In this article we will discuss about how to process ripe mangoes.
Fully ripe mangoes are washed, peeled and cut into slice. The slices are then homogenized into pulp, which is filtered through a sieve to remove the fiber. The pulp is heated to 76 -780 centigrade and to 2 gram citric acid and 2 gram potassium meta-bisulphate are added per kg of pulp. It is filled in sterilized glass/ jars and lids are sealed with wax. For mango jelly, mango is cut into 6 to 8 slices, the bulky juice is sent to sieve, seeds are separated and thick mango juice collected in wooden pot.
Sugar or jiggery is mixed in 1.4 proportions. The preparation is subjected to natural drying process on bamboo-thatched beds. About 7 to 9 layers of juice is applied for natural drying every day and process goes for 25 days.
Mango juice may be prepared by mixing 1/ 3rd of fresh or stored pulp with 2/5th of water. Sugar and citric acid are added so that total soluble solid (TSS) and acidity of the product reach 15 and 03 per cent respectively. The mixture is heated to 95 0 C filled hot in clean sterilized bottle. The bottles are sterilized for 10-15 minutes, cooled to room temperature and stored. Squash is prepared by mixing 1 kg of pulp with sugar syrup (1 kg sugar in 750 ml water). The whole mixture is heated to 76-78 °C and 25-30 gram citric acid added to it. The prepared squash is filled in sterilized bottle and stored.
The homogenized mango pulp is taken and potassium meta-bio-sulphate is added to it @ 2 gram/kg of pulp. The pulp is then spread on trays smeared with butter and sundry. The process is repeated so as to obtain a thickness of 0.60 to 1.25 cm. Finally the dried product is cut into piece and wrapped in butter paper or polythene cellophane sheet.
The different processing activities in the mango product chain are presented in following chart:
Waste Utilization:
During the processing of mango, peel and stones are generated as waste, which is about 40-50 per cent of fruit weight. They are rich in various nutrients and many value added products could be obtained from them. Good quality jelly grade pectin and edible fiber could be extracted from ripe mango peel Mango peel has lignocellulose composition and hence its complete breakdown is difficult. Its composition depends on cow dung in 3: 1 ratio, which results in its successful biodegradation.
Mango kernel contains high amount of fat and starch. The oil extracted from kernel is of good quality and could be used in cosmetic and shop industries. About 10 per cent alcohol could be obtained from mango kernel by co-culture fermentation.
Mango Processing in Sample District:
Major value products prepared out of mango are pulp, pickles and jelly. These have been taken up as village and house hold enterprises in Krishna, East Godavari and Vishakhapatnam districts. Sunsip, Allana, Vinsari, Fruitech, Jain Irrigation, Galla Foods, Capricorn Food Products are major processors of mango fruit pulp are concentrated in Chittor district.
Manufacturing Process of Mango Pulp:
A flow chart of process involved in preparation of mango pulp is presented in Chart 9.2.
Once mango season starts, matured mangoes are brought from the market and are ripened in the ripening shed. Usually, fruits ripened about 7-8 days under tropical conditions. The usual practice is to place the fruits in single layers on paddy straw in closed but well ventilated rooms. The fruits ripe uniformly in a temperature ranges from 19.4° to 21.1° C. The ripen fruits are than washed with water in Tubs to remove the adhering impurities and dirt.
The prepared mangoes are passed through pulpier fitted with 30 mesh sieve to obtain the pulp. The pH of the pulp is adjusted to 3.8-4 by adding citric acid. It may also be sweeten so that a brix value of 16-18° is attained, as per the requirement. Ascorbic acid if added to the pulp is helpful for retention of colour, flavor and carotene. The pulp is then heated to 85°C and sterilized cans are filled with pulp.
Thereafter, the cans are sealed, processed at 100° C for 45 minutes and cooled. Then the cans are moved to store room where the cans are labeled and packed in card board cartoons until they are lifted by the export houses/agents.
Invest Cost of Pulp Making:
The indicative cost for establishing mango pulping unit with an installed capacity of 600 tons of pulp per annum is about Rs. 35 lakh, while for an aseptic unit the cost is estimated at Rs. 2000 lakh as shown in the table 9.1.
Costs and Returns of Processing Mango into Canned Pulp:
The length of operation of mango processing units depends on the varieties of mango processed and source of procurement. For example, if the unit processes only the Totapuri mango produced in Chittor district, the fruits are available from the first week of June to the end of July (50-60days of operation). If the fruits of Totapuri are produced from Krishna District the length of processing could go up by another 15 days (from 15 May).
Similarly, those units, depending on the orders received from the export houses, when processed Alphonso Mango, the fruits are available from April end onwards from Karnataka. Thus, the operation of these units is seasonal. With a view to increasing the operational days, the profit ratios, some of the units have been exploring the possibilities of processing other fruits and vegetables, such as papaya, tomato, guava, etc.
The average annual operational cost of a 600MT capacity pulp making unit was estimated to be about Rs. 105.7 lakh (Table 9.2). The cost of production per ton and per kg of pulp worked out to Rs. 12,858.50 and Rs. 12.85. The canned units reported gross income of Rs. 122.12 lakh and net income of Rs. 16.42 lakh .The profit margin was arrived at 13.45 per cent in case of canned pulp making units.
Packaging is an important component in canning. However, as all canned pulp units mostly do job work and after receiving orders from various houses, they need not incur any cost on packing. The export houses are supplying all materials for canning and packaging. Tin cans are made of thin steel plate of low carbon content lightly quoted with tin metal.
The cans are lacquered inside with acid resistance gold colored enamel to seal microscopic spaces on the surface of ordinary tin can. Depending upon the requirement of the export houses, the cans are manufactured in situ in the processing units. Three sizes of cans namely 5.25 kg, 3.1 kg and 0.85 kg are extensively used by canning units for consignment.
Various Profitability Ratios of Canned Pulp:
Various profitability ratios have been computed and presented in Table 9.3. These ratios measure the efficiency of canning units’ activities, thus, identifying operating problems and strengths. The ratio of net profit to sales measures the earning capacity of caned firms. The ratio of expenses to sales indicates the extent of expenses that occurred in relation to sale and denotes the control of the management over the expenses. The ratio is indicative of the operational efficiency of canning firms.
The high value of this ratio suggests that limited control is exercised over the expenses casting aspersions on the operational efficiency. The ratio of net profit to capital employed is a measure of return on investment and is a useful way of looking at the overall performance of the business. It indicates that performance can be improved either by generating more sales volume per rupee of capital employed or by increasing the profit margin of each rupee.
However, the ratio (0.47) was not that encouraging for canning units. The capital intensity and limited scope of triggering demand for mango pulp posed as hurdle to improve the ratio. Further, the narrow margin (13.45%) in canned units (% of manufacturing cost to gross value to production) is an area of concern suggesting appropriate management of various cost centers for greater profitability.
Profitability Ratio of Canned Pulp Making Unit:
Ratio of Expenses to Sales, Ratio of Net Profit to Sales, Ratio of Net profit to Capital Employed, Capital Output Ratio, Capital Employed Ratio and Manufacturing Cost as % to
Gross Value of Production have been worked out in the table below:
Manufacturing Process of Mango Jelly Cluster:
Mango jelly is an age old industry in East Godavari district. It is mostly a seasonal industry functioning from May to July in a year.
Manufacturing of Mango Jelly:
Jelly is a semi solid product prepared by boiling a clear strained solution of pectin containing fruit extract free from pulp after the addition of sugar and acid. Pectin is the most important constituent of jelly. Usually, 0.5-1.0 per cent of pectin of good quality in the extract is sufficient to produce jelly. Pectin, sugar, acid, and water must be present approximately in the required proportion (i.e. pectin 1, sugar 65-70%, citric acid 1% and water 33.38%). The ripe mango fruits are cut into 6-8 slices by manual peeling.
The bulky juice is sent to sieving. The sugar is sprinkled in to fruit extract while it is boiling to ensure complete dissolution. Well prepared mango pulp is spread on clean bamboo mats to form a sheet of 2 mm thickness. The size of the mat generally used is 1.35 m x 1.35 m. On its drying another layer is spread over this and allowed to dry. About 7-9 layers of pulp are applied for natural drying. The dried slab is cut into required sizes and packed for marketing.
Economics of Jelly Making:
Generally, from one metric ton of ripe mango fruit, 350- 400 kg of pulp used in jelly making is produced.
The economics of sample jelly manufacturing units is presented below:
Average cost of production per unit and per kg of jelly was worked to Rs. 2.45 lakh and Rs. 28.54 lakh respectively. Net income has been arrived at Rs. 54,500 per unit and Rs. 6.36 per kg. Cost of production constitutes 81.83 per cent of gross income.
Various profitability ratios are computed and presented in the table below:
The ratio of net profit to capital employed (0.64) was encouraging for jelly units that demonstrate efficiency in the use of capital with higher rate of return. However, profit margin (18.16%) in jelly making units needs to be further improved through appropriate management of various costs.