Project of Parle Agro
-
Upload
dhirender-singh -
Category
Documents
-
view
793 -
download
41
description
Transcript of Project of Parle Agro
1
Chapter-1 Purpose of the Study
Objective
There are certain sequentially laid down objectives stated as under:-
1. The objective of this project report is to do study of production process of Beverage in
parle agro pvt. Ltd. Company.
2.To evaluate the major competitors of Parle Agro product in the market.
Scope
The ultimate scope of study this topic was to know about parle agro pvt. Ltd
company and about the production process of parle agro’s products.
2
Chapter- 2 Introduction
2.1About the Industry
Parle products Pvt Ltd based in Mumbai, India has been India’s largest
manufacture of biscuits and confectionery, for almost 80 years. Makers of the world’s
largest selling biscuits parle-G, and the host of other very popular brands. Its reach even
of the remotest villages of India. Many of the parle products – biscuits or confectionery,
are market leader in there category an have won acclaim at the monde Selection, since
1971. With a 40 share of the total biscuit market and a 15 share of the total confectionery
market in India, Parle has grown to become a multi-million dollar company. Parle Agro
is a food and beverage company based in Mumbai, India.
Parle Agro – a trusted name in the beverage industry for agro based drinks. Parle
Agro is a leading Indian Beverage Company, the only Indian transnational giant with the
past experience of having successfully launched leading soft drink brands like ‘Frooti,
Appy Classic, Appy – Fizz Bailley Packaged Drinking Water & Confectionery brands
like Mintrox and Buttercup. Parle Agro strength is our people who have worked towards
making our presence felt throughout the country and all over the world through a strong
franchisee network and well – developed strong infrastructure. Parle Agro has its
factories located in Silvassa, Patalganga, Bhopal, Chennai, Ghaziabad and Hyderabad.
At Parle Agro, success is a habit, where greater heights are achieved through consumer
insight, sound business practices, marketing and sales innovation, with the focus on the
consumer. Thinking consumer, Tasting success, Always’ – that is what Parle Agro is all
about.
3
2.2Nature of business
Parle agro is a trusted name in the India beverage industry an has been refreshing
India since more than two decades with leading brands like frooti, appy classic, Appyfizz,
Balley saint juice, LMN & recently launched grappo fizz. Parle agro Pvt Ltd.
Manufacture, distributes, sells, and export fruit drinks in India and internationally. The
company offers fruits and milk drinks, packaged water. And apple and mango drinks in
polyethylene terepthalate(PET) bottles and containers, and tetra packs. The company also
operates a healthy and fitness studio for woman. The company distributes its products
through franchisees. Parle Agro., Pvt LTd. Was founded in 1985 and is based in Mumbai,
India
Parle Agro has been trusted name in the beverage industry providing wholesome and
healthy agro-based drinks brands. It has successfully launched some of India’s leading
beverage like Frooti, appy and N-joi,
And packaged drinking water, Bailley, over the last two decade. In a country were health
consciousness is growing at a rapid pace, Parle Agro, with its numerous fruit-based
drinks, has struck a chord with the masses. It brings to the consumer the magic of
premium quality fresh fruits drinks conveniently packed and available all through the
year. Fruit beverage are wholesome, easy to digest, highly refreshing with natural
nutritional values as compared to synthetic and aerated drinks. Parle Argo’s Frooti is
India’s first national mango drink. The mango segment is 95% of the India fruit drink
market and Frooti has 855 market share in the tetra pack segment. Made from fresh and
premium India mangoes, Frooti has gone to be one of India’s top 50 most trusted brands.
When Parle Agro launch N-joi with real fruit and fresh milk, it not only launched a new
healthy beverage, but also created a whole new category in India. The milk shake claims
to contain no preservatives and it’s full of nutritional goodness. It’s a delicious filler and
an apt quick refreshing nourishment for today’s hectic stressful life.
4
2.3Geographic area
Figure-2.1
5
Chapter-3 Company Profile
3.1Organisation Structure
An organizational structure is a mainly hierarchical concepts of subordinates of entities
that collaborate and contribute serve one common aim.
Organization are a variant of clustered entities. An organization can be structured in
many different ways and styles, depending on there objective and ambience. The
structure of an organization will determine the mode in which it operate and performs.
Organizational structure allows the expressed allocation of responsibilities for different
function and processes to different entities such as branch, department, workgroup, and
individual. Individual is an organizational structure are normally hired under time limited
work contract or work order, or under permanent employment contract or program
orders.
Figure-3.1
BUSINESS HEAD
BUSINESS MANAGER (GENERAL RETAIL)
BUSINESS MANAGER (HoReCa
BUSINESS MANAGER (INSTITUTIONAL)
BUSINESS MANAGER (MORDEN TRADE)
MARKETING TRADE
6
3.2Vision & Mission
Vision
To be the leaders in our business. We will stand apart from the competition by being the
first in the market to innovate.
Mission
“We will be the leader in our business by –maintaining high quality, introducing new and
innovative product, reaching every part of India, remaining customer-centric , constantly
upgrading our knowledge and skill’’
“To provide consumers superior, wholesome agro based food and drink brands through
which parle can build a profitable; growth oriented organization”.
Parle is a leading Indian Food and Beverage Company, the only Indian Transnational
gaint with the past experience of having successfully launched leading soft drinks like
‘‘Frooti, Appy, Njoi and Bailley”. Toady its brand portfolio consists of No. 1 brands like
froti along with Appy, Njoi and Bailley.
7
3.3Products/Services offered
Parle agro Pvt. Ltd operate under three business verticals. Beverage –fruit drinks,
neetars, 100%juice, sparkling drinks, Water – packed Drinking water, foods-
confectionery, snacks.
Figure3.2
Beverage-
1.Frooti – launched in 1985 as a mango drink, Frooti is the first beverage to be launched
in tetra packed in India’s. Frooti is India’s favorite Mango drink and its ranked amongst
the most trusted brands in numerous national surveys..
just like that’
‘Fresh and juicy! What a beauty! Mango Frooti!’
‘juice up your Life’
Accepting that Frooti would perhaps always be identified as ‘Fresh and juicy’, Frooti
packs currently incorporate the decades-old tagline, with a minor change, saying, “Fresh
‘N’ Juicy Mango”. Even the ad plays the jingle towards the end. But Frooti’s brand
communication is based around the theme of “Why grow up.
Figure-3.3
8
2.Appy Classic:Launched in 1986 as apple nectar and originally available in a white tetra
pack with an applle and leaf graphic, today it comes in black tetra packaging. Apply
remains the first apple neetar to be launched in India.
Figure-3.4
3.Appy Fizz: Launched in 2005, appy Fizz is India’s first sparkling apple drink available
in a champagne shaped PET blttle. Considered the ‘Champagne’ of Fruit drinks
Apply Fizz jis a one of a kind product in the beverage market, Recently, Appy
Fizz has been given a makeover in terms of a new packaging.
Figure-3.5
4.Grappo Fizz: Launched in 2008, Grappo Fizz is a sparkling grape juice drink.
Credited with crfeating the sparkling fruit drinks category in India, Grappo Gizz is along
the lines of existing product Appy Fizz. It is purple-red in color and has no close
competition in the market.
Figure-3.6
9
5.Hippo: Hippo is a baked snack with the goodness of wheat. It is available in seven
flavors from around the world-Italian Pizza, Chinese Manchurian, Hot-n-Sweet Tomato,
Thai Chili, Yoghurt Mint Chutney, Indian Chatpatta and Arabian Salted. These baked
wheat munchies have no added MSG, no GMO, and no cholesterol and zero trans-fat.
Figure-3.7
6.Saint Juices: Launched in 2008, Saint juice is available in four variants-Orange, Mixed
fruit, Grape and Apple. Sanit Juice is 100% juice with no added color, sugar or
preservatives.
Saint Apple Juice comes with the natural benefits of green apples. Compared to other
varietes of apples, Green Apples are richer in Vitamin C and are high on fiber
content.They are an excellent source of potassium and antioxdants. The concentrate for
Saint Apple Juice is made from carefully selected green apples from the best orchards in
Austria and imported to India.
Figure-3.8
10
Water
1.Bailley Aqua:
It is a mineral water and was launched in the year 1993. It is one of the first brands to get
an ISI certification. Bailley conforms to stringent BIS Norms. It undergoes 51 Quality
control tests includes 32 chemical tests, 9 microbiological tests and 10 physical tests
meets international standards laid down by WHO, USFDA, PFA.
Parle Bailley Aqua is unique because it has the same consistent taste across India. This is
because of the unique purifying processing system, which removes all minerals and salts
and puts back only exact premeasured quantities of salts and minerals necessaryfor the
human body. Bailley Aqua is purified with chemical free natural U.V. Treatment.
Figure-3.9
11
Confectionary-
1.Mintrox: Mintrox is a hard mint candy. It is available in two flavors- Hard Cinnamon
Mint and Hard Menthol Mint
Figure-3.10
2.Buttercup Softies: A Buttercup softie is a toffee which gi8ves a uniquely chewy &
smooth eating experience with a rich after taste. It is available in 4 variants – Strawberry,
Coconut, Vanilla and Caramel
12
3.4 Distribution Network
Regions
For all the trades, Delhi is divided into five regions
Ø North Region
Ø Central Region
Ø South Region
Ø West Region
Ø East Region
Genral retail Distribustion
Figure-11
DELHI
NORTH CENTRAL SOUTH WEST EAST
NORTH1 NORTH2 CENTRAL1
CENTRAL2
SOUTH1 SOUTH2 WEST1 WEST2 EAST1 EAST2
13
HoReCa, Institutions and modern trade
Figure-3.12
Coverage plane followed by distributors
Figure-3.13
For Delhi
Beverage Factory location-Ghaziabad
Warehouse- Alipur,North Delhi
Ø Parle agro has a wide product line with frooti as theire flagship product. Frooti
has such as an impact that almost every distributor is involve and the rest of the
product are carried along with the dirstibution of frooti
Ø Penetration of frooti is to level of outlets such as small kiosks, telephone booths
and even stationery shope now sall Frooti.
For Delhi company has two approaches
DELHI
NORTH CENTRAL SOUTH WEST EAST
14
(MODELS)
MODEL-1
Figure3.14
FACTORY
COMPANY (ALIPUR)
DISTRIBUTORS
GENRAL RETALER
WHOLESALER
15
MODEL-2
Figure-3.15
Ø These two models are Implemented through their sales team and Distributor.
Ø Company reaches out to 15000 retailers in Delhi directly.
FACTORY (GHAZIABAD)
COMPANY (ALIPUR)
MORDEN RETALIERS (FOOD BAZZAR,VISHAL etc)
16
Distributor requirements
1) General trade Distributer;
Ø Fees: Initial fees of Rs 5 lakh through draft
Ø Space requirement: min. 100 sq metre
Ø Transportation required: commercial vehicles depending upon the
area such as: Tata Ace, Vikram etc.
Ø I.T infrastructure: No requirement
Ø Inventory management capability: Done manually
Ø Manpower requirement: 1auto driver multi tasking and educated
(12thpass)
2) Institutional Distributor:
Ø Fees: initial fees of Rs 15 lakh through draft.
Ø Space requirement : Min.300 sq. mt
Ø Transportation required: commercial vehicles depending upon the
area such as: Tata Ace, Vikram etc
Ø Inventory management capability: computerized, centrally
monitored from Alipur warehouse.
Ø I.T infrastructure: 2-3 computers
Manpower requirement: 1auto driver per vehicle multi tasking and educated
(12thpass) and 1 computer operator
17
Company initiatives in distributors:
v PARB:A lot of support is provided by the company’s active recharge wing, Parle
agro retail barometer (PARB)intelligence, the company support its franchisees with
an array support system which include,
Ø Quality control,
Ø Periodic technology up gradation,
Ø Fresh distribution pattern
Ø Even the installation of new machinery.
3.5 SWOT Analysis
Strength
1.PARLE Agro effective growth strategy and strong distribution channel due to effective
distribution model to reach interior of the untapped market.
2.A systematic, planned and quick action taken up which will lead to quick reactions by
the HORECA Channels ultimately is providing a competitive edge to PARLE AGRO.
3.A dedicated Intellect; Marketing and Distribution team enhances the sales of the Fruit
Juices and other fmcg products. Moreover, PARLE has monopoly in the market
4.For its fruits drink FROOTI. PARLE association with the rural and retail market
making the fmcg products in reach of the common man.
Weakness:
1.The data collected cannot be considered as 100 accurate but it is only an estimated
figures gathered by the various HORECA Channels in the M.P. region.
2.The analysis so done cannot be regarded as the final as change is the constant thing
which happens.
18
Opportunities;
A huge rural and retail untapped market can be the new platform. Brand image of
PARLE AGRO products and it is the time to increase to product line by introducing other
fmcg products.
Threats;
Throat cut competition with Pepsi.co. And Coca-Cola and other Local products in Retail
market with respect to sales margin. Non availability of stock for Rural and Retail
market Carriage problem hinders the distribution, specifically in rural market.
19
3.6Competitor information
Beverages
1.Frooti
There are over 100 mango based drinks in India. It is one of the largest selling Mango
drinks in India. However, if faces stiff competition from Mango Slice which is a Pepsi
product. It was launched in the Indian markets in 1993. Slice’s sensuous positioning is in
complete contrast to the positioning of other mango drinks. Last year, Slice brought
Katrina Kaif on board, making her the first star to endorse the brand. The brand was also
revamped – a new look, a new three-dimensional logo, reformulation of the taste, and a
fresh concept – Aamsutra – the art of experiencing mango pleasure. Also, the target
group for the brand, which was earlier between the ages of 18 - 24 years, shifted. The
brand sought a new target audience – people aged 22 years and above. It occupies a much
larger shelf space and more facings as compared to Frooti in retail outlets. Another stiff
competition which Frooti faces is in the form of Coca-Coal’s Mazaa. Mazaaisa fruit drink
brand marketed in India and Bangladesh, the most popular drink being the mango variety,
so much which over the years, the Maaza brand has become synonymous with Mango.
Initially Coca-Cola had also launched Maaza in orange and pineapple variants, but these
variants were subsequently dropped. Coca-Cola has recently re-launched these variants
again in the Indian market. Maaza was launched in 1976 in India. The Union Beverages
Factory, based in the United Arab Emirates, began selling Maaza as a franchisee in the
Middle East and Africa in 1976.By 1995, it had acquired rights to the Maaza brand in
these countries through Maaza International Co LLC Dubai. In India, Maaza was
acquired by Coca-Cola India in 1993 from Parle-Bisleri along with other brands such as
Limca, Citra, Thums Up and Gold Spot. As for North America, Maaza was acquired by
House of Spices in 2005.Star Bazaar has come up with its own Mango drink. However,
that is available only at Star Bazaar. But it is being offered at comparable prices and even
discounts are given on it. Hence, it is posing as a competition, not just for Frooti but for
Slice and Mazaa as well.
20
2.Appy classic and appy fizz
Appy Classic and Appy Fizz are the undisputed leaders in the Apple drink category.
Appy Classic is plain aerated apple drink whereas Appy Fizz is carbonated apple drink.
Litchica International has brought out its Apple flavor product in the market. Litchica
products are a hit in the states of Bihar and Madhya Pradesh. However, the apple juice
from Litchica is in a very nascent stage and will take time to capture substantial market
share (if consumers like the product).Star Bazaar has come up with its own Apple drink.
However, that is available only at Star Bazaar. But it is being offered at comparable
prices and even discounts are given on it. Hence, it is posing as a competitor to Appy at
Star Bazaar.
3.grappo fizz
Grappo Fizz is the new sparkling grape drink in town. It is a first of its kind product
with no close competition in the market. However, Appy Fizz faces competition from
Grappo Fizz after it launch. People who were regular consumers of Appy Fizz might shift
to Grappo Fizz now.
4. LMN
LMN is a natural lemon juice drink and the only brand in India with a taste closest to
home made, fresh lime water, also known as nimbu pani. With no artificial flavours and
real lemon juice, LMN will provide consumers a healthy, refreshing drink with the
goodness of vitamin C. Every summer, the Indian beverage market has seen cola majors
battle it out. This summer, the launch of LMN saw the cola wars taking a back seat and
the battle spilled over to the non-cola segment, to be more precise in the nimbu paani
category. Major competitors for LMN in this category are Nimbooz from Pepsi and
Minute Maid Nimbu Fresh from Coca-Cola. Nimbooz was the first brand that was
launched in market which was positioned as natural lemon refresher. It was positioned as
asli Indian, asli nimbu(Real Indian, Real Lemon). Then came LMN, which also
positioned it as lemon based refreshing drink. Now few months back, Coca-Cola too
21
entered the battle with the lemon flavor of its brand Minute Maid which was available in
Pulpy Orange flavor. The positioning is similar. They claim it to be Ghar Jaisa(Home
Like).The shelf space at all retail outlets is also directly proportional to the time they have
been in market. Nimbooz occupies the maximum shelf space in this category followed by
LMN and then Minute Maid Nimbu Fresh. However, Nimbooz and Minute Maid are
rising real fast as brands.LMN is not that much visible in the market.
5.Saint juice
Saint Juice is the new entrant to the fast growing fruit juice market. The brand is
making a foray into a market which is highly segmented and often highly confusing (to
the consumer).Indian beverages industry which is worth Rs 7000crore is divided broadly
into carbonated and non-carbonated categories.
The fruit based drinks market is highly confusing for a customer. Frooti, Tropicana,
Maaza, Real etc are all fruit based beverages. If you look at the products, there are
different types of fruit beverages: Fruit Drinks: These are those drinks where there is a
less than 20% fruit pulp. Frooti, Maaza etc belong to this category. Fruit drinks is the
dominant category which is worth around 250-300 crores. Fruit Nectar: These contain
less around 25- 85% fruit pulp. Brands like Godrej Xs and Real Nectar belongs to this
category. This is a small category worth around Rs 35 crore. Fruit Juice: These are fruit
beverages that contain 85% and more fruit pulp. Tropicana and Real belongs to this
category. This category is worth Rs 150crore.With in the Fruit Juices segment, a new
category is emerging which is the 100% juice category. Most consumers are not aware of
this micro segmentation. Those who drink Frooti or Maaza do not know or is not
bothered about the fruit pulp content. The reason is that, they drink these beverages for
the taste (and quenching thirst).Unlike the fruit drinks, customers of fruit juices are health
conscious. One of the reasons for them taking this product category is that they want a
healthy drink. The product is more of a health supplement than a beverage. The fact that
these products are less tasty compared to fruit drink is a proof that only the health
conscious ones will take it. The category of fruit juices are dominated by Dabur's Real
and Pepsi's Tropicana. Real is the market leader with around 55 - 60% share and
22
Tropicana takes the rest. Saint Juice is a 100% fruit juice. The brand is positioned as a
100 % juice. This positioning is relevant because consumers are confused about the
category. The 100 % juice positioning of Saint is a real threat to Real and Tropicana. Real
and Tropicana had extended itself into fruit drinks and fruit nectar categories. Real have
Real Twist and Tropicana have Twirl in the fruit drinks category. Both these brands have
their nectar variants. Recently Real and Tropicana launched their 100 % juice variant.
This is atypical case where a brand is trying to be everything to everybody.
6. Packaged drinking water
Bailley is Parle Agro’s contribution towards the packaged drinking water
segment.The Indian packaged water business is estimated at around Rs 2,500crore with a
growth rate of close to 35 per cent. While India ranks in the top 10 largest bottled water
consumers in the world, its per capita per annum consumption of bottled water is
estimated to be five liters which is comparatively lower than the global average of 24
liters. Today it is one of India's
fastest growing industrial sectors. Between 1999 and 2004, the Indian bottled water
market grew at a compound annual growth rate (CAGR) of 25 per cent - the highest in
the world. With over a thousand bottled water producers, the Indian bottled water
industry is big by even international standards. There are more than 200 brands, nearly 80
per cent of which are local. Most of the small-scale producers sell non-branded products
and serve small markets. In fact, making bottled water is today a cottage industry in the
country. Leave alone the metros, where a bottled-water manufacturer can be found even
in a one-room shop, in every medium and small city and even some prosperous rural
areas there are bottled water manufacturers. Despite the large number of small producers,
this industry is dominated by the big players -Parle Bisleri, Coca-Cola, PepsiCo, Parle
Agro, Mohan Meakins, SKN Breweries and so on. Parle was the first major Indian
company to enter the bottled water market in the country when it introduced Bisleri in
India 25 years ago. Bailley faces stiff competition from Parle Products’ Bisleri, Pepsi’s
Aquafina, Tata’sHimalayan, United Spirit’s Kingfisher Drinking Water, Aqua, Sumeru,
etc. Now even the International brands like Evian and Schweppes are entering the Indian
market screating further competition.
23
7. Snacks
Following the recent launches of LMN and Grappo Fizz, Parle Agro has extended
its presence into the snack food category, by the launch of a new baked wheat snack
brand'Hippo'. Hippo is a baked product which has minimum levels of cholesterol and fat.
It falls into the baked product category. However, it has to compete with the products
present in the fried chips category like Ruffles Lays, Kurkure, Bingo, Musst Chipps and
Pringles. In all the retail outlets, Hippo is kept along with the fried wafers and potato
chips category. Ideally it should fall into the baked products category. Also, these kinds
of products give better margins to the company, in addition to the fact that companies
want to capitalize on the growing health consciousness of Indian consumers. Parle Agro
has positioned 'Hippo' as a healthy-baked snack with the goodness of wheat. Ideally it
should be competing with Frito Lays Aliva which is also newly launched.
8.Confectionery
Parle Agro has forayed into the confectionery category also by launching Butter
Cup candies. These are hard boiled candies made with caramel. Post that PAPL launched
Butter Cup Softease which is easy chew toffee available in different flavours.Both these
are directly in competition with Alpenliebe, Eclairs, Mentos, Coffee Bite, Parle Poppins
and many more.
However, the presence and visibility of Butter Cup and Butter Cup Softease is very poor
in modern trade as compared to its competitors. Also, no promotion activities and
advertisements can be seen in this regards.
24
3.7 Market share & Growth rate Frooti has 85% market share in the tetra pack segment and a 15% share of the total
confectionery market in India.
Figure-3.17
25
Parle agro has been a trusted name in the beverage industry providing wholesome and
healthy agro-based drink brands. It successfully launched some of India’s leading
beverage like frooti, appy and N-joy, and packed drinking water, bailey, over the last two
decades. In a country where the health consciousness is growing at a rapid pace, Parle
agro, with its numerous fruit- based drinks, has struck a chord with the masses. It brings
to the consumer the magic of premium quality fresh fruits drinks conveniently packed
and available all through the year. Fruit beverage are wholesome, easy to digest highly
refreshing with natural nutrition value as compare to synthetic and aerated drinks. Parle
agro’s frooti is India’s first national mango drink. The mango segment is 95% of Indian
fruit drink market & frooti has 85% market share in the tetra pack segment. Made from
fresh & premium Indian Mangoes, frooti has grown to be one of India’s top 50 most
trusted brands. When parle agro launched N-joi with real fruits & fresh milk, it not only
launched a new healthy beverage, but also created a whole new category in India. The
milk shake claim to contain preservatives & it’s full of nutritional goodness. Its delicious
filler and apt quick refreshing nourishment for today’s hectic stressful life.
Appy, another premium drink from the Parle portfolio, is a deliciously light and
refreshing apple drink made from orehard fresh apple from himachal pradesh. It’s a
favourit with the young generation as a tasty, healthy, nourishing drink.Parle agro has
also diversified into the fitness industery and has setup fitness center in juhu & malad in
mumbai with aggressive plans to expend nationally .says Ms Nadia Chauhan,director,
marketing,”parle agro remains committed refreshing india and contantly caters to the
health and quality conscious consumer through newer and varied initiatives’ parle agro is
the first to introduce fruit drink in a tetra packed in india’s the first to introduce fruit
drinks in PET bottles in india the first to develop a real fruit and dairy fresh milk brands.
26
Chapter-4: Relate with organisation
4.1 Production
There has been a considerable increase in the consumption of fruit & vegetable juices
in the world during last few years and there are possibilities of further increase. The
export of fruit juices from developing countries has been increases steadily. The total
production of fruits and vegetables in the world is around 370 MT. India ranks first in the
world with an annual output of 32 MT. While there are almost 180 families of fruits that
are grown all over the world, citrus fruits constitute around 20% of world’s total fruit
production. Major Indian fruits consist of mango, banana, citrus fruits, apple, guava,
papaya, pineapple and grapes. The fruits are processed into various products such as fruit
juices & concentrates, canned fruit, dehydrated fruit, jams & jellies etc, but it constitutes
only 3-4% of total production.
India with its current production of around 32 MT of fruit, accounts for about 8% of
the world’s fruit production. The diverse agro-climatic zones the country makes it
possible to grow almost all varieties of fresh fruits and vegetables in India. The fruit
production in India has recorded a growth rate of 3.9%, whereas the fruit processing
sector has grown at about 20% per annum. However, the growth rates have been
extensively higher for frozen fruits & vegetables (121%) and dehydrated fruits &
vegetables (24%). There exist over 4000 fruit processing units in India with an aggregate
capacity of more than 12 lakh MT (less than 4% of total fruits produced). It is estimated
that around 20% of the production of processed fruits is meant for exports, the rest caters
to the defense, institutional sectors and household consumption, Mango and mango-based
products constitute 50% of exports.
Fruit Beverages:
The beverage industries are by far largest outlet for fruit juice and concentrate absorbing
over 80% of production. Much different type of beverages such as fruit juices, fruit
27
drinks, squashes, cordials and fruit punches are available. They are broadly defined as
follows:-
• Fruit juice: This is a natural juice pressed out of a fruit. This is unaltered in its
composition during preparation and preservation.
• Fruit drink: This is made by liquefying the whole fruit and at least 10% of the
volume of undiluted drink must be whole fruit. It may be diluted before being
served.
• Fruit squash: this consists essentially of strained juice containing moderate
qualities of fruit pulp to which sugar is added for sweetening, e.g., orange squash,
mango squash, etc.
• Fruit cordial: This is fruit squash from which all suspended material is
completely eliminated and is perfectly cleared. e.g., lime juice cordial.
• Fruit punches: These are made by mixing of desired fruit juices at the time of
serving.
• Fruit juice concentrate: This is fruit juice which has been concentrated by the
removal of water either by heating or freezing.
4.2 Raw material
Apple concentrate
Apple concentrate used for the production of Appy classic™ or Appy Fizz™ is
purchased from different fruit processing units situated in Jammu & Kashmir and some
part of Shimla where the production of Apple is in abundant. The concentrate received at
the unit is tested before use whether satisfying the under listed criteria or not.
Description : Seven fold brownish red colored, free from any visible
Impurities.
Storage condition : In a cool, clean place shielded from direct sunlight.
Packaging details : 85 liters HDPE containers.
28
General appearance : Brownish red.
Brix : 70 (min).
Acidity : 0.14% (min.).
Aroma : Good, free from fermentative smell.
Flavour : Sweet and slightly acidic, free from fermentative taste.
Standard plate count : Less than 20 colonies per gram sample.
Totapuri mango pulp:
Description : Single strength golden yellow colored with soft texture.
Storage condition : In a cool, clean place shielded from direct sunlight.
Packaging details : 3.1kg, 5.2kg Tin cans.
General appearance : Golden Yellow.
Brix : 14 (min.).
Acidity : 0.5% to 0.65%
Aroma : Fresh mango flavour free from off smell.
Taste : No fermentative taste.
Standard Plate Count : less than 5 colonies per gram sample.
29
Crystalline sugar
(C6H22O11; Molecular Weight: 342)
The most commonly used traditional sweetener is sucrose. It not only contributes
to the sweet taste but also maintains the overall balance of the beverage with the other
components. It should be available as hard, white, dry crystals, odour less, sweet taste
and must be soluble in water.
PARAMETER STANDARD
Grade M30/S30.
Grain size Pass through IS sieve 10.70mm.
Sucrose content not less than 98.5%
Moisture content < 0.5%
Solubility (at 20°C) 2 parts in part of water.
Packaging 100 kg Jute bag.
Activated Carbon Powder
Activated carbon is carbon that has been treated with oxygen to open up hundreds of
thousands of pores inside of it. Opening up these tiny pores between atoms expands the
surface area of the carbon enormously. In fact, in terms of raw surface area, one gram of
activated charcoal would be able to cover several football fields if it were rolled flat. The
surface are of activated charcoal is only one of the reasons why it is so useful. Carbon is a
naturally absorbent element, and it is able to absorb a wide variety of harmful chemicals.
The large surface area of activated charcoal allows it to absorb and trap millions of
chemicals at its countless bonding sites.
Activated carbon is used in the purification process of sugar syrup. It is derived from
hard wood charcoal or pinewood.
30
PARAMETER STANDARD
Moisture content < 5
pH 2 – 5
Bulk density (ml/gm) 3.5 – 4.5
Particle size 0.05 mm
Raw material Specification:
Raw Material Physical Chemical Microbiological Frequency
Apple
concentrate
Appearance,
taste, aroma,
foreign object,
colour
Brix, acidity TPC, yeas,
mold
All drum in
the given lot to
be tested
Totapuri
Mango pulp
Colour, flavor,
consistency
Acidity, pH,
TSS
NA Each receipt
Citric acid Colour,
lumpiness
Purity NA Each receipt
Malic acid Colour,
lumpiness
Purity NA Each receipt
Sugar Colour,
lumpiness
Purity, floc
test
TPC, Yeast,
Mold(once in
week)
Once on 10
lots
CO2 Odour, taste Purity, H2s,
traces
NA Each recipt
Water Appearance.
Odour, taste,
turbidity
Alkalinity,
hardness
TPC,E. coli
(once in week)
As per BIS
standards
Table-4.1
31
4.3 Production process Process involved in fruit beverage production
• Juice concentrate / Pulp:-
Pulp is collected from the cans by using can cutting machine. This pulp is pumped
through pipelines to blender.
• Sugar syrup:-
Sugar and sugar substitutes contributes the sweetness necessary to balance the
various ingredients and also act as a carriers to distribute the flavor components
uniformly throughout the drink. Crystalline sugar is used here as sweetening agent. Some
other sweetening agents are sucrose, fructose syrup (processed from corn starch) and
cyclamates (which is banned due to its harmful effects).
Sugar syrup is prepared by mixing dry sugar with hot water at 80°C in 8200 liter tank.
• Filtration:-
After preparing sugar syrup it passes through filtration unit. Activated carbon is
used as filtration medium as it absorbs all the off flavours, colour making the syrup
suitable for further use.
• Blending / Mixing:-
Sugar syrup and pulp are transferred in a tank where proper mixing is carried out
for several hours. Proper mixing is facilitated by impellors. At the same time
formulation (flavours, colours, etc.) is also added.
• Homogenization:-
Blended mixture is then transferred to homogenizer for homogenization. The
process of homogenization takes place at 2700 psi. During this process ascorbic acid is
used to prevent the flavour loss.
32
• Pasteurization:-
When homogenization completes, product is then send to the pasteurizing unit
which is fully automated. Here heating takes place through hot steam in counter current
manner. Pasteurization takes place at 95°C for 30 – 45 seconds.
• Cooling:-
Before filling the temperature of pasteurized product is lowered by ~25°C.
• Bottling:-
Cooled product is then filled in PET bottles. Since the temperature during filling
is nearly 72°C therefore the process is called as Hot Fill. These bottles are then cooled by
the help of showers before there storage.
For the preparation of carbonated beverages CO2 is mixed with the product before
filling. In order to facilitate proper mixing of CO2 in the product, the temperature of
product is lowered up to 0 – 1°C. This is done by the help of any cooling agent, which in
this case is glycol.
33
PROCESS FLOW DIAGRAM OF PRODUCTION
Figure-4.1Schematic representation of fruit beverage production.
34
4.4 Quality control
Microbiological analysis of raw material
A complete microbiological program involves testing of three separate groups of
microorganisms. These includes following:-
• Yeast
• Mold
• Bacteria
Yeast:-
Yeast is spherical, oval or rod shaped unicellular fungi. The most common yeast is
3-20µ in diameter. Some of the yeasts are capable of growth in acidic, carbonated and
chemically preserved beverages. Yeasts enter in the production process through raw
material, atmosphere, etc and spoils the beverages. Sacchromyces, Zygosacchromyces,
Torulopsis, Cadida and Rhodotorula are some common yeast that causes spoilage in
beverages.
Molds:-
Molds grow in the form of tangled mass (mycelium) of cellular filament that
spreads rapidly. Molds are aerobic and are capable of growth under acidic conditions.
Under normal conditions they can grow on packaging materials, sugar, filling
equipments, walls, floors, etc. Therefore whenever mold is found in the beverage then it
indicates the improper hygiene and manufacturing practices in the plant.
Peniflium, Physarum and Dictyostelium are a few of the most common molds found
in the aseptic filling plants.
Bacteria:-
Bacteria grow in the form of spheres (cocci), straight rods (bacilli) or bent rods
(spirila). The differences between these are very slight and can be determined by staining
methods and with the aid of microscope. The number of bacteria present can be
indicative of the sanitary condition of the material being tested. Juice or other nutrient
35
containing ingredients can enhance bacterial growth, and thus present an increased
spoilage problem. Bacteria most commonly found are more than 0.0005 mm in diameter.
Acetobactor, Bacillus, Gluconobactor, Lactobacillus and Gluconostoc are a few
acid tolerant bacteria foun commonly in carbonated beverages.
Coliform bacteria are of special concern, as they are associated with fecal waste od
humans and animals. Even though this bacterium may not be pathogenic, its presence is
indicative of pollution problems, and therefore is particularly significant from a public
health stand point.
4.5Methods of quantitative estimation of microorganisms
The quantitative estimation give san idea of how much extent of contamination takes
place. This is done by mainly three methods:-
v Pour Plate method:-
For estimation of environmental count as well as raw material and product count.
v Air sampler:-
For estimation of environmental and critical area count.
v Membrane filtration:-
Mainly used for water testing.
Pour Plate method:-
In Pour Plate method, a diluted sample is pipetted into a sterile petriplate, and
then
melted agar is poured in and mixed with sample.
§ Requirement:-
i. Laminar air flow.
ii. Incubator (temperature 37°C ±1).
iii. Petridish.
iv. Pipettes
36
v. Molten Parle Media and nutrient agar at 45°C (pre sterilized at 15psi at
121°C for 15 min).
§ Procedure:-
i. Dilute specimen to yield approximately 30- 300 CFU per aliquot to be plated.
ii. Inoculate labeled empty petridish with the aliquot of diluted specimen.
iii. Pour 15ml of melted plate count agar (45°C) into the inoculated petridish.
iv. Cover and mix thoroughly by gentle tilting and swirling the dish. Do not slope
the agar over the edge of the petridish.
v. Place on a flat surface undisturbed for about 10min to allow the agar to
completely gel.
vi. Invert and incubate at 37°C for 24-48hrs.
vii. Count, record and calculate: - Count all colonies, a magnifying colony counter
can aid in counting small embedded colonies. Record the data. Calculate CFU/ml or
CFU/g by the formula:-
CFU/ml = (CFU/plate × Dilution Factor × 1) per aliquot
Air sampler:-
It is a light weight portable system for testing the microbial quality of air in
clean room, barrier environment and critical filling areas. The tester is small enough to be
used in confined spaces, but powerful enough to sample up to 1000 liters in just 7
minutes.
Membrane filtration:-
The membrane filtration technique is the recommended method for microbiological
testing in the plant. Membrane filters are thin pourous sheets of inert cellulose plastic
containing capillary ploes of uniform size, small enough to prevent the passage of
microorganisms. During filteration of a sample, the microorganisms can not pass through
37
the membrane, and therefore remain on the surfaces. Through selection of pore size,
nutrient medium and incubation temperature, specific microorganism will grow to form
visible colonies that can be counted.
§ Requirement:-
i. Laminar air flow.
ii. Incubator (temperature 37°C ±1).
iii. Petridish.
iv. Pipettes
v. Molten Parle Media and nutrient agar at 45°C (pre sterilized at 15psi at
121°C for 15 min).
§ Procedure:- i. Wipe the sampling area with disinfectant. ii. Put sterile air blower ‘on’ for 10 minutes at low-pressure position.
iii. Close the shutter and keep UV lamp ‘on’ for 45 minutes.
iv. Keep sterile air blower ‘on’ at medium pressure position.
Swab Test:-
§ Requirement:-
i. Presterilized hot molten Parle Media.
ii. Nutrient agar and EMB Levine agar.
iii. Sterile ready swabs.
iv. Millipore unit.
v. Cellulose titrate membrane filter paper.
vi. Presterilized water.
vii. Incubator.
viii. Laminar flow unit.
38
§ Procedure:-
i. Transfer approximately 10ml hot molten media into petri dish under laminar
flow in three separate petri dishes.
ii. Allow media to solidify in petri dish.
iii. Take a bottle containing sterile distilled water to the required area of testing.
Sanitize bottle mouth with acetone or disinfectant.
iv. Remove the ready cotton swab and place it to the area and instantly dip the
swab into the sterile bottle containing sterile distilled water. Carry the same for
inoculation. Rub the swab on a 100 cm2 area of the equipment to be tested and
immediately transfer to the sterile bottle.
4.6 Microbiological analysis of products
Microbiological analysis of product and raw material It allows us to monitor level of microorganism and permits us to take corrective
actions before serious problem arise.
v OBJECTIVE: - Determination of TPC
To determine total colony count in water, on enrichment agar, method is applicable
to filter water of Sand Filter and Carbon Filter, DM Plant, Softener Plant, Frooti Plant,
Norit Carbon Filter I and II.
§ Requirement:-
i. Filtration flask.
ii. Vacuum pump.
iii. Petri dish 5 tarn.
iv. 0.45 µ filter paper.
v. Sterile filter assembly.
vi. Hot molten enrichment media.
39
§ Procedure:-
i. Collect 100 ml DM water in a sterile flask in aseptic condition.
ii. Now filter 10 ml of sample water through 0.45 micron filter paper and place the
filter paper over enrichment media.
§ Incubation: - Incubate the petri dish at 37°C for 24 hrs.
§ Evaluation: - Max. Limit 20 colonies / ml.
v OBJECTIVE: - Determination of Yeast and Mold for sugar samples.
§ Procedure:-
i. Prepare aseptically 20 % sugar solution with sterile distilled water.
ii. Deliver 1 ml of solution in triplicate into sterile petri dishes by means of sterile
1ml pipette.
§ Pour Plate:-
i. Melt the above medium in bacteriological tubes and keep at 44-46°C.
ii. Introduce medium aseptically into petri dishes.
iii. Mix with swirling motion of hands and allow to set.
§ Incubation: - Invert petri dishes and incubate at 37±1°C for 2 days, count the
colonies and compute the total colonies per gram.
§ Evaluation: - Max. limit 20 colonies / ml
40
v OBJECTIVE: - To determine TPC/ Yeast and Mold in sugar syrup.
§ Requirement: -
i. 100 ml sterile DW in a conical flask.
ii. Petri dish (100mm).
iii. Nutrient agar.
§ Procedure: -
i. Collect aseptically about 10 ml of sugar syrup in a sterile flask.
ii. Add 50 ml sterile DW in it.
iii. Pour 5 ml of the solution into each of the two sterile petri dishes.
iv. Melt nutrient agar and Parle media separately and cool them up to 44 - 46°C.
v. Introduce the media aseptically into the petri dishes respectively containing sugar
syrup.
vi. Mix by swirling motion of hands and allow to set.
Incubation: -
Incubation time Incubation temperature
i. TPC 24hrs 37°C
ii. Yeast and Mold 48hrs 37°C
Evaluation: -
Maximum limit : 5 colonies / plate for TPC.
Maximum limit : Nil (for Yeast).
1 colony / plate (for Mold).
v OBJECTIVE: - To determine TPC/Yeast and Mold in intermediate product
of mango pulp and apple concentrate
§ Requirement: -
i. 100 ml sterile DW in a conical flask.
ii. Petri dish (100mm).
iii. Hot molten nutrient agar media.
41
§ Procedure: -
A. For determination of TPC:
i. Collect aseptically about 10 ml of sugar syrup in a sterile flask.
ii. Add 50 ml sterile DW in it.
iii. Pour 5 ml of the solution into each of the two sterile petri dishes.
iv. Melt nutrient agar and Parle media separately and cool them up to 44- 46°C.
v. Introduce the media aseptically into the petri dishes respectively containing
sugar syrup.
vi. Mix by swirling motion of hands and allow to set.
B. For determination of Yeast and Mold:
i. Melt Parle media and keep at 44-46°C.
ii. Introduce the media aseptically into the ready prepared petri dish containing
sugar.
iii. Mix by swirling action of hand and allow to set.
§ Incubation: Invert the petri dish and incubate at 37°C for 48 hrs.
Microbiology of finished product
One sample per batch per machine should be analyzed every day for TPC and Yeast &
Mold. Finished product should be free from microorganism as per standards specified by
the parent company.
v OBJECTIVE: - To determine TPC/ Yeast and Mold in finished product.
§ Requirement: -
i. Petri dish (100mm).
ii. Hot molten nutrient agar.
iii. Sterile glass rod.
42
§ Procedure: -
For TPC:
i. Take 5ml sample to be analyzed in a petri dish in a perfect aseptic condition.
ii. Introduce 10 ml hot molten nutrient agar into petri dish.
iii. Mix by swirling motion of hand and allow to set.
Incubation: Invert the petri dish and incubate at 37°C for 24hrs.
Evaluation: Maximum limit 1 colony/ml.
A. For Yeast and Mold:
i. Take 2 ml sample to be analyzed in a petri dish in perfect aseptic condition.
ii. Introduce 10 ml of molten nutrient agar into the petri dish.
iii. Mix by swirling motion of hand and allow to set.
Incubation: Invert the petri dish and incubate at 37°C for 48hrs.
Evaluation: Maximum limit:
Yeast- Nil.
Mold- 1 colony/ plate.
4.7 Physical & chemical parameters of product:
APPY CLASSIC
Appearance : Yellowish brown.
Acidity : 0.36 – 0.37.
Brix : 14.8 – 15.2.
pH : 3.5 – 4.0.
Viscosity : 5 – 10.
Specific gravity : 1.065.
Microbial count : Nil.
43
APPY FIZZ
Acidity : 0.25 – 0.27.
Brix : 12.8 – 13.2.
Microbial count : Nil.
FROOTI HOT FILL
Acidity : 0.311 – 0.322.
Brix : 14.8 – 15.2.
pH : 3.3 – 3.5.
Viscosity : 45 – 55.
Specific gravity : 1.035.
44
Chapter-5
CONCLUSION
This report is based on whole procedure involves in production & quality controls in fruit
beverage production. During this study we have learnt all the processes (blending,
pasteurization, filtration, etc.) which are required in fruit beverage production. In addition
to this we have also observed different types of safety measures which are applied to
ensure the manufacturing of good quality product.
All the products of Parle Agro Pvt. Ltd. are manufactured under the most hygienic
conditions. Great care is exercised in the selection & quality control of raw materials,
packaging materials. Rigid quality standards are ensured at every stage of the
manufacturing process. Every batch of drink, are thoroughly checked by quality experts
using the most modern equipment.
45
BIBLIOGRAPHY
ü www. Parleproducts.com
ü Www.Parle agro.com.
ü www.google.com (for definition and products)