PROJECT REPORT

Name : Rajat Gulati

Roll No. : 10038

Subject : Business Exposure Visit

Date : 24th February 2012

Name of the Industry : Mapro Food Private Ltd.

Apart from the efforts of me, the success of any project depends largely on the

encouragement and guidelines of many others. I take this opportunity to express my gratitude

to the people who have been instrumental in the successful completion of this project. The

guidance and support received from all the members who contributed and who are

contributing to this project, was vital for the success of the project. I am grateful for their

constant support and help.

My first word of gratitude is due to Mr. Tapan Joshi , the Executive of the Mapro Food Pvt.

Ltd in the Quality Control Department, my corporate guide, for his kind help and support and

for his valuable guidance throughout the project. I am thankful to him for providing I with

necessary insights and helping me out by providing necessary information required.

I express my sincere gratitude to my project guide Ms. Vaidehi Suryavanshi for her valuable

guidance & support given to me endlessly from time to time. Without her encouragement and

guidance this project would not have materialized.

Finally, I would also like to thank all my dear friends for their kind cooperation, advice and

encouragement during the long and arduous task of preparing this report and carrying out the

project.

Rajat gulati

INTRODUCTION

Mapro Foods Pvt. Ltd is the manufacturers and resellers of the natural fruit products. It is one of the growing companies of India which is situated at Panchgani Mahabaleshwar Road. It produces jams, confectionaries, squashes, jellies and many more fruit products.

It is the fruit processing business over more than forty years and it is known for the innovation and quality in the industry. The Chief Executive Officer of the Company is Mayur Vora. It has its manufacturing units in Panchgani, Wahi and Gurgaon. It is most likely to spread its operation in Delhi and Pathankot. There are more than 500 local employees in the company and about 100 contract labourers.

Mapro Foods is a well-known brand in jams and squashes. It is a family started in 1959 by the Vora family, making jams from strawberries and raspberries. Mapro was one of the first to use traditional ingredients to make plant-based beverage concentrates such as strawberry crush any rose syrup. The company was also the first in India to introduce pectin jellies and fruit sweets

50 Fruitful Years

Founded in 1959, the company had its humble beginnings in the hill-town of Panchgani near Mahabaleshwar, when a businessman named Kishore Vora a pharmacist by profession, decided to make some strawberry jam. He then went on to develop innovative products such as jelly sweets, fruits cubes with fruit juice and rose syrups with rose petals - all for the first time in country. Today, his 'hobby' has borne fruit in the shape of Mapro, one of the most modern, hygienic, quality-focussed fruit product manufacturing units in India. His vision has been taken forward thereby transforming the region around Mahabaleshwar and Panchgani , the erstwhile sleepy hill stations of Maharashtra, into a flourishing fruit processing zone.

1959 :: Started their Operations as a Home Business

1963 :: Started Production for Local Sales and Innovative Products

1978 :: Launched Mapro brand

1987 :: Started First owned factory

2005 :: Set up state-of-the-art 3000MT cold storage at Wai Satara Plant

2006 :: New state-of-the-art line set up processed fruit product at Wai Satara Plant

2009 :: Celebrated Golden Jubilee Year

Mapro Foods Pvt Ltd is a Leader in the fruit Beverage and Fruit Jam market in Western India. Set up as aFamily business over 45 years ago, it has earned a name for Quality and consistency. Mapro products enjoy Premium Status in the Indian market. The Manufacturing facilities are Certified ISO 9001:2000 and HACCP by BvQi. The Company has expanded capacity to now produce 30000MT of proccessed frozen foods p. A. It is setting up a Frozen and Fresh Food Distribution Chain in Indian Metros to service the fast growing modern Organised Retail Supermarkets being set up in India.

Estimated Annual Sales (USD) : US$5 Million - US$10 Million 

Year of Establishment : 1959

CEO / Legal Representative : Mayur Vora

Corporate Status : Corporation/Limited Liability Company 

Products Manufacturing : Food Products ( Jam, Honey , Cordials, etc )

& Supplying

Head Branch : 122, Shendurjane Wai-Surur Road Wai,  412 803 India

Website : www.mapro.com

Mapro Foods Pvt. Ltd. Is fruit processing company. It was founded by visionary Shri Kishore Vora. It came into existence in 1959 A.D. the company used to produce jams from

strawberries and raspberries when it was established but later it started manufacturing various other products like crushes, squash, confectionaries, sweets, jellies and many more products. The company is one of the leading companies in India. The managing Director of the company at present is Mayur Vora. The company is situated at Chesson Road, Mahabaleshwar, Panchgani. The plant is BVQI certified and provided with facility of state of art food park and cold storage.

Mapro Foods Pvt Ltd. Is the flat organization where management works along with their technical and sales functionaries to achieve the vision and mission of MFPL.

Mission of MFPL: Mapro will develop, produce, package & sell food products, with high regards for safety, nutrition & taste, which we can confidently give to our customers by implementing

and continually improving Quality Management system & food safety management system to meet & exceed customers’ expectations.

History of MFPL: Over 40 years ago, in small town of Panchgani, near Mahabaleshwar, a Businessman named Kishor Vora decided to make some Strawberry Jam. Today his Hobby

has borne fruit in the shape of Mapro ..... one of the most modern, hygienic, quality-

conscious Jam and Fruit Products Manufacturing concerns in Western India. Mr. Vora could have rested easy on success of his Fruit recipe. But he wanted to on develop innovative ideas such as vegetarian Jelly sweets, Fruit Cubes with Fruit Juice and rose Syrup with Rose petals.... All for the first time in country. Mapro does not use advertising medium like press, radio and television to propagate its product but the taste of the product and nutritional value and uniqueness result in repeat sales.

Today Mapro is leading supplier of tasty as well as nutritious fruit product to the International Market. Mapro is known to care for its employees. Mapro is a home where there is mutual understanding between employee and employer like member in the family. It features a blend of hard work and dedication. It is now in the process of certification under ISO 9000.

Most of Mapro’s business is largely concentrated in the westen region of India. Currently, Mapro exports its products to about 12 countries through merchant distributors, these account for less than 10% of its total sales. It has its manufacturing units in Panchgani, Wahi, Gurgaon. The company is going to open its manufacturing units in Delhi and Pathankot lately. The main market segment currently is in Maharashtra and Gujarat. It is also concentrating in expanding its market to the other cities like Kanpur, Lucknow and in Punjab.

The annual growth rate of the company is more than 50%. It earns 40%-50% profits from the sales of its product. The leading product of Mapro is rose syrup (made from the rose petals and their extracts).

For the production of the products the company buys the fruits both the sectors i.e. the local farmers and market and import from other countries as well. The machineries and other raw material are imported from various countries like Egypt, China, New Zealand, Australia, etc.

Mapro Foods Pvt. Ltd uses all types of employees like skilled, semi-skilled, and unskilled labour. Skilled labour means the one who has higher level of qualifications as well as the experience. Semi-skilled labours means they have less qualification and the experience is also comparatively less and the Unskilled labour may not have any qualification or experience. However at all the levels of the management there must be a minimum technical as well as conceptual knowledge about the field.

Mapro's portfolio of products provides a high quotient of natural fruit in the form of Jams, Fruit bars and chews, Syrups, Crushes, Squashes, and Dessert Toppings. Its range of premium product such as Thandai crush and Kesar syrup are made from the finest selection of exotic ingredients. Mapro's product are known for their wholesome taste and quality, as also their natural goodness and nutritive value.Mapro was the pioneer of fruit-based confectionery in India, with its first jelly sweets being made from fruit juices and liquid glucose. The 'Falero' pulpy fruit chews, which are better known as 'Pates de Fruit" in the rest of the world - are excellent exemplars of mapro's very own Innovative Labs. Faleros come in unique indigenous flavours that are suited to the Indian palate, like Kacchi Kairi (Raw Mango), Alphonso Mango and Strawberry.

These are various products produced by the Mapro Foods. It is basically involved in producing jams, faleros, squashes, crush, syrup, ice cream, etc. The various produced manufactured by Mapro Foods Pvt. Ltd are listed below along with few details.

Jams: Jams are used in various meals courses especially for refreshments

and light snacks and they are found tasty with fresh breads buns and toasts, parathas, rotis and puri and also on a variety of salted biscuit. Mapro jams are made from the respective pulp, pectin, sugar and citrus acid.

Mapro Squash: Squashes are used in the preparation of Soft Drinks in chilled water, soda water and ice lollies and slush’s and mock tails. The key inebriants used by the Mapro Foods for the

preparation of the Squash are sugar, water, respective fruit juice or pulp and some added inebriants like pectin acid depending upon the flavour or fruit. The different flavours of squashes are: Strawberry, orange lemon, pineapple.

Syrups: Syrups have a number of applications such as to make refreshing soft drinks is chilled water. Soda water and in milk for milk shakes and add a taste to Floods and Shah Lassa and Mock tails. Syrup is also used in preparing Ice Creams as desert topping and to give a taste to ice cream lollies and slush’s. It uses the same inebriants as the squashes.

The various syrup available are: Rose Syrup, Khush Syrup, Mahakool syrup, Strawberry syrup, Cesar Syrup, Pineapple Syrup.

Crushes: Crushes gives a refreshing and nourishing drink when prepared in chilled water and soda water. Kokum syrup is also used in ice Lollies and in the preparation of slush’s. Mapro food uses sugar, water, citric acid, pectin and respective fruit juice or pulp. The various Mapro Crushes are listed in the table below: Lichi crush, strawberry crush, pineapple crush alphanso crush.

Falchoos: These are the fruity sweets with the real fruit jam. They are made from sugar, glucose, fruit juice, pectin, citric acid and permitted stabilizers. They are available in different packing details.

Honey: Honey is the only natural sweetener known that needs no additional refining or processing to be utilized. Honey is as invert sugar composed of 38% fructose, 31% glucose, 1% sucrose and 9% other sugars sugar along with water and small amounts of vitamins, minerals, enzymes and amino acids. As a carbohydrate, honey is a good supplier of energy at 64 calories per tablespoon. Because of honey’s unique composition, it is digested a little differently than other sweeteners. When compared to table sugar, honey has less of an effect

on blood glucose levels primarily due to its higher fructose content.

Mouthwatering pulpy fruit chews made from real fruit juice.Made from fragrant, succulent mangoes, these translucent yellow pulpy fruit chews are an instant spurt of energy. Their delectable taste and bursting pulpiness make Faleros unique. Just pop one in your mouth and experience how it melts away, leaving you asking for more! It is the first fruit chew introduced in India by any company. It is the first   jelly sweets being made from fruit juices and liquid glucose. It has also launched Falero Kacchi Kairi which is a pulpy fruit chew made from fruit pulp of

raw mangoes and is available in three flavours of strawberry, daingo mango and kacchi kairi

Frutons.

Manufacturing and Production Operations

1.Manufacturing Operations

As we mentioned above the company products jams, confectioneries, crushes, squashes, jellies, sweets, toppings and many more. So basically they have three sections where there are ranges of products produced. The sections are Liquid Sections, Jam Section and Falero Section.

Under Liquid Section, syrups (Rose, Khush Thandai, Pineapple, Strawberry, Cesar and Mahakool), crushes (strawberry, Litchi, Kiwi, mango, kokum and pineapple) and squashes (orange, lemon, lemon barley water, strawberry, lime juice, cordial, lemon ginger, strawberry cordial and pineapple cordial) are manufactured. In one day there are 8 lots are manufactured. As manufacturing of liquid section is a cold process, so, normal temperature is to be maintained. There is just one shift in this section.

Under Jam Section, there are a variety of flavours of jams that are produced. These flavours are mango, pineapple, strawberry, orange marmalade, raspberry, mix fruit, etc. There are more than 30 flavours of jams. The production capacity is 10-14 tonnes. The temperature in this section is very high as the boiling process is done at more than 95 °C. There is just one working shift in this section.

Under Falero Section, the fruity sweet with taste of pure jam is produced. This is the product which earns more than 50% of the profit. The Faleros have a monopoly as they are produced by Mapro only. It is one of leading product of Mapro as the Rose Syrup. The production capacity in this section is about 18 metric tonnes. It has flavours like strawberry, raw mango and alphas . in future litchi and guava flavours will also be available in the market. Yhe Mazana chocolates also come under this section. Production of Falero is critical and a temperature of 22 °C is maintained for its production. The working hours are 24X7 i.e. 2 shifts.

2. Production Process

We are just showing the production process of jams and jellies just to understand how the company works in this technical part.

Raw materials: Jams and Jellies are made from a variety of fruits, either singly or in combination. Most of the fruits are harvested in the fall. The level of ripeness varies. Pears , peaches, apricot, strawberries and raspberries gel best if picked slightly under ripe. Plums and cherries are best if picked when just ripe. The fruit is purchased from farmers. Most jam and jelly producers develop close relationships with their growers in order to ensure quality. The production plants are built close to the fruit farms so that the time elapsed between harvest and preparation is between 12-24 hours.

The Manufacturing Process: the ingredients must be added in carefully measured amounts. Ideally, they should be combined in the following manner

Inspection: When the fruit arrives at the plant, it is inspected for quality, using colour, ripeness and taste as guides. Fruit that passes inspection is loaded into a funnel-shaped hopper that carries the fruit into pipes for cleaning and crushing.

Cleaning, crushing and chopping: As the fruit travels through the pipes, a gentle water spray clears away surface dirt. Depending on whether the finished products is to be jam or jelly, paddles push the fruit and or just its juice through small holes, leaving stems and any other excess debris behind. Some fruits such as citrus and apples may be manually peeled, cored, sliced and diced. Cherries may be soaked and then pitted before being crushed.

Pasteurizing the Fruit: the fruit or juice continue through another set of pipes to cooking vats. Here, it is heated to just below the boiling point (210°F [100°C]) and then immediately chilled to just below freezing (32°F[0°C]). This process, pasteurization prevents spoilage. For jelly, the pulp is forced through another set of small openings that holds back seeds and skin. It will often then be passes through a dejuicer or filter. The juice or fruit is transferred to large refrigerated tanks and then pumped to cooking kettles as needed.

Cooking the jam and jelly: Premeasured amounts of fruit or juice, sugar, and pectin are blended in industrial cooking kettles. The mixtures are usually cooked and cooled three times. When the mixtures reaches the predetermined thickness and sweetness, it is pumped to filing machines.

Filling the jars: Presterilized jars move along a conveyor belt as spouts positioned above pour premeasured amounts of jam or jelly into them. When the fruit arrives at the plant, it inspected for quality, using colour, ripeness, and taste as guide. Fruit that passes inspection is cleaned, crushed, and pasteurized. Next, the premeasured mixture is cooked with added sugar and pectin until it reaches the appropriate thickness and taste. Then it is vaccum-packed in jars and labelled. Metal caps are then vaccumed sealed on top. The process of filling the jars and vaccum packing those forces all of the air out of the jars further insuring the sterility of the product.

Labelling and Packaging: The sealed jars are conveyed to a machine that affixes pre-printed labels. According to law, these labels must list truthful and specific information about the contents. The jars are then packed into cartons for shipment. Depending on the size of the producer’s operation, labelling and packing is either achieved mechanically or manually.

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After roasting and winnowing (removing the outer shell from the cacao beans) they are ground making cocoa liquor, see the left side of the picture.

Pressure is employed to a part of the cocoa liquor (slightly heated to be in a liquid form) to obtain cocoa butter (fat), see the right side of the picture. Cocoa liquor and sugar are mixed and ground down smaller and smaller for a long time. More cocoa butter is added in addition to

emulsifier and flavoring agents, especially vanilla. During the continued grinding the mixture becomes smooth. The next step in the process is called conching: mixing, heating, agitating and aerating for 24 hours to obtain the final velvet-like texture and less bitter flavor.

Before moulding the chocolate into bars or squares it must be tempered. Tempering is done by mixing the melted chocolate at a controlled temperature until the

right form of tiny chocolate crystals are formed. This gives the chocolate the right appearance and texture. Then the chocolate is moulded and cooled rapidly.

Customers

Mapro Foods Pvt. Ltd has customers from a wide range of people. Mostly the customers of the company are children as the products of Mapro are targeted for this group only i.e. Mapro produces chocolates

and jellies and jams and many more which is mostly liked by the children only. But this doesn’t mean that other age groups are not

covered.

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Competitors

Mapro Foods Pvt. Ltd is in food business which is highly and rapidly growing business & has few competitors also. Some of them are listed below:-

Haldiram : Manufactures Syrups & exports of the syrups have increased by 20% since 2005 touching 18,000 bottles in 2009.

Kissan : In jams, Mapro Foods Pvt. Ltd is close second to Kissan in market share.

Mala’s : It manufactures jam, crush, crush, squash, syrups which is same as the manufacturing of Mapro Foods Pvt Ltd.

Manama : Their range of products consists of cordials, syrups, fruit and chocolate desert toppings.

The project is prepared to fulfil various objectives. The objectives to prepare this project is:

I. For better understanding of the working of the food industry.II. To make the students understand the importance of quality and hygiene.

III. To understand how the firm works in a real world.

During our visit to Mapro Foods Pvt. Ltd and while preparing this report, I observed various things. They are:

Mapro takes special care of hygiene and quality. We found all the labour directly involved in the production were wearing gloves and hair caps. To take care of hygiene outsiders or visitors were not allowed to enter the production area.

There is more than 118000 metric tonnes of consumption of the strawberry throughout the year.

They manufacture luxury chocolates like Mazana. It is found inn special stores as this chocolates is not preferred by the normal people due to its cost. It is sold at the price of Rs.20 to Rs.50 per piece. Mazana is generally exported. Falero has a monopoly type of market and this product earns more than 60% profits on sales.

There are 500 local employees. There are 100 contract labourer employed as well.

This comapany grew without the help of any kind of advertisement. It is known by its product and quality and not because of the external advertisements.

The company earns a profit of about 40-50% profit in an average. Mapro is the first company to introduce pectin jellies in India.