIQUID STORAGE FACILITIES

CHILLING FACILITIES
PASTEURIZATION
HOMOGENIZERS
EVAPORATORS
SPRAY DRIERS
CRYSTALLIZER
CENTRIFUGES
HIGH PRESSURE PUMPS
MIXER AND AGITATORS
PULVERIZERS
BLENDERS (WET & DRY)
PACKAGING FACILITIES SEMI AUTOMATIC
FINISHED GOOD STORAGE
CAPTIVE POWER GENERATION
WELL EQUIPPED QA SYSTEM & OFFICIALS
INTERNATIONAL LEVEL HYGIENE CONDITIONS
R&D AND PRODUCT DEVELOPMENT TEAM
CRITICAL EQUIPMENTS SUPPLIERS INCLUDE
VALIO ENGG (FINLAND), WESTFALIA
(GERMANY), SEPPO RALLI (FINLAND),
SEPRATECH (UK), GOAVEC (FRANCE),
 KENT KELLER (USA), ALFA LAVAL (INDIA) ETC.

OUR PLANT IN U.P. IS KOSHER CERTIFIED

Nutraceutical applications

The nutritional values of proteins from a physiological perspective are

evaluated on the basis of following parameters :-

A table showing essential

amino acid profile for
Whey Proteins is given hereunder :-
Essential Amino
Acid
Whey Proteins

Iso-Ieucine
55

Leucine
111

Lysine
88

Methionine
25

Phenylanine
34

Threonine
72

Tryptophan
30

Valine
52
Biological Value measures the amount of protein
nitrogen that is retained by the body from a given
amount of protein nitrogen that has been consumed.

The comparison chart for BV for different source of

proteins is listed below :
Protein Source
B.V.

Whey Proteins
104

Whole Egg
100

Egg Whitw (Albumin)

88

Casein
77

Rice
74

Soya
59

Wheat
54
The Protein Efficiency Ratio (PER) is used as a
measure of growth expressed in terms of weight
gain of an adult by consuming 1 gramme of food protein.

Given below is the table showing PER value for various

proteins :
Proteins Source
PER Value

Wheat
1.00

Rice
1.25

Soya
2.12

Casein
2.50

Lactalbumin
2.86

Whey Proteins
3.00
 Formulation of physiologically suitable infant foods
necessitate reduction of protein and mineral levels from
bovine milk, rich in lactose and whey proteins and
containing appropriately low leavels of essential minerals.
Demineralized whey is an ideal ingredient for infant
formula. Demineralization of whey permits formulation of
infant foods with a gross composition closest to mothers
milk.

Lactose and its breakdown products, glucose and

galactose have several metabolic and developmental
functions in infants. Whey proteins made from milk are
universally known for their immunological values for infants.
That is the most important factor in mother’s milk
considered best for babies. In low birth weight baby
formula’s the Whey Protein are now made essential in ratio of 60:40 with Casein, hence fortification by
whey protein powder is the only solution to achieve this.

It is reported that whey Proteins are digested much

faster than less advanced proteins. Increased rate of digestion has been shown
as results in increased plasma amino acid and protein synthesis attributes, which
makes it particularly attractive in the fields of clinical nutrition.

Whey Proteins are studied by various nutritionist and it is of great interest that
whey proteins are very useful in post operative care of patients as most digestible
proteins. It is highly recommended in body cell repairing & growth as well as
provides all essential Amino Acids in sufficient amount to provide the best
possible solution for formulation of clinical foods. Whey Proteins consist of various
minor proteins like L-lactoalbumin, Lactoferrin, immunoglobulin, serum albumin,
Lactoperxidase etc. Having high therapeutic values. These constituents have
special medical application in dietetic products to treat & prevent a large number
of clinical problems such as :
Special formulation for diabetic patients
For cardiac ailments
For high cholesterol patients
For liver, arthritis patients
For burnt patients
To deal with situation like renal failure, gout, trauma etc.

Recent researches have shown better efficacy of dietary whey proteins over other proteins including
casein, meat & soya, because of special attributes in whey protein. Some of the details are as under

IMMUNE- ENHANCING PROPERTIES - FOR H.I.V. & AIDS PATIENTS :

Recently it is discovered by research Scientist in Canada that whey Proteins contain the most critical
three bio active proteins required for the regeneration of intracellular stores of glutathione (IGSH). These
three proteins are alpha lactalbumin, lactoferrin and thermolabiles serum albumin, and facilitate cellular
GSH replenishment or maintenance required for the immune system of the body in case of HIV or AIDS
infections.
ANTI CANCER EFFECTS OF WHEY PROTEINS :
The clinical trials conducted have demonstrated better efficacy of
total dietary Whey Proteins in preventing or retarding the
development of chemically induced colon cancer and improving
the immunocompetence, as compared to other dietary including
casein, meat & soya.

ANTI- TUMOR EFFECTS OF DIETARY WHEY PROTEINS :

Whey Protein has been shown to stimulate cell mediated and
humoral immunity, to improve the body’s nutritional status in
stressed individuals, to have an antioxidant role by increasing
tissue glutathione and, perhaps because of these, to have an
inhibitory effect on the growth of several types of tumors including
head and neck cancer.

BIOPRESERVATIVES IN WHEY PROTEINS :

Whey contains several proteins that display antimicrobial and in some cases antiviral activity. These
components contribute to the natural defence system following birth and during development. Proteins
from whey which possess bio-preservative activity include lactoferrin, lactoperxidase, lysozyme and
immunogbulins. The power of these defense systems in part in part arises from the synergism between
these proteins, which function by distinct but complementary mechanisms without harming the body.
Lactoferrin binds iron very strongly and renders this essential component unavailable to bacteria. In
contrast to lactoferrin, lactoperxidase inactivates or kill a board spectrum of microorganisms through an
enzymatic reaction.

The importance of Whey Protein supplementation is critical to any individual

looking to build and maintain muscle mass. Protein has been called the
“building block of life’ and without proper Whey Protein supplementation the task of building and
maintaining muscle mass is next to impossible. The reason for this is that whey protein has superior
biological value ( which means it may “yield” more usable grams of protein than other protein
supplements).

Every athlete is aware of the importance of protein supplementation. If you are on any
strength- training program, building muscle will meet or defeat optimum performance.

Whey Protein have been enriched by nature with Branched chain Amino Acids (BCAA),
namely- L-Isoleicine, L- Valine. These branched chain Amino Acid must be present in the
muscle cell to promote protein synthesis. These BCAA helps increase the bio- availability of
high complex carbohydrate intake and are absorbed by muscle cells for anabolic muscle building activity.

The current theory is that during prolonged exercise, the BCAAs are released from skeletal muscle, the
carbon part is used as fuel and the nitrogen part is used to make the amino acid alanine which then goes
to the liver where it is turned into glucose for energy. So for athletes who want to protect their existing
mass, the idea is to take a BCAAs reduce muscle breakdown and act as an energy source during this
period. While maintaining exercise performance and delaying exertion, BCAAs are very important for
muscle growth.

It is a compelling scenario for strength athletes and

body builders. “ the use of branched chain amino
acids in sports nutrition is especially interesting in
making exercise feel easier. These amino acids
improve the turnover of muscle proteins which is very
important in athletes.

Whey proteins are highly recommended for athletes

and sportpersons as it helps in speedy repairing of
injured and torn muscles during practice and performance.

Whey Proteins provide excellent nutritional values, in nutrition foods formulated for kids,
adults and old aged people as growth tonic for body health maintenance. The major
products are general health food products as well as protein supplements as under :

Nutritional supplements for all age- groups containing USP as high protein foods,
low fat foods, low salt foods :
For Lactose intolerance for all ages.
Griatric food formulations- for old age
people with low
digestibility.
For pregnant, lactating and nursing
women.
Pediatric foods for growth of children,
for anemic
children, for memory boosting of
children etc.
For faster postoperative recovery or
recovery
from illness.
For general health beverages, stamina
building
& vitality.

Whey proteins general fulfill need of essential Amino acids for growing kids as they
require constant supply of high amount of essential non essential amino acid. The
excellent PER value gives the regular weight gain as per their growth requirements.

For adults whey proteins are highly recommended as these protein facilitate the weight control
management of body.

Whey Proteins improve iron absorption in body. Since whey Proteins are rich in calcium
and phosphorous, they provide good bio availability of these minerals essential for bone
formation and better bone strength.

Concentrated protein levels lend whey protein powders to use in product categories
such as nutritional bars where it leaves maximum space in the formula for addition of
other ingredients such as fruit, nuts and honey.

Functional applications

Whey Proteins have many valuable functional properties desired in eggless cakes,
vegetarian sausages, sauces & soups, spreads, salad dressings, meat products, dairy
products, bakery and confectionery products etc. Whey Proteins act as excellent
emulsifier, whipping agent, viscosifier, water retention aid, tecture aid, texture improver
etc.

Whey Proteins and Whey Powders as food

ingredients can modify organoleptic, visual,
hydration, surfactant, structural, textural and
rheological properties of food, resulting in
improved consumer acceptance of the
finished product. In many cases, Whey
Proteins serve more than one functional
purpose in foods. For example, as whey
proteins remain soluble over a wide Ph
range, and in particular near pH 4.5, they
may be used in acidic drinks as protein
fortifiers. They may also bring emulsifying
properties to these products and, if desired,
may also add turbidity.

Whey Powders with lower protein concentration can ne successfully used in Desserts,
Soups and sauces, meats, baby food, ice cream, bakery, fermented products, and
chocolate as a substitute to skimmed milk power / milk powder, with an attractive price
differential.
Functional
Property
Mode of
Action
Food
System

Whipping /
Foaming
Forms stable
film
Eggless cakes,
deserts, whipped
toppings

Emulsification
Formation and
stabilisation of
fat emulsions
Vegetarian
sausages, salad
dressings, coffee
whiteners,
soups, cakes,
infant food
formulas,
biscuits.

Gelation
Proteins matrix
formation and
setting
Meats, baked
goods, cheeses

Viscosity
Thickening,
water binding
Soups, gravies,
salad dressings

Water binding
Hydrogen
bonding of
water;
Whey
• Enhances sensory attributes
• Improves nutritional profile with complete and bio-available amino
acids
• Contributes high calcium content–approximately 100 grams of dry
 sweet whey contain 770 mg of calcium and 100 grams of dry acid
whey contain 2,280 mg of calcium

• Contributes to a healthful image and clean label

Lactose

• Contributes low relative sweetness

• Enhances emulsification
• Improves moisture retention
• Is non-hygroscopic
• Contributes to improved crumb texture and
freshness

• Contributes to increased volume, reduced fat

levels, improved gas retention and enhanced
flavors
Milkfat
• Contribute rich, unique flavor unmatched by any other fat
• Provide structure to cakes, pie crusts and pastries
• Act as a flavor carrier for fat-soluble ingredients, spices, herbs and sweet flavors
• Help maintain crumb softness and tenderness of bakery products

• Butter's color makes bakery products visually appealing

Concentrated and Dry Milk
• Form and stabilize emulsifications
• Enhance water-binding and machinability
• Enhance texture and perceived freshness
• Form dense foams with finer, more uniform
air bubbles
• Improve structure of baked products
• Contribute to browning and appealing color
• Contribute a subtle, pleasant dairy flavor and
aroma

• Increase nutritive value

Whey
• Enhances sensory attributes
• Improves nutritional profile with complete and bio-available amino acids for
beverages such as low-pH sports drinks, meal replacers and dry mixes
• Contributes high calcium content–approximately 100 grams of dry sweet whey
contain 770 mg of calcium; 100 grams of dry acid whey contain 2,280 mg of calcium
• Contributes to a healthful image and clean label
• Many whey ingredients remain soluble at pH 4.5, the point at which other proteins
become insoluble, making them the protein-fortifying ingredient of choice in acidic
beverages
Lactose
• Used in the manufacture of beer because
it is not fermented by the yeast–it remains
in the finished product, increasing
viscosity and improving mouthfeel and
flavor
• Enhances flavor and provides stability in
juice beverages
• Improves shelf life by reducing flavor loss
during processing and storage

• Enhanced flavor stability helps reduce added flavors, resulting in a possible cost
savings
Concentrated and Dry Milk

• Form and stabilize emulsions, especially in dry mixes that combine oil ingredients
with water, such as cocoa mixes
• Bind water in rigid, heat-induced gels to reduce the cost of a beverage
• Improve a beverage's mouthfeel and texture

• Form foams in beverages such as eggnog and shake-like drinks

Whey
• Provides emulsifying and whipping/foaming functionality in
confections such as mousse, meringue and nougat
• Assists in the stabilization of creams and foams

• Improves whipping and foaming properties important in many

confections
Lactose
• Contributes to overall flavor, color and texture
• Replacing part of the sucrose with lactose
can prevent excessive sweetness in finished
candy–replacements of 15%-20% have been
achieved in the production of nougat,
chewing gum and fondants
• Emphasizes and enhances various
confection flavors, reducing flavor loss during
processing and storage

• Can enable a reduction in added flavors,

resulting in a possible cost savings
Milkfat

• Provide unique flavor and taste to buttercream, fudge and toffee

• Butter combines more than 120 different compounds that impart a unique, rich flavor
to confections
• Butter creates flavor notes traditionally
associated with caramel, praline and toffee.
Most sources agree that a high-quality
caramel must be made using condensed
milk and butter
• Enzyme-modified butteroil provides distinct
dairy flavors in chocolate coatings

• Butter works well as a flavor carrier for

spices, vanilla and other fat-soluble
ingredients in confections with a cream
center, butter can be used to produce a
myriad of new flavors while maintaining the filling's desired texture
Concentrated and Dry Milk Ingredients

• Provide flavor and functionality in caramel, frosting and fudge

• Help oil-water interfaces to form and stabilize emulsions
• Form rigid, heat-induced irreversible gels that hold water and fat, and provide
structural support to confections
• Improve water-binding to reduce the cost of confections (since water is an
 inexpensive ingredient)
• Bind water to produce the firm, chewy texture of several confections

Whey
• Improves overall product quality of dairy foods in such areas as
flavor, texture, foam stability and moisture retention
• Aids in the dispersion of milkfat, which can help reduce fat levels in
some formulas and prevent defects such as creaming,
coalescence and oiling off
• Delivers exceptional nutritional value and high calcium—100 grams
of sweet whey contain 770 mg of calcium and 100 grams of dry
acid whey contain 2,280 mg of calcium
• Returns some of the milk solids lost during the cheese-making
operation to process cheese

Lactose

• Binds volatile flavor components, reducing flavor loss during processing and storage
to enable a reduction in added flavors and possible cost savings
• Sweetness contributed by lactose often enables a
reduction in added sucrose
• Can contribute browning ability, protein stabilizing
qualities, alteration of crystallization, flavor
enhancement, selective fermentation and nutritive
qualities

Concentrated and Dry Milk Ingredients

• Provide flavor and functionality in cheese, sour

cream, ice cream and yogurt
• Form and stabilize emulsions
• Form rigid, heat-induced gels that hold water and fat, and provide structural support
to dairy foods

• Provides water-binding properties, which may reduce the cost of food (since water
is an inexpensive ingredient) and improve sensory perception
Whey

• Enhances sensory attributes of meat products such as bologna,

reduced-fat sausage and roast beef
• Delivers exceptional nutritional value to meat products, including
amino acids that are readily digestible and completely bio-available
• Provides an excellent source of calcium, an essential nutrient not
readily available in other regularly consumed foods–approximately
100 grams of dry sweet whey contain 770 mg of calcium and 100
grams of dry acid whey contain 2,280 mg of calcium
• Contributes to a food’s healthful image and clean label, and
ultimately, to the sale of the food
 • WPC, properly processed, provides outstanding fat distribution in
meat products

Lactose

• Enhances the color intensity and stability of many meat products

• Brightens and preserves color
• In sausage and meat products, the
addition of lactose helps control
browning-especially important during
heat treatments like frying or
microwave heating
• Masks salty and bitter flavors, such
as the characteristically strong taste
of liver in liver-based spreads or
pâtés
• Injecting brine solutions containing
lactose can improve product and
structure formation

• Provides an effective starter culture carbohydrate for the preparation of fermented

sausages–suggested levels are 1%-3% in fermented sausage and 0.5%-3.0% in
cooked hams
Concentrated and Dry Milk Ingredients
• Enhance stable emulsifications
• Form rigid, heat-induced irreversible gels that hold water and fat, and provide
structural support to meat products
• Provide water-binding properties, which may reduce the cost of food (water is
inexpensive) and improve sensory perception
• Enhance the flavor of meat products

• The milkfat present in the milk ingredient acts as a flavor carrier for fat-soluble
ingredients, spices and herbs–milkfat’s low melting point ensures complete flavor
release
Whey
• Forms stable emulsions over prolonged periods of time under a
variety of storage conditions, even in acid emulsions such as salad
dressing
• Because of the exceptional gel forming abilities and water-holding
capacities of whey proteins, they can act as a component of a fat
mimetic system
• Delivers exceptional nutritional value to salad dressings, including
amino acids that are readily digestible and completely bio-available
• Provides an excellent source of calcium, an essential nutrient not
readily available in other regularly consumed foods–approximately
 100 grams of dry sweet whey contain 770 mg of calcium and 100
grams of dry acid whey contain 2,280 mg of calcium

• Contributes to a food’s healthful image and clean label, and

ultimately to the sale of the food
Concentrated and Dry Milk Ingredients

• Form and stabilize salad dressing emulsions

• Undenatured dairy proteins are able to form
rigid, heat-induced irreversible gels that hold
water and fat, and provide structural support
in salad dressings, especially highly viscous
creamy-style dressings
• Provide water-binding properties which are
very important in formulating reduced-fat
salad dressings because of the fat-like
attributes such as lubricity and mouthfeel they
contribute
• Enhance the appearance of salad dressings, particularly reduced-fat creamy-style
products, by providing opacity

• The milkfat present in concentrated and dry milk ingredients adds richness to
certain salad dressings

Whey
 • WPC can partially replace or extend egg protein in sauces,
reducing costs while enhancing perceived health and
microbiological safety benefits
• Delivers exceptional nutritional value to salad dressings, including
amino acids that are readily digestible and completely bio-available
• Provides an excellent source of calcium and an essential nutrient
not readily available in other regularly consumed foods-
approximately 100 grams of dry sweet whey contain 770 mg of
calcium and 100 grams of dry acid whey contain 2,280 mg of
calcium
• Contributes to a food’s healthful image and clean label, and
ultimately, to the sale of the food

• Emulsification properties of whey ingredients aid in the dispersion

of fat in sauces and soupsefficient dispersion can reduce the fat
level in some formulas and prevent defects such as creaming,
coalescence and oiling off
Milkfat

• Milkfat ingredients provide unique flavor, mouthfeel and emulsification properties to

gravies, white sauces and cream soups
• Butter adds a rich, unique flavor that is unmatched by any other fat

• Butter can be heated to different

temperatures to produce characteristic
flavor notes associated with different
sauces: lightly melted butter is typically
used in cream and white sauces such as
Hollandaise, to provide rich, dairy notes;
slightly overheated butter provides
roasted, cooked notes that complement
brown sauces and gravies; overheated,
unburned butter contributes flavor notes
that complement barbecue and smoke-
flavored sauces
• Butter works well as a flavor carrier for
spices, sweet and savory flavors, herbs and other fat-soluble ingredients
• Butter aids in the even distribution of oil-soluble flavors throughout sauces and
soups–its narrow melting range ensures quick flavor release and complete melting
of butter at body temperatures for a “melt-away” effect, which aids in smooth
mouthfeel

• Butter contributes a visually appealing golden color, or a darker color after heat
treatment, to sauces and soups
Concentrated and Dry Milk Ingredients
• Effectively form and stabilize emulsions in sauces and soups
• Undenatured dairy proteins are able to form rigid, heat-induced irreversible gels that
hold water and fat, and provide structural support to soups and sauces
• Provides water-binding properties, which are very important in formulating reduced-
fat sauces and soups
 • Enhances the color and appearance of sauces and soups, particularly reduced-fat
creamy-style products, by providing opacity

• Milkfat adds richness to certain soups and sauces; acts as a flavor carrier for fat-
soluble ingredients, spices, herbs and sweet flavors; and milkfat’s low melting point
ensures complete flavor release

Indian food industry

India is the world's second largest producer of food next to China, and has the
potential of being the biggest with the food and agricultural sector. The total food
production in India is likely to double in the next ten years and there is an
opportunity for large investments in food and food processing technologies, skills
and equipment, especially in areas of Canning, Dairy and Food Processing, Specialty
Processing, Packaging, Frozen Food/Refrigeration and Thermo Processing. Fruits &
Vegetables, Fisheries, Milk & Milk Products, Meat & Poultry, Packaged/Convenience
Foods, Alcoholic Beverages & Soft Drinks and Grains are important sub-sectors of
the food processing industry. Health food and health food supplements are another
rapidly rising segment of this industry which is gaining vast popularity amongst the
health conscious.

India is one of the worlds major food producers but accounts for less than 1.5 per
cent of international food trade. This indicates vast scope for both investors and
exporters. Food exports in 1998 stood at US $5.8 billion whereas the world total was
US $438 billion. The Indian food industries sales turnover is Rs 140,000 crore (1
crore = 10 million) annually as at the start of year 2000. The industry has the
highest number of plants approved by the US Food and Drug Administration (FDA)
outside the USA.

India's food processing sector covers fruit and vegetables; meat and poultry; milk
and milk products, alcoholic beverages, fisheries, plantation, grain processing and
other consumer product groups like confectionery, chocolates and cocoa products,
Soya-based products, mineral water, high protein foods etc. We cover an exhaustive
database of an array of suppliers, manufacturers, exporters and importers widely
dealing in sectors like the -Food Industry, Dairy processing, Indian beverage
industry etc. We also cover sectors like dairy plants, canning, bottling plants,
packaging industries, process machinery etc.

The most promising sub-sectors includes -Soft-drink bottling, Confectionery

manufacture, Fishing, aquaculture, Grain-milling and grain-based products, Meat
and poultry processing, Alcoholic beverages, Milk processing, Tomato paste, Fast-
food, Ready-to-eat breakfast cereals, Food additives, flavors etc.

Market size

The Indian food market is estimated at over US$ 182 billion, and accounts for about two thirds
of the total Indian retail market. Further, according to consultancy firm McKinsey & Co, the
retail food sector in India is likely to grow from around US$ 70 billion in 2008 to US$ 150
billion by 2025, accounting for a large chunk of the world food industry, which would grow to
US$ 400 billion from US$ 175 billion by 2025.

Spices

Despite a global slowdown, Indian spice exports are growing. During April-February 2008-09,
India exported spices and spice products valued at US$ 1.02 billion. In 2007-08, India exported
444,250 tonne of spices and spice products valued at US$ 1.10 billion.

Food Processing

The food processing industry is presently growing at 14 per cent against 6-7 per cent growth in
2003-04. The industry received foreign direct investments (FDI) totalling US$ 143.80 million in
2007-08 against US$ 5.70 million in the previous fiscal. The cumulative FDI received by the
industry from April 2000-January 2009 stood at US$ 760.32 million.

However, India’s share in exports of processed food in global trade is only 1.5 per cent; whereas
the size of the global processed-food market is estimated at US$ 3.2 trillion and nearly 80 per
cent of agricultural products in the developed countries get processed and packaged.

India has set itself a target of doubling its processed food production by 2015, and will set up 10
food technology parks during the next year with a view to achieving this.

The first mega food park in western India under the Ministry of Food Processing Industries
Mega Food Park scheme in the 11th Plan was launched at Shirwal near Pune.

Snacks and Confectionery

The Indian market holds enormous growth potential for snack food, which is estimated to be
worth US$ 3 billion. The market is clearly and equally divided into the organised and
unorganised sector. The organised sector of the snack food market is growing at 15-20 per cent a
year while the growth rate of the US$ 1.56 billion unorganised sector is 7-8 per cent.

Dairy

According to Dairy India 2007 estimates, the current size of the Indian dairy sector is US$ 62.67
billion and has been growing at a rate of 5 per cent a year. The dairy exports in 2007–08 rose to
US$ 210.5 million against US$ 113.57 last fiscal, whereas the domestic dairy sector is slated to
cross US$ 108 billion in revenues by 2011.

Beverages

According to industry experts, the market for carbonated drinks in India is worth US$ 1.5 billion
while the juice and juice-based drinks market accounts for US$ 0.25 billion. Growing at a rate of
25 per cent, the fruit-drinks category is one of the fastest growing in the beverages market.
Sports and energy drinks, which currently have a low penetration in the Indian market, have
sufficient potential to grow.

The market for alcoholic beverages has been growing consistently. 'The Future of Wine', a report
on the state of the wine industry over 50 years, suggests that the market for wine in India was
growing at over 25 per cent per year.

Retail Landscape: Food Chains and Restaurants

The food and grocery market in India is the sixth largest in the world. Food and grocery retail
contributes to 70 per cent of the total retail sales. According to industry estimates, the segment is
growing at a rate of 104 per cent and is expected to grow to US$ 482 billion by 2020.

According to a BMI forecast, India is likely to see a huge 443 per cent increase in mass grocery
retail (MGR) sales during the 2007-2012 period.

Ninety nine per cent of this segment is unorganised, and therefore, there is immense scope for
growth for the organised sector. The organised food retail sector is largely dominated by
restaurants, fast food outlets, coffee joints and the like.

Major investments

Private investment has been one of the key drivers for growth of the Indian food industry. The
'India Food Report 2008', reveals that the total amount of investments in the food processing
sector in the pipeline for the next three years is about US$ 23 billion.

• The government has received around 40 expressions of interest (EoI) for the setting up of
10 MFPs with an investment of US$ 514.37 million.
• Adani Wilmar, the owner of Fortune edible oil brand, is eyeing acquisitions of greenfield
and brownfield assets for sunflower, soya and mustard oil projects. It plans to invest close
to US$ 199 million in these projects over the next year.
• Reliance Industries Ltd has invested US$ 1.25 billion in a dairy project.
• Britannia Industries Ltd has signed an agreement with Fonterra Brands (Mauritius
Holding) to acquire Fonterra's 49 per cent equity and preference shareholding in
Britannia New Zealand Foods, their dairy joint venture.

Government Initiatives
The new trade policy places increased focus on agro-based industries.

• Food processing industries have been put in the list of priority sectors for bank lending.
• Fruit and vegetable processing units have been completely exempted from paying excise
duty.
• Automatic approval for foreign equity up to 100 per cent is permitted for most of the
processed food items.
• Items like fruits and vegetables products, condensed milk, ice cream, meat production
have been completely exempted from Central Excise Duty.
• Excise duty on ready to eat packaged foods and instant food mixes has been brought
down to 8 per cent from 16 per cent.
• Excise duty on aerated drinks has been reduced to 16 per cent from 24 per cent.

Looking ahead

According to the India Food and Drink Report Q3 2008 by research analysis firm Research and
Markets, by 2012, India’s processed food output is likely to grow by 44.2 per cent to touch US$
90.1 billion, while packaged food sales will increase by 67.5 per cent to reach US$ 21.7 billion.
On a per capita basis, per capita packaged food spending is expected to grow by 56.5 per cent to
US$ 18.06 by 2012.

India's food industry on the

path of high growth
By Aroonim Bhuyan
INDIA'S $182-BILLION food processing industry has been
growing at over 13 percent despite the global slowdown.
And now the government is aiming to double the turnover in
the next five or six years by setting up mega food parks to
attract global capital.
The vision: Bring about a three-fold growth in the size of
the country's food processing business, increase the level of
processing perishables from six percent to 20 percent, raise
the value addition from 20 percent to 35 percent and increase
India's share in the global food trade from 1.5 percent to three
percent.
"We have seen the revolutions in the information technology
and biotechnology. I now feel the time has come for a revolution
in food technology," said Minister of State for Food
Processing Subodh Kant Sahai.
"People say whatever the circumstances, one will need
food. So, this is one industry that will never close down,"
Sahai, who holds independent charge of the ministry, said in
an interview.
He has statistics as well to back his confidence. The
country's gross domestic product (GDP) saw a decline in
growth to 5.3 percent for the third quarter of this fiscal from
8.9 percent in the like period of the previous year, with both
manufacturing and agriculture actually registering a decline
in output. But the food processing sector continued to maintain
a positive growth rate. "In the midst of the global economic
meltdown and with the growth in our manufacturing
sector also having fallen, the food processing industry is growing
at a robust 13.7 percent today, from levels of 6.7 percent
in 2004-05," said Sahai.
Agreed Pradeep Chordia, chairperson of the Chordia Food
Park at Shirwal in Maharashtra: "Food is an essential item. I
don't think that the global recession will have any effect on the
food industry in India."
According to the India Food Report 2008 prepared by leading
markets data provider Research and Markets, the Indian
food industry was estimated at over $182 billion, accounting
for about two-thirds of the country's total retail sector. "We
expect this market to grow to $300 billion by 2015, which is
not very far. And by 2025, it is expected to be worth $344 billion,"
said an official in the ministry of food processing
industries.
SOME FACTS ARE WELL KNOWN AND BACK THE
AMBITIOUS VISION SET BY THE GOVERNMENT:
! India is the world's largest producer of milk.
! It has the largest number of livestock in the world.
! It is the world's second largest producer of fruit and vegetables.
! It is the third largest producer of food grain.
! It has the third largest output of fish.
! It the largest producer, consumer and exporter of spices.
At the same time, while processing of food to consumable
standards are at levels of up to 80 percent in some developed
countries, the overall processing level in India has languished
at single-digit level till recently.
"While the whole world was processing at 70-80 percent,
we were processing just six-seven percent. Now, after four
years, this has gone to 10 percent," said Sahai, adding that
India's share in exports of processed food in a global market is
just 1.5 percent at $3.2 billion.
The main reason for this is that much of the farm and horticultural
produce goes waste or farmers are compelled to dispose
them of in distress sales as there is no adequate infrastructure
to process and preserve the produce and especially
increase its shelf life till it reaches retail stores.
The wastage level of fruit and vegetables in India currently
stands at a whopping 35 percent, explain ministry officials,
adding it was to bring a complete turnaround to this scheme
of things that the government launched the ambitious Vision
2015 programme. An essential part of the programme is the
flagship Mega Food Parks Scheme, which is instilling a lot of
hope among stakeholders - from agriculturists to industrialists
- and 10 such projects are already in the pipeline across
the country. The idea behind these parks is to make the country's
farm sector more market-driven than supply-driven. In
other words, farmers will need to produce what the markets
demand rather than what they feel like.
"Through food parks, processors will tell farmers, 'Look!
this is what you will produce now since this is what is needed.
We need so much of this produce every year. This is the
current market rate, this was what you were getting, and this
is what we will pay you'. So all sides are happy," explained
the ministry official.
"What we want is the farmers should get more and more
market information."
Each of these parks is expected to generate 30,000 direct
jobs and several times of it in indirect opportunities. Based on
the success parameters of the first 10 parks, the number will
be scaled up to 30 in the next five years. These initiatives are
also seen opening up new opportunities for youth and that is
why the government is setting up the National Institute of
Food Technology Entrepreneurship and Management
(NIFTEM), not far from the national capital. "Courses in
the institute will start from the 2010 session," said Sahai,
adding a series of laboratories for carrying out research and
development work at various institutes was also in the
pipeline.
The minister said India's food processing industry - which
has the potential to attract Rs.1,000 billion ($20 billion) worth
of investment, now needed to link better with the world market
to achieve its full potential. "We will become the food factory
of the world."
In India agricultural and dairy sectors have achieved remarkable successes over the last three and
a half decades. Besides being one of the world's largest producers of food-grains, India ranks
second in the world in the production of fruits and vegetables, and first in milk
production�providing much needed food security to the nation.
The accomplishments of the green and white revolutions have, however, not been matched
by concurrent developments in supply chain management, and in new technologies for better
processing, preservation, and storage of food. Pockets of shortages and near starvation,
substantial wastages due to spoilage, quality deficiencies, and inadequate returns to the farmer
are still very much in evidence.
 Increased urbanization, improved standards of living, and the convenience needs of dual
income families point to major market potentialities in the food processing and marketing
sectors. This is also evident from the presence of several global foods giants and leading Indian
industrial enterprises in the country's food processing sector, such as: Nestle India Ltd, Cadbury's
India Ltd, Kelloggs India, Hindustan Lever Ltd, ITC-Agro, Godrej Foods and MTR Foods Ltd
Besides, in the current globalized milieu, our surplus food production, as well as the increasing
preference for Indian foods (in several regions of the world) need to be leveraged to achieve
economic, and strategic objectives through exports. The Food and Agriculture Integrated
Development Action (FAIDA) report (1997) prepared by McKinsey has estimated that, driven by
changing consumer preferences, the annual consumption of 'value-added' foods alone would
grow to Rs.225, 000 crores by 2007�larger than the entire manufacturing sector! A more recent
report has stated an absolute revenue increase of Rs. 900 billion in food manufacturing between
1993 and 2000. This is in contrast with Rs. 150 billion and Rs. 300 billion in the pharmaceutical
and IT industries, respectively. Overall, the value of the Indian food industry has increased from
Rs. 3.09 trillion in 1993-94 to Rs. 3.99 trillion in 2000-01. The segments with the largest growth
potential have been identified as dairy, wheat, fruits and vegetables, and poultry. This report has
also identified some of the major challenges for the emerging food industry in India (see box).
Major Challenges for the Indian Food Industry

 Consumer education that processed foods can be more nutritious

 Low price-elasticity for processed food products
 Need for distribution network and cold chain
 Backward-forward integration from farm to consumers
 Development of marketing channels
 Development of linkages between industry, government and institutions
 Taxation in line with other nations

 Streamlining of food laws

Challenges in Food Processing
Unprocessed foods are susceptible to spoilage by biochemical processes, microbial attack and
infestation. The right post harvest practices such as good processing techniques, and proper
packaging, transportation and storage (of even processed foods) can play a significant role in
reducing spoilage and extending shelf life. The challenges in processing lie in retaining the
nutritional value, flavour, aroma, and texture of foods, and presenting them in near natural form
with added conveniences. However, such qualities cannot be readily quantified and correlated
with physico-chemical parameters, sensory evaluations providing the only means of
benchmarking. Besides, processed foods need to be offered to the consumer in hygienic and
attractive packaging, and at low incremental costs.
The challenges for the food preservation, distribution and processing sectors are diverse and
demanding, and need to be addressed on several fronts to derive maximum market benefits.
Presently, the organizations addressing the educational and R & D requirements are too few, and
there is a pressing need for supplementing their efforts. In the emerging scenario, the Food
Engineering professional needs to develop sufficient awareness and appreciation of the relevant
principles of life sciences, and physical sciences, as well as of a wide variety of other topics
including: nutrition, preservation and storage techniques, processing unit operations, bio-
processing, waste management, distribution and supply chain management, food laws and
regulations and so on. Besides, the professional needs to develop an appreciation of R&D and
innovation in critical technology areas such as: newer or novel process development in
preservation and storage techniques, rheology, colloids and dispersal systems, packaging-
polymers and composites, sensors for detection and process control, bioprocess engineering, and
so on
Food Process Engineering Mission Projects at IITB
IIT Bombay has developed an appreciation of the challenges, as well as opportunities in this area
over the last decade, and has played a leading role in conceptualizing a Technology Development
Mission Project (funded by MHRD, Govt. of India) on Food Process Engineering with IIT
Kharagpur, IISc, Bangalore, and several industry partners. The projects addressed four major
areas described below:
Supercritical Fluid Extraction (SCFE) process1
SCFE process can help the Indian industry to compete in a fast growing international market for
value-added natural products. Presently, the high cost of imported SCFE equipment deters
economically viable use of SCFE technology. Our objective has been to develop viable, world-
class SCFE technology through indigenous design and manufacture of components. The SCFE
prototype plant designed and installed at IIT Bombay has state-of-the-art safety and process
control features of commercial SCFE plants. It is used for technology demonstration, scale-up
studies, test sample (extract) generation, and process optimization. Products extracted using this
technology have the advantages of purity, high concentrations and extended shelf life. The
process allows flexible operating conditions for multiple product extraction, and simultaneous
fractionation of extract. It also eliminates toxic residues due to the use of supercritical CO2 as
solvent. The technology has been licensed, and SCFE plants based on this technology have been
sold to industries in India and abroad. More details at www.iitbombay.com
Controlled Atmosphere (CA) Technology for
Long term Storage of food grains 2
CA storage consists of reduction of oxygen by
elevating nitrogen and/or carbon dioxide
concentrations in storage units, so as to enable
preservation of the quality of food products
during storage. The technique of chemical
fumigation that is widely used for storage,
although effective to an extent, is not
environment friendly. As an alternative, a
Pressure Swing Adsorption N2 generator was
designed and established at IIT Bombay. This aids the creation of nitrogen and/or carbon
dioxide-rich, and oxygen-depleted atmosphere in a storage unit. Bag-stacked items such as,
cereal grains, seeds and black tea have been successfully stored without any infestation, moisture
pick-up, and with superior quality maintenance in terms of taste, color, lustre and aroma. The
choice of plastic films used as covering material for the stored grains was based on their gas
permeability and water vapour transmission rates. The work has culminated in the transfer of the
CA technology. More recently another project on black-tea storage has been executed, and the
resulting technology transferred after filing an international patent jointly with the industrial
partner.
Engine exhaust-fired Truck Refrigeration System (TRS) 3
Proper refrigeration is critical to the transport of perishable items. A novel technology developed
at IIT Bombay, which utilizes engine exhaust has shown encouraging results with both prototype
testing and full demonstration. The engine exhaust-fired TRS can replace the conventional
dedicated engine-driven vapour compression truck refrigeration system (DEDVCRS) used for
transporting fresh fruits, flowers and vegetables, frozen vegetables, fish, meat and ice cream. The
TRS can be slightly modified for use in milk transport trucks. The salient features of the system
are: rugged and reliable design due to few moving parts, low life-cycle costs due to lower initial
and operating costs, and the use of environment friendly ammonia as refrigerant
A similar 'Shipboard Chilling System' for small fishing trawlers is being transferred to an Indian
client for commercialization. Using these systems, the cost of co-generating power for hot and
cold utilities can be 15 to 50% lower than current methods, where a significant amount of heat is
lost to the atmosphere from the engine cooling water and exhaust gases. Successful
implementation of these technologies will help reduce fuel consumption, and also save valuable
foreign exchange in importing the DEDVCRS, or its components.
Liquid nitrogen based Individual Quick Freezing
(IQF) technology for seafood 4
India has excellent potential for development of
the seafood industry, which has emerged as an
important foreign exchange earner. The industry
has recognized the need for IQF technology,
which is far superior to the conventional processes
in terms of quicker freezing time, better flavour
and shape retention etc. Compared with the IQF
process using mechanical refrigeration (currently
being used in India), the cyrogenic process
developed at IIT Bombay uses liquid nitrogen as
the freezant. The seafood is frozen individually by
direct contact with nitrogen vapours and liquid nitrogen spray. This offers greater convenience to
the consumers and adds value to the products.
IIT Bombay has indigenously designed and developed a cryogenic tunnel which possesses the
following advantageous features:
 low initial investment.
 compact unit�allowing mechanization and automation of the production process
 rapid freezing�ensuring retention of original texture, flavour, and a good marketable
appearance.
 prevention of oxidation of the product due to presence of nitrogen gas during packing.
To summarize, the projects pursued at IIT Bombay have led to notable contributions. Besides
sensitization to the critical aspects of food processing and preservation, they have helped develop
a strong knowledge base, expertise, and important facilities in these areas. The Institute has
initiated a continuing education programme series, including courses on 'Engineering Concepts
for Food Industry.' The Ministry of Food Processing Industry (MFPI) has provided first-phase
support for the development of a modern Food-Process Engineering laboratory at IIT Bombay.
The Institute is now well equipped to launch a five-year Dual Degree programme in Food and
Bioprocess Engineering (with Chemical Engineering as the core discipline), by employing the
institutional strengths in a wide range of related disciplines such as: Biotechnology and
Bioprocess Engineering, Chemical, Mechanical and Post Harvest Engineering, Information
Technology and Technology Management.

Facts about food processing

industry in india

• India is one of the world’s major food producers but accounts for less than 1.5 per
cent of international food trade. This indicates vast scope for both investors and
exporters. Food exports in 1998 stood at US $5.8 billion whereas the world total was
US $438 billion.

• The Indian food industry’s sales turnover is Rs 140,000 crore (1 crore = 10 million)
annually as at the start of year 2000.

• The industry requires about Rs 29,000 crore in investment over the next five years
to 2005 to create necessary infrastructure, expand production facilities and state-of-
the-art-technology to match the international quality and standards.

• The office of the Agricultural Affairs of the USDA / Foreign Agricultural Services in
New Delhi says that one of India’s proudest accomplishments has been achieving a
tenuous self-sufficiency in food production and that the country produces a wide
variety of agricultural products at prices that are at or below world values in most
cases.

• The Indian palate is accustomed to traditional foods, mostly wheat and rice-based,
rather than potato and corn-based western palate. In marketing perspective, this is
considered an important factor for foreign marketers.

• The USDA report says initially consumer-ready food products may have to be tailored
to include Indian spices and traditional ingredients. In addition to traditional tastes,
there are other social factors which affect consumption in India. Hindus account for
approximately 80 per cent of India’s population, and while only 25 or 30 per cent are
strict vegetarians, beef slaughter is prohibited in all but two states (Kerala and West
Bengal) and consumption of other meats is limited. Incidentally, India is the only
country where the US-based MacDonalds sells its burgers without any beef content
and even offers purely vegetarian burgers.

• India’s middle class segment will hold the key to success or failure of the processed
food market in India. Of the country’s total population of one billion, the middle class
segments account for about 350-370 million. Though a majority of families in this
segment have non-working housewives or can afford hired domestic help and thus
prepare foods of their taste in their own kitchens, the profile of the middle class is
 changing steadily and hired domestic help is becoming costlier. This is conducive to
an expansion in demand for ready-to-eat Indian-style foods.

• India’s food processing sector covers fruit and vegetables; meat and poultry; milk
and milk products, alcoholic beverages, fisheries, plantation, grain processing and
other consumer product groups like confectionery, chocolates and cocoa products,
Soya-based products, mineral water, high protein foods etc.

• According to latest official statistics, India exported processed fruits and vegetables
worth Rs 5240 million in 1997-98. The horticulture production is around 102 million
tonnes. Foreign investment since 1991, when economic liberalisation started, stood
at Rs 8,800 crore. Products that have growing demand, especially in the Middle East
countries include pickles, chutneys, fruit pulps, canned fruits, and vegetables,
concentrated pulps and juices, dehydrated vegetables and frozen fruits and
vegetables.

• Another potential processed food product is meat and poultry products. India ranks
first in world cattle population, 50 per cent of buffalo population and one-sixth of
total goat population of the world. Buffalo meat is surplus in India. There is vast
scope to set up modern slaughter facilities and cold store chains in meat and poultry
processing sector. India’s current level of meat and meat-based exports is around Rs
8,000 million. In last six years foreign investment in this segment stood at Rs 5,000
million which is more than 50 per cent of the total investment made in this sector.

• Compared with meat, poultry industry has registered significant growth. India ranks
fifth in the world with annual egg production of 1.61 million tones. Both poultry and
egg processing units have come in a very big way in the country. India is exporting
egg powder, frozen egg yolk and albumin powder to Europe, Japan and other
countries. Poultry exports are mostly to Maldives and Oman. Indian poultry meat
products have good markets in Japan, Malaysia, Indonesia and Singapore. While
meat products registered a growth of 10 per cent, eggs and broilers registered 16-20
per cent growth.

• There are about 15 pure line and grand parent franchise projects in India. There are
115 layer and 280 broiler hatcheries producing 1.3 million layer parents and 280
million broiler parents. They in turn supply 95 million hybrid layer and 275 million
broilers, day-old chick. Presently there are only five egg powder plants in India which
is considered insufficient in view of growing export demand for different kind of
powder - whole egg, yolk and albumen. The scope of foreign investment and state-
of-the-art technology in this field is therefore tremendous.

• Milk and milk products is rated as one of the most promising sectors which deserves
foreign investment in a big way. When the world milk production registered a
negative growth of 2 per cent , India performed much better with 4 per cent growth.
The total milk production is around 72 million tonnes and the demand for milk is
estimated at around 80 million tonnes.

• By 2005, the value of Indian dairy produce is expected to be Rs 1,000,000 million. In

last six years foreign investment in this sector stood at Rs 3600 million which is
about one-forth of total investment made in this sector. Manufacture of casein and
 lactose, largely being imported presently, has good scope. Exports of milk products
have been decanalised.

• Grains could emerge as a major export earner for India in coming years. India’s food
grains production is now at around 225-230 million tones. These include rice, jawar,
bajra, maize, wheat, gram and pulses. Indian basmati rice enjoys command in the
international market. Besides growing Middle east market for basmati rive, many
other countries are showing interest for this food grain. In 1998-99 export of
basmati and non-basmati rice stood at Rs62000 million. There is a total rice milling
capacity of 186 million tones in the country.

• Among plantation, tea emerged as major foreign exchange earner. India is the
largest producer and exporter of black tea. However, the most worrying factor for
Indian tea industry is that from early next year with the implementation of tea
imports into the country, India tea may face a stiff competition within the country as
well, specially threat of Sri Lanka’s presence in the Indian market is looming large.

• The current year’s tea export prospect is not that very good in terms of forex
earnings because international prices has fallen significantly this year . India exports
between 150-170 million kilogram’s of tea per annum. Of course, the scope of
foreign investment in this sector is good and the multinational tea companies would
either be trying for marketing joint ventures with the Indian producers or acquire
stakes in Indian tea companies. There is strong possibilities of third country exports
through such joint venture as quality wise still Indian teas are ruling the international
market.

• Alcoholic beverages is another are where India witnessed substantial foreign

investment. Foreign investment in this sector stood at Rs 7000 million which about
70 percent of the total investment made so far. The IMFL (Indian Made Foreign
Liquor) primarily comprises wine, vodka, gin, whisky, rum and brandy. Draught beer
is a comparatively recent introduction in the Indian market. The Indian beer market
is estimated at Rs7000 million a year. One of the major advantages for any investor
eyeing the Indian liquor market is that India offers enough raw materials like
molasses, barely, maize, potatoes, grapes, yeast and hops for the industry.

• Yet another catchy investment sector is fisheries. There is growing canned and
processed fishes from India. The marine fish include prawns, shrimps, tuna,
cuttlefish, squids, octopus, red snappers, ribbon fish, mackerel, lobsters, cat fish etc.
In last six years there was substantial investment in fisheries to the tune of Rs
30,000 million of which foreign investments were of the order of Rs 7000 million. The
potential could be gauged by the fact that against fish production potential in the
Exclusive Economic Zone of 3.9 million tones, actual catch is to the tune of 2.87
million tones. Harvesting from inland sources is around 2.7 million tones.

• The biggest bottleneck in expanding the food processing sector, in terms of both
investment and exports, is lack of adequate infrastructure.

• Without a strong and dependable cold chain vital sector like food processing industry
which is based mostly on perishable products cannot survive and grow. Even at
current level of production, farm produce valued at Rs 70,000 million is being wasted
every year only because there is no adequate storage, transportation, cold chain
 facilities and other infrastructure supports. Cold chain facilities are miserably
inadequate to meet the increasing production of various perishable products like
milk, fruits, vegetables, poultry, fisheries etc.

• Prevention of Food Adulteration laws is not only stringent one but time consuming
also. It is considered as an archaic and no industry friendly food law. It substantial
varies from Codex standard. Harmonization of multiple food laws is an urgent
necessity.