Spice production & food manufacturing app
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Spice production – spice manufacturing
01. Collection & Sorting
Samagi Spice Exports (Pvt) Ltd owns and operates ten collection centres for Pure Ceylon Cinnamon. Fresh cinnamon barks are collected daily in these seven centres and transported to the processing facilities. The unloaded cinnamon barks are firstly taken through the initial sorting process, to separate the wet barks from the already dry barks. Cinnamon can only be processed if 100% dry and therefore ensuring each bark is fit for packing is the first essential step of the manufacturing process.
02. Peeling & Rolling
The dry barks peeled to remove knots and then scraped to a smooth texture by experts, taking care to preserve the original quality. Cinnamon quills are manufactured by rolling the barks into a cigar-shaped quill. This is a manual process that has been mastered through centuries and is nothing short of amazing. It requires an immaculate technique and handicraft skills.
The assorted quills are then taken directly to one of the seven Sulphur Rooms. The Sulphur Rooms are where the dry cinnamon quills are processed using Sulphur Dioxide (SO2); an agent that helps in the fumigation process of cinnamon. SO2 use in the cinnamon industry is a centuries-old practice and is still widely in use in the manufacturing processes. The SO2 fumigation process locks in the hygienic quality of the cinnamon. It is an agent that prevents excessive browning of the quill and helps to maintain the significant pale, golden-brown hue of Pure Ceylon Cinnamon. SO2 also acts as a preservative during the fumigation process.
The European Union has accepted the use of Sulphur Dioxide which was approved in 2011 after the requests made to the World Trade Organisation in Geneva. It has approved maximum level of use of 150 mg/kg for sulphites (including Sulphur Dioxide) in Food Category 12.2.1 “Herbs and Spices.”
04. Moisture Checking & Storing
While the dry barks go straight to the Sulphur Rooms, the wet bark remains to be dried. With the adoption of new technology a crucial tool used in this process is the Moisture Meters which can detect the level of moisture in the quills. Depending on the levels of moisture retained in the barks, the storing and drying time will range from 2-6 days.
The bark fumigating in the Sulphur rooms are sorted daily by experts of the cinnamon grading profession. Each quill is inspected and then sorted into different grades, The H2 grade (comprises of the sorted thicker barks rolled into quills and has a good demand due to its quality) and C4 grade (this grade has a higher demand because it has a smooth texture, exquisite aroma and it is the best quality, pale golden brown tinge with a sweet taste). All the quills are graded according to the requirements of different local and international buyers.
The packaging process of the cinnamon quills is divided into two separate sections; the baking section and the cutting section. In the cutting section is where the cinnamon quills are cut into different lengths ready for packaging. The majority of these are smaller quantity packaging both for local and international buyers. Six cutting machines cut the cinnamon quills into different lengths; 21 inches, 5 inches, 3 inches and 18 cm, 13 cm, 8 cm and 5 cm. These are then sent for cellophane wrapping in different quantities again as specifically requested by the buyers. The 21 inch is export quality and packed in export boxes.
07. Adding A Final Touch
The baling section of the manufacturing process sorts the long quills into different grades and bundles or rolls then into bales. Bringing these bales to exporting standards takes more effort than this. The packaging consists of three steps; first wrapped in polythene, then in jute gunny bags. They are finally sewn with caps on either side of the bale.
Spice production & manufacturing process
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The Manufacturing process at Land Spices integrates production and packaging equipment lines with exacting food engineering and safety standards. Land Spices has achieved operational efficiency with customized spice production equipment. Our engineers employ innovative methods to further clean and process spices as required by our wide array of discerning clientele. The equipments in our Factory are used to:
- Remove Dust & Stone
- Remove Metal and Iron filings “Metal Detector “
The above manufacturing process ensures that the product is not only clean & sterile but within the specified physical and chemical parameters.
Land Spices Co works hard to earn the trust of local and global communities by acting in a socially responsible manner. We want to create a more sustainable world, and take steps to ensure safety and reliability of our products while carefully considering the impact of our business activities on the environment. In addition, we follow strict compliance and corporate government policies. Together, these efforts serve to enhance the overall value of our company.
Food safety and security:
We have developed and upgraded quality- and sanitation-control to ensure product safety; we enforce strict quality and safety controls at every stage ofthe supply chain, from raw materials procurement and product development to production and distribution. In addition, our cross-organizational Quality Assurance Committee maintains comprehensive oversight of safety assurance.
Land Spices Co pays much attention to all factors could support quality assurance achieving by using plans of Food Safety Management supported with professional allocation of machinery processing and high caliber labor. It’s applied for whole chain of production process starting with, farming, drying, sorting, processing, sampling, storing, analysis, packaging, handling and shipping. Working in clean environmental farms providing naturally built shield from pesticides residuals.
Placing our production facility in the middle of the main farm helps in linking all the production procedures smoothly from reception, all the ways through natural drying in shadow, storing, processing in isolated chambers and packing.
We are interested in conformance to specifications so the absence of defects is the major focus of our department of packing through well managed process including all technical quality control gaudiness and restricted measures have been taken according to current EU standards in food business with consideration of Hygiene rules of EU – Regulations (EC No 8522(P41).
Our strict quality control is self evident in the Pharmacopoeia results, as tests for contamination, Starting with testing of required physical analysis, we regularly apply all chemical analysis such as (pesticides, microbiology, aflatoxin,….etc.) as per current EU regulation for pesticides in case of conventional products and BNN Guidance in case organic products within EU accredited national & international labs, such as: Central Laboratory of Residue analysis of Pesticides and Heavy Metals in Food – Egypt
Our Quality Assurance process is the most important process that complements each stage of our total supply-chain. We test our products multiple times, at every point of the supply chain to ensure the highest quality and product consistency. The Land Spices Quality Assurance program consists of a fully-integrated QC lab which is complete with testing capabilities on physical, chemical, micro/ macro-sanitary & microbiology parameters as well as Plant Sanitation and Inspection standards.
The program integrates the knowledge of our agronomists, chemists, micro-biologists, food engineers and various quality control personnel. The program involves:
- Raw Material Quality Control
- In-process Quality Control
- Shipment Lot Quality Control
- Pest Control Program
- Plant Sanitation Program: Environmental Swab-testing
Spices in Pouch Packing
Manufacturing of masalas basically can be in tiny scale and at the most may be in small scale. Spices and spice derivatives are predominantly used in the processing of meat. Vegetable products, bakery and other prepared food items. On account of the valuable spices in food and other industries the world demand for spice and spices derivative are increasing steadily. The spices exported from India include pepper, cardamom, chilies, ginger, turmeric, curry powder etc. and are mostly exported to East European countries. Read more
Spice (Chili) Oleoresin
India is world’s largest producer and consumer of spices and chili. A huge amount of spices is also exported all over the world. Oleoresins of spices consist of essential oils that impart aroma and resins that impart taste. Supercritical technology is state of the art technology which can be applied to extract oleoresins from spices & chilies. The taste efficiency of oleoresin is more than 100%. Read more
Whole Spices Processing (Cleaning / Grinding & Packaging)
Spices constitute an important group of agricultural commodities which are virtually indispensable in the culinary art. Spices are natural products widely accepted by consumers. Spices are most important constituents of Indian food and cuisines, and are used not only for house hold purpose, but also in hotels, restaurants, eateries and food processing industries. Separate the spices from any larger contaminants, such as stones, dust, leaves or sticks. Then wash it with clean water until the water ceases to have any trace of dust or dirt in it. Read more
Spices and Masala Grinding, Blending and Packing
Spices are non-leafy parts (e.g. bud, fruit, seed, bark, rhizome, and bulb) of plants used as a flavoring or seasoning, although many can also be used as an herbal medicine. They impart aroma, color and taste to food preparations. The volatile oils from spices give the aroma and the oleoresins impart the taste. India is the largest producer, consumer and exporter of spices and spice products in the world and produces more than 50 spices. India is also a big exporter of Chili, turmeric, cumin, pepper and many other spices. Read more
Spices (Turmeric Powder, Red Chilli Powder, Dhaniya Powder, Garam Masala, Sabji Masala, Popcorn Masala)
Spices impart aroma, color and taste to food preparations. The volatile oils from spices give the aroma and the oleoresins impart the taste. Spices are non-leafy parts (e.g. bud, fruit, seed, bark, rhizome, and bulb) of plants used as a flavoring or seasoning, although many can also be used as an herbal medicine. A closely related term, ‘herb’, is used to distinguish plant parts finding the same uses but derived from leafy or soft flowering parts. Read more
Spices (Turmeric, Red Chilli, Dhaniya and Jeera Powder)
Spices are non-leafy parts (e.g. bud, fruit, seed, bark, rhizome, and bulb) of plants used as a flavoring or seasoning, although many can also be used as an herbal medicine. A closely related term, ‘herb’, is used to distinguish plant parts finding the same uses but derived from leafy or soft flowering parts. Spices are essential ingredients in any good cook’s kitchen. They are also used in the manufacture of incense, oils, cosmetics, preservatives and flavorings. Read more
Extraction of Essential Oil and Packing of Ground Spices
Spices are Nature’s own production. In the art of cooking these are the magic constituents without which all culinary creations would be dull and lifeless. The essential oils are used in manufacture of flavours, perfumes etc. It is also used in pharmaceutical, medicines, cosmetics and food processing industries. Essential oils and spices both are the high demandable products. There are good domestic and export market for both. So new entrepreneurs can enter into manufacturing of spices and essential oils. Read more
Extraction of Methi (Fenugreek) Seed
Methi Seeds are source of vitamins, minerals, proteins, fats, alkaloids etc. This robust herb (fig) has light green leaves, is 30 to 60 cm tall and produces slender beaked or sickle-shaped pods, 10 to 15cm long. Each pods contains 10 to 20 small hard yellowish-brown seeds, which are smooth and oblong, about 3mm long, each grooved across one corner giving them a hooked appearance. Seed is the dried ripe fruit of an annual herb. It has a pleasantly bitter taste and a peculiar dour and flavor of its own very much-used in curry powder, pickles and other spices blends. Read more
Curcumin is the main biologically active phytochemical compound of Turmeric. Molecular chemical formula of Curcumin: C21H20O6. The most important constituents in organic turmeric are Curcuminoids, which is approximately 6%, and the yellow coloring principles of which Curcumin constitutes 50-60%.Curcumin is extracted from the dried root of the rhizome Curcuma Longa. The process of extraction requires the raw material to be ground into powder, and washed with a suitable solvent that selectively extracts coloring matter. Curcumin has antioxidant, anti-inflammatory, antiviral and antifungal actions. Studies have shown that curcumin is not toxic to humans. Read more
Spices are non-leafy parts (e.g. bud, fruit, seed, bark, rhizome, and bulb) of plants used as a flavoring or seasoning, although many can also be used as a herbal medicine. A closely related term, ‘herb’, is used to distinguish plant parts finding the same uses but derived from leafy or soft flowering parts. The two terms may be used for the same plants in which the fresh leaves are used as herbs, while other dried parts are used as spices, e.g. coriander, dill. Spices are no longer regarded as wonders of medicine, but they still play an important part in the manufacture of many cosmetics and perfumes and are grown commercially for their coloring and preservative properties. Read more
Red Chilli Powder
Chilli is cultivated mostly as a rain-fed crop, but in areas of low rainfall it is grown under irrigation. In the genetic area, it is a cold weather crop. The crop is raised on a variety of soil. For cultivation as a rain fed crop, well drained heavy soils which retain moisture should be selected. Chilli powder is a well-known name among the Indian people. All the people in the world use this, irrespective of their region. Indians are using the curry powder, contains more chilli. Consumption of chilli powder is increasing, so the quantity required is increasing day by day. Read more
The ginger whole shall be the rhifume of Zingiber officinale rose in pieces irregular in stapes and size not less than 20mm. in length or in small cut pieces, pale brower in colour and fibrous with peel not entirely removed washed and dried in the sun. The material may be garbled by removing pieces that are too lighter and it may also be lime bleached. The dried rhizomes may also be ground into powder. It can be used as pharmaceuticals for the production of herbal medicines in the treatment of cold fever. Read more
Extraction of Salt from Sea Water
Salt is an essential ingredient for the survival of all living creatures, including humans. Salt is needed in regulating the fluid balance or water content of body. Salt cravings may occur as a result of trace mineral deficiencies or due to the deficiency of sodium chloride itself. Salt is important for life, but its overconsumption can cause health problems, such as high blood pressure, in those individuals who are genetically predisposed to hypertension. Main source of salt is rocks and sea. Maximum consumption of salt is in its natural form after being produced from sea or directly from rock. Read more
Curry powder is a well-known name among the Indian people. Curry powder is the combination of finely powdered spices. For each dish there is different curry powders but the ingredients are more or less the same. Now a day’s most of the housewives are using this ready-made curry powder instead of using them individually. Consumption of curry powder and so the quantity required is increasing day by day. So this is an industry by which a new entrepreneur can start without second thought. But the manufacturers should give attention for capturing the market. Read more
The dehydration or drying of garlic is used for its preservation. Garlic powder is used in ayurvedic medicines for ailments for flavouring purposes. The exports of garlic powder are also picking up fast. There is ready market for the products. Read more
Chili sauce is a liquid or concentrated product which can be poured from a container. It may be either homogeneous or a mixture. It is intended for use as a seasoning or condiment. The product should be prepared from good quality, clean ingredients which are mixed, processed appropriately to obtain the desired quality, and subjected to an appropriate process by heat before or after packing in a hermetically sealed container, so as to prevent spoilage. Increasing young population coupled with increasing globalization has led to an advent of diversity in food choices of young people, who are significantly proffering spices, thus fueling revenues in the global hot sauce market. Read more
SPICE HISTORY AND STATISTICS
From various ages, spices have always been a crucial component of India’s external trade with foreign countries unlike Arabia, Sumeria, Mesopotamia, China, Egypt and, along with textiles and perfumes.
The giant history of spices includes in its place in each holy book. The Ramayana also in the writings dating back to the Roman Empire in the first century AD. The caravans of camels moved regularly from Calicut, Goa and the Orient. They even transport these spices to distant destinations such as Carthage, Alexandria, and Rome. source
Today, Indian spices are available everywhere, but there was a time when people have to risk their existence to gain access to Indian spices. From the Indian point of view, it brought in traders and invaders alike – a century after century.
In the fiscal year 2019, the export value of spices from India amounted to over 231 billion rupees. Top 10 importers of spices in India between Apr-Oct 2018 were the US, Vietnam, China, Hong Kong, Thailand, UK, UAE, Malaysia, Bangladesh and Sri Lanka. The top 10 exported spices and spice products in terms of value were Mint products, Chilli, Spice Oils & Oleoresins, Turmeric, Cumin, Pepper, Curry powders/paste, Cardamom seeds, other spices (Tamarind, Asafoetida, and Cassia) and Garlic. The total export of various spices in 2017-18 stood at US$ 3.11 billion.
Consumption of spices in an Indian household is massive; hence the market is growing with the 40000 crores annually. When one can see so much potential in spice business which ensures good returns with low investment, then any individual can start a business even home-based spice making business is turn out profitable.
Indian spices exports have been able to record strident gains in value as well as volume wise. During 2018-19, a total of 11,00,250 tons of spices and spice products valued Rs.19505.81 crore (US$2805.50 Million) have been exported from the Country as against 10,28,060 tons valued Rs.17980. in 2017-18, registering an increase of 7% in volume and 8% in rupee terms and 6% in dollar terms of value. Source
HOW TO START SPICE BUSINESS IN INDIA
Check Successful Case Study of Spices Packaging Design
1.COSTING INVOLVED IN STARTING UP A SPICE BUSINESS?
The Indian spices market is projected to reach approximately USD 18 billion by 2020, with growth in the sector expects to be led by branded spices and spice mixes. India being the largest spice producing country producing 50 different types of spices people are looking for ready-made food, and spice powder makes their cooking more accessible. Hence the usage of the spice powder is increasing consistently and futuristic.
Powdered spices are convenient to use, and it saves time and physical efforts for preparing different delicious cuisine. Every commercial food industry like hotels, restaurants, catering business and many more are using powder spices on a daily basis.
Spice powder makes it an easy and profitable business to start, and one can start this business with small-scale investment.
Basic Investment : 50000 INR to 100000 INR
Area Required: 250 Sq yard
ProfitPercentage : 50% to 70%
Earning: Average Sale 100Kg /Day, 50000 to 150000 Per Month
Other additional expenses will include equipment maintenance, employee salaries and marketing costs.
As spice powder is part of the food category hence, it has to satisfy a lot of regulations from state government such as follows,
1.Registration of firmshould be done depending upon the scale of business if its Pvt. Ltd. or partnership or single person company, the firm is registered accordingly.
GST registration is also essential to gain GST number, which is a must.
If it is SME, then companies can register themselves and get facilities and subsidies from the state government.
2. Obtain trade license, FSSAI and apply for Trademark, BIS certification and IEC. It is advisable to obtain AGMARK certification.
No massive space is required when it comes to starting a business with spices, around 250 sq yard can be used for processing of pieces and other 250 sqyard is needed for the packaging of the spices. Check commercial space where basic amenities are available such as water, electricity, etc.
The state government have restriction to start the food business from home hence ensure that the location is obeying the law of the government decided.
Make sure the location is transportation friendly and easily accessible to the target market.
4.RAW MATERIALS REQUIRED
The essential ingredients required in spice powder are ungrounded spices, and along with raw materials, you will need packaging materials which will act as protection of spice powder.
Grinding machine is necessary machinery required in spice business depending upon the scale of industries the equipment is used. Large scale industries use Impact Pulverizer machine while small scale industries use Double stage Pulverizer.
Other machinery such as spice grinder, weighing scale, packaging machine, compressor, roster are also required.
6.SPICE MANUFACTURING PROCESS
It is a very initial process for spice making in which the ungrounded spices are clean manually by removing impurities like stone, dust, and dirt.
After cleaning and washing process display them in sunlight so that they dry, the quality of the spice powder will depend on the well-dried spice. If proper cleaning and washing do not take place, it will lead to the growth of bacteria, which will poison food.
Once spices are dried, they are going through the roasting process, the roasting of the spices is essential because it will help to give the aroma, colour and good taste to spice powder.
Grinding machine is used for pulverizing to convert the spices into powder form.
The grading is a process which is the basis of the inclusion and proportion of spices mix with their raw material used, also depends on the type of spices (flavour), size, shape, density, and colour.
Make sure that spice powder has a uniform mesh size
7.PACKAGING OF SPICE
Seasoning and spices add massive flavour to your favourite dishes, but to work their magic, they must be fresh; hence correct packaging is mandatory.
Protect and preserve your spices and seasonings with stand up pouches with zip locks and such packaging bags will give you the flexibility to choose the best size, style, and features for your spices. Choose from options like gas release valves, tear notches, heavy-duty zipper tops, hang holes, pour spouts, and, as well as different styles that give you plenty of room to bring your brand to life.
Once spice is converted into powder form, then the spice powder weighted as per quantity that needs to pack. The spices are then wrapped in a polythene bag and sealed with the help of the sealing machine.
Stand up; pouches will protect your spices from issues such as moisture, puncture, odour, and more. You are hence guaranteeing that your seasonings and spices make it safely from the warehouse to your customers’ taste buds.
Also Read : Indian Masala Packaging Design
CHALLENGES FACED BY SPICE MANUFACTURING COMPANIES IN INDIA:
1.WORKING LABOUR ISSUE
The pungent odor of spices which gives sharp sensation is not suitable for health if exposed for a more extended period. Hence there is always a significant issue of discovering working labour in the Indian spice industry.
The credit market risk with distributers or mediators in the spice industry is always at high, and hence this leads as a significant challenge.
There are many small scale industries in India where still hand-made packaging is done due to budget constraint, which results in packaging leakage. If they plan to opt hi-tech types of machinery, then costing is increased; hence this has always been the point of concern.
4.EXPANSION IS DIFFICULT BECAUSE OF HI-TECH MACHINERIES
Each day innovation is introduced, to keep updated and in trend, companies have to adapt to each change. For SME’s, it is challenging to expand themselves due to the introduction of new technology and this act as a challenge for brands.
5.A LOT OF COMPETITION
The spice industry faces intense competition since the concentration of suppliers is more Its competition is often at the regional level. There are also many small local companies often operating in a specific location, and as the demand for authentic organic spices increased the demand for maintaining the quality of the product raised.
Branding helps to develop a memorable impression on consumers and allow customers to know what to expect from your brand. It is a way of distinguishing yourself from the competitors and clarifying what it is you offer that makes you the better choice.
DesignerPeople have listed below elements of branding:
In spice industry brand identity is the way audience recognize the brand which can be through brand logo, punch-lines, stationary identities such as business cards, envelop, letterheads and other associated visuals.
Everest punchline- Taste Mein Best Mummy aur Everest
The process of creating the idea of brand in the minds of customers as it also dictates what they expect from the brand. We all know its universal that saffron is premium spice hence it cannot be presented with budget environement.
Spice brands carry their own brand story along with value added elements such as home-made, no preservatives, on basis of taste or flavours and many more. It is very important to create competitive advantage and occupy the space in the minds of customers and branding does this effectively.
Brand personality is just like the personality of human beings. It is certain emotional or personal qualities that we associate with a particular brand.
It takes 7 second for customers to make purchasing decision and hence spice packaging design plays very crucial role in deciding. The colour, font style, text placement, content, tagline, and illustrations all together reflect the brand story. Packaging design agency are experts who ensure your packaging design acts as marketing tool.
Posters, brochures, websites, banners every collection of media used to support the sales of service or product is considered in marketing collaterals.
The digital media platforms such as Facebook, Twitter, Instagram and LinkedIn are in trends for spice campaigning . In spice industry, the brand has become a pioneer in involving digital media and leveraging various activities, events and various festivals which are ongoing in our country to gain traction and keep users engaged with brand across all platforms.
One of the campaigns run by the brand, #BadshahKeSaath, has seen an impression of over 10 million individuals and has an engagement of over 1 million people. Hence this simply means that the right kind of investments at the right place can result in a fair growth for the brand.
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