INSTANT COFFEE [FREEZE DRIED]

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Instant (or soluble) coffee has been widely used for decades because of its convenience. During the height of its popularity in the 1970s, nearly a third of the roasted coffee imported into the United States was converted into an instant product, resulting in annual sales of more than 200 million pounds. Today, about 15% of the coffee consumed in the United States is prepared by mixing instant granules with hot water, either at home, in offices, or in vending machines. Furthermore, development of good quality instant products has helped popularize coffee in cultures that historically drank tea.

Since its invention, researchers have sought to improve instant coffee in a variety of ways. For example, some of the early powdered versions did not dissolve easily in water, leaving clumps of damp powder floating in the cup. Coffee aroma dissipates easily, and manufacturers have tried to develop treatments that will make a jar of instant coffee smell like freshly ground coffee when it is opened. More modern manufacturing processes make instant coffee granules that look more like ground coffee. Finally, a major goal has been to produce an instant coffee that tastes as much as possible like the freshly brewed beverage.

The primary advantage of instant coffee is that it allows the customer to make coffee without any equipment other than a cup and stirrer, as quickly as he or she can heat water. Market researchers have also found that consumers like making coffee without having to discard any damp grounds. Some coffee drinkers have become so used to drinking instant coffee that at least one manufacturer found in taste tests that their target audience did not even know what fresh-brewed coffee tastes like.

Two of the 50 known species of coffee beans dominate the beverage coffee industry. Coffee arabica varieties, grown primarily in Latin America, India, and Indonesia, are relatively mild in flavor and, consequently, bring a higher price. They are also relatively expensive to harvest, since individual coffee cherries must be handpicked at their peak of ripeness. Coffee robusta varieties, grown mainly in Africa, India, and Indonesia, have a harsher flavor, but they are cheaper to grow since they can be harvested over a range of ripeness and are more resistant to diseases and insects. Because of their more attractive price, the robustas are widely used in the manufacture of instant coffees.

Roasting at temperatures above 300°F (180°C) drives the moisture out of coffee beans. Beans destined for use in instant products are roasted in the same way as beans destined for home brewing, although the moisture content may be left slightly higher (about 7-10%). The beans are then ground coarsely to minimize fine particles that could impede the flow of water through the industrial brewing system.

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Description

INTRODUCTION
RAW MATERIALS FOR COFFEE
GREEN COFFEE PROCESSING
COMPOSITION OF THE GREEN COFFEE
B.I.S. SPECIFICATIONS
COFFEE CONSUMPTION PATTERN AND TRENDS IN INDIA
MARKET OVERVIEW OF INSTANT COFFEE
INSTANT COFFEE MARKET GROWTH DRIVERS AND TRENDS:
GROWTH DRIVERS:
TRENDS:
INSTANT COFFEE MARKET PLAYERS PERSPECTIVE:
COFFEE SECTOR IN INDIA
THE COFFEE PRODUCTION STATES
BRANDED COFFEE MARKET IN INDIA
THE COFFEE TRADE: RETAIL MARKET CONSTRUCT
PRESENT MANUFACTURERS OF INSTANT TEA AND COFFEE PREMIX
DESCRIPTION OF INSTANT COFFEE PRODUCTION
[FREEZE DRYING METHOD]
GENERAL FLOW SHEET OF INSTANT COFFEE PRODUCTION
(A) EXTRACTION:
(B) CONCENTRATION:
FREEZE-DRYING
STAGES IN INSTANT COFFEE MANUFACTURE [FREEZE DRYING METHOD]
THE NINE STAGES OF MANUFACTURING INSTANT COFFEE
STAGE ONE: DELIVERY
STAGE TWO: ROASTING
STAGE THREE: GRINDING
STAGE FIVE: EVAPORATION
STAGE SIX: FREEZING
STAGE SEVEN: SUBLIMATION
STAGE EIGHT: LOST AROMAS READDED
STAGE NINE: PACKAGING
INSTANT COFFEE AND PROCESS
PROCESS FLOW DIAGRAM OF INSTANT COFFEE
PROCESSING DETAILS OF INSTANT COFFEE BY FREEZE DRYING METHOD
AROMA IS RECOVERED MAINLY BY TWO METHODS
FREEZE DRYING AND ITS PRINCIPLE
STAGES OF FREEZE DRYING
PRETREATMENT
FREEZING AND ANNEALING
STRUCTURALLY SENSITIVE GOODS
PRIMARY DRYING
SECONDARY DRYING
FREEZE DRYING PRINCIPLES
FREEZE DRYING PRINCIPLES
SUBLIMATION CONSIDERATION
FREEZE DRYING PROCESS
CLEANING-IN-PLACE
REFRIGERATION
PROCESS CONTROL
POLLUTION CONTROL IN COFFEE PROCESSING INDUSTRY
CHARACTERIZATION OF WASTEWATER FROM COFFEE PROCESSING
INDUSTRY:
TABLE: EFFLUENT STANDARDS-SUGGESTED RANGE FOR POLLUTANTS
DISCHARGE INTO INLAND SURFACE WATERS
SOURCES OF WASTEWATER:
FIG: WATER BALANCE DIAGRAM
ENVIRONMENTAL PROBLEMS OF WASTEWATER FROM COFFEE
PROCESSING INDUSTRY:
COFFEE IS PROCESSED IN TWO WAYS:
TREATMENT OF WASTEWATER FROM COFFEE PROCESSING INDUSTRY:
WATER RECYCLING:
FIG: FLOW CHART ILLUSTRATING WATER RECYCLING PROCESS
FIG: WATER RECYCLING MECHANISUM
CONVENTIONAL TREATMENT METHODS:
IT HAS 3 TANKS:
FIG: SCHEMATIC FLOW SHEET OF WASTE WATER TREATMENT UNITS
EQUALIZATION TANK:
ANAEROBIC TANK:
AEROBIC TANK:
AIR POLLUTION AND ITS CONTROL IN COFFEE PROCESSING
A. ROASTING
B. QUENCHING
C. COOLING
D. DESTINING
E. GREEN BEAN HANDLING
F. GRINDING
G. DECAFFEINATION
H. CONTROL EQUIPMENT
RECENT TRENDS IN EFFLUENT TREATMENT FOR COFFEE PROCESSING
COFFEE PROCESSING EFFLUENT FOR PRODUCTION OF BIOGAS:
FIG: ANAEROBIC TREATMENT SYSTEM
COFFEE PROCESSING WASTE MANAGEMENT PRACTICE
TABLE. AFRICA: COFFEE PRODUCTION (AVERAGE IN THOUSAND
BAGS OF 60 KG EACH)
COFFEE INDUSTRY RESIDUES APPLICATIONS
PROCESSING OF COFFEE
WET METHOD
DRY METHOD
FIG. SUN DRYING OF COFFEE FOR DRY PROCESS
PROBLEMS OF COFFEE WASTE
TABLE. HEALTH PROBLEMS REPORTED BY THE POPULATION
LIVING NEARBY INDUSTRIES
MANAGEMENT OF COFFEE WASTE
TABLE. CHARACTERISTICS OF EFFLUENT WASTEWATER FROM CONVENTIONAL WET COFFEE PROCESSING PLANTS
ENVIRONMENTAL ISSUES
TABLE. COMPOSITION OF COFFEE WASTE
CONCLUSION
SUPPLIERS OF PLANT AND MACHINERY
SUPPLIERS OF CONDENSER
SUPPLIERS OF SPRAY DRYERS
SUPPLIERS OF CENTRIFUGE
SUPPLIERS OF INSTRUMENTATION AND PROCESS CONTROL EQUIPMENTS
SUPPLIERS OF PACKAGING MACHINE
SUPPLIERS OF LABORATORY EQUIPMENTS
SUPPLIERS OF GRINDER
SUPPLIERS OF BOILERS
SUPPLIERS OF STAINLESS STEEL TANKS
SUPPLIERS OF WEIGHING SCALE
SUPPLIERS OF PLANT AND MACHINERY (GLOBAL)
SUPPLIERS OF RAW MATERIALS
SUPPLIERS OF MILK POWDER
RAW MATERIALS CALCULATION

APPENDIX – A:

01. PLANT ECONOMICS
02. LAND & BUILDING
03. PLANT AND MACHINERY
04. OTHER FIXED ASSESTS
05. FIXED CAPITAL
06. RAW MATERIAL
07. SALARY AND WAGES
08. UTILITIES AND OVERHEADS
09. TOTAL WORKING CAPITAL
10. TOTAL CAPITAL INVESTMENT
11. COST OF PRODUCTION
12. TURN OVER/ANNUM
13. BREAK EVEN POINT
14. RESOURCES FOR FINANCE
15. INSTALMENT PAYABLE IN 5 YEARS
16. DEPRECIATION CHART FOR 5 YEARS
17. PROFIT ANALYSIS FOR 5 YEARS
18. PROJECTED BALANCE SHEET FOR (5 YEARS)

Additional information

Plant capacity

30 MT./Day

Land and Building

(20,000 sq.mt.)

Plant & Machinery

US$ 46714285

Rate of Return

59%

Break Even Point

35%