Agriculture & Cooperatives Department

(Value Addition of Apple)

Construction of Apple Processing / Grading Plants in Apple
Growing Districts of Balochistan
 Area & Production of Apple in Project Districts
Area and Production of Apple in the Project Districts
(Agriculture Statistics Balochistan 2021-22)
S. No. Districts Area (Hectares) Production (Tons)
1 Kalat 1,702 13,397
2 Ziarat 1,944 53,911
3 Quetta 1,334 32,496
4 Pishin 6,744 61,060
5 K. Saifullah 38,808 269,843
6 K. Abdullah 5,549 67,650
7 Zhob 6,463 68,670
8 Loralai 1,233 9,685
9 Mastung 2,742 74,607
Total 66,519 651,319
Average whole Sale rates of Apple / Tone = Rs. 130,000
Summary of Project Cost

Sr. No. Description of Works Total Amount Rs.

(Mln)
A) Description of Works
i Civil Works 485.452
ii Provision of Machinery 338.120
iii Provision of Packaging Machinery 17.384
iv Design & Consultancy Charges 16.471
Total Cost Rs. 857.427
B) Add Contingency @ 1% 8.57
Total Project Cost Rs. 866.001
Average Per Unit Cost
Total Amount Rs.
Sr. No. Description of Works
Mln
A) Civil Works
i RCC Foundation, Processing / Grading Plant 9.720
ii Steel Structure of Building Processing / Grading Plant 13.680
iii Tube Well with Accessories 4.972
iv Const: of Boundary Wall 5.285
v Office Building 3.840
vi Road Works 6.687
vii Internal Electrification 2.734
viii Water Supply 0.500
ix Overhead Water Tank 4.454
x Gate 0.966
xi Dust Bin 0.563
xii Septic Tank 0.539
Sub-Total Rs. 53.940
B) Provision of Machinery
i Apple Processing / Grading Machnery 20.000
ii Provision of Solar System 8.800
ii Provision of Packaging Material 1.932
Sub-Total Rs. 30.732
C) Provision of Small Units of Value Addition 8.769
Sub-Total Rs. 8.769
D) Design and Supervision Consultancy @ 2% 1.830
Total Rs. 95.270
Contingency @ 1% 0.953
Grand Total Rs. 96.22
Most Common Verities of Apples
 The most grower districts are Ziarat, Quetta, Mastung, Kalat, Killa
Saifullah, Killa Abdullah, and Pishin.
 Apple varieties that are mostly grown in Balochistan are Tor Kolu
(Red Delicious), Shine Kolu (Golden Delicious) Kashmiri, Amri, and
Gaja.
Most Common Verities of Apples
Tor Kolu Shin Kolu Kashmiri
Kashmiri

Black
Gaja Amri Red
Diamond
Process Flow Chart of Apple Packaging for Value Addition

Washing Waxing Drying Grading

Packaging
Process Flow Chart of Apple Packaging for Value Addition
Process Flow Chart of Apple Packaging for Value Addition

S.No Machine Cost (Pkr)

1 Washing 1,200,000
2 Waxing, Drying, Grading 12,000,000
3 Packaging 2,000,000
Total 15,200,000
Process Flow Chart of Apple Jam for Value Addition

Juice Juice
Washing Pulp Making
Extraction Filtration

Filling in
Labeling Blending Pasteurization
Bottles
Process Flow Chart of Apple Jam for Value Addition
Cost Analysis of Machinery for Apple Jam

S.No Machine Cost (Pkr)

1 Washing 1,200,000
2 Pulp Making 2,500,000
3 Juice Extraction 1,000,000
4 Juice Filtration 1,000,000
5 Pasteurization 5,000,000
6 Blending 12,000,000
7 Filling in Bottles 2,500,000
8 Labeling 1,500,000
Total 26,700,000
Process Flow Chart of Apple Juice for Value Addition

Washing Pulp Making Pasteurization Homogenizer

Juice
Sterilization Filling Blending Filtration

Cooling
Process Flow Chart of Apple Juice for Value Addition
Cost Analysis of Machinery for Apple Juice

S.No Machine Cost (Pkr)

1 Washing 1,200,000
2 Pulp Making 2,500,000
3 Juice Extraction 1,000,000
4 Pasteurization 5,000,000
5 Homogenizer 2,400,000
6 Juice Filtration 1,000,000
7 Blending 12,000,000
8 Filling 2,500,000
9 Sterilization 5,100,000
Total 32,700,000
Process Flow Chart of Apple Cider Vinegar for Value Addition

Washing Pulp Making Juice Filtration Fermentation

Filling in Storage in
Labeling
Bottles Oak Barrels
Process Flow Chart of Apple Cider Vinegar for Value Addition
Cost Analysis of Machinery for Apple Cider Vinegar

S.No Machine Cost (Pkr)

1 Washing 1,200,000
2 Pulp Making 2,500,000
3 Juice Filtration 1,000,000
4 Fermentation 4,000,000
5 Storage in Oak Barrels (1000) 6,000,000
6 Filling 2,500,000
9 Labeling 1,500,000
Total 18,700,000
Apple Washing
Apple Washing
Apple Pulp Making
Apple Pulp Making
Juice Extraction
Juice Extraction
Juice Filtration
Juice Filtration
Pasteurization
Pasteurization
Blending
Blending
Filling in Bottles
Filling in Bottles
Labelling
Labelling
Homogenizer
Homogenizer
Sterilization
Sterilization
Technological Flow Sheet For Processing Of Jam (conti…)

Ripe firm
fruits

Washing

Peeling

Pulping

Addition
of Sugar
Technological Flow Sheet For Processing Of Jam (conti…)

Boiling

Addition of Citric Acid

Judging of end point by further cooking

up to 105 degrees Celsius or 68% TSS or
by Sheet Test

Filling Hot into Bottles

Cooling

Waxing

Caping

Storage
Problems in Jam Production:

I. Crystallization
II. Sticky or Gummy Jam
III. Premature Setting
IV. Surface Graining and
Shrinkage
V. Microbial Spoilage
 Jelly
 A 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.

 A perfect jelly should be transparent, well-set, but not too stiff, and should have the original flavor
of the fruit. It should be of attractive color and keep its shape when removed from the mould.
 It should be firm enough to retain a sharp edge but tender enough to quiver when pressed.
 It should not be gummy, sticky or syrupy or have crystallized sugar. The product should be free
from dullness, with little or no syneresis (weeping), and neither tough nor rubbery and should
have TSS 65%, 0.5-0.75% acid and 45% of fruit juice.
In The Home Can Be Prepared By Using the Following Recipes:
Fruit Ingredients for one

Sugar (Kg) Citric Acid

Guava 0.75 3.0
Sour Apple 0.75-1.00 2.0
Gooseberry 0.80 -
Karonda 0.75 -
Jamun 0.75 1.0
Wood Apple 1.00 -
Plum 0.75 2.5
Loquat 0.80 2.0
Papaya 0.75 3.0
Important Considerations In Jelly Making:

A. Pectin
I. Alcohol test
II. Jelmeter test
Alcohol test
B. Acid
C. Sugar
D. Judging of end point
I. Sheet or flake test
II. Drop test Sheet test Temperature test
III. Temperature test

Drop test
Technological Flow Sheet For Processing Of Jelly (Conti…)
Fruit (firm not over
ripe)

Washing

Cutting into thin

slices

Boiling with water (for

about 20-30 min)

Addition of citric acid during

boiling (2gm per kg of fruit)

Straining of extract

Pectin test (for

addition of sugar)
Technological Flow Sheet For Processing Of Jelly (conti…)

Addition of sugar

Boiling

Judging of end point

Removal of scum or foam (1 teaspoonful

edible oil is added for 45 kg sugar)

Color and remaining

citric acid added

Filling Hot into Bottles

Waxing

Caping

Storage at
ambient
temperature
 Problems in Jelly Making:
1. Formation of crystals:
2. Failure to set: (i) Addition of too much sugar
(ii) Lack of Acid or pectin
(iii) Cooking below the end point
(iv) Cooking beyond the end point
(v) Prolonged Cooking

3. Cloudy or foggy jellies: (i) Use of non-clarified juice or extract

(ii) Use of immature fruits
(iii) Over-cooking
(iv) Over-cooling
(v) Non-removal of scum
(vi) Faulty Pouring
(vii) Premature gelation

4. Syneresis or weeping of jelly: (i) Excess of acid

(ii) Insufficient pectin
(iii) Premature gelation
(iv) Fermentation
 MARMALADE
 This is a citrus fruit product prepared by cooking fruit pulp or extracts with sufficient amount
of sugar and using shreds of peel as suspended material.
 Marmalades are classified into:
1. Jelly marmalade
2. Jam marmalade

 The method of preparation for jam marmalade is practically the same as that for
jelly marmalade. In this case, the pectin extract of fruit is not clarified and the whole
pulp is used. Sugar is added according to the weight of the fruit. Generally in the
proportion of 1:1. the pulp-sugar mixture is cooked till the TSS content reaches 65
percent.
PROBLEMS IN MARMALADE MAKING:
 Browning during storage is very common which can be prevented by addition of
0.09 g of KMS per Kg of marmalade and not using tin containers. KMS dissolved in a
small quantity of water is added to the marmalade while it is cooling. KMS also
eliminates the possibility of spoilage due to moulds.
Technological Flow Sheet For Processing Of Marmalade (Conti…)
Ripe Fruit

Washing

Peeling outer yellow

portion (flavedo)

Cutting yellow portion into fine shreds (1.9-2.5 cm

long and 0.08 – 0.12 cm thick)

Boiling

Straining the extract

Testing for pectin

content (alcohol test)

Addition of sugar
Technological Flow Sheet For Processing Of Marmalade (Conti…)
Cooking to 103 to
105 degree Celsius

Addition of prepared shreds

Boiling till jellying point

Testing for end point

Cooling (82-88 degree Celsius)

flavouring

Filling in sterilized
bottles

Sealing

Storage at ambient
temperature
Machinery and Equipment
Automatic Fruit Cutting Machine
This multi-functional cutting machine is suitable for cutting all kinds of fruits. It is a low consumption and high
efficiency machine. It is used in kitchens, restaurants, cooking schools, hotels and food processing plants. The
proposed business will use this machine for cutting apples into 4 slices. Its material is made up of stainless steel.
Its capacity is 500 kg/hour and electricity consumption is 1,600W. Figure 1 shows automatic fruit cutting
machine.
Pulp Maker Machine
This machine is used to make fruit pulp and its juice. The machine’s part which contacts the fruits is made of stainless steel. This is important
to keep the product safe from any contaminants. It is widely used in fruit processing industry. The proposed business will use it to extract
pulp and juice from apple. Its capacity is 500kg/hour and electricity consumption is 1500W. Figure 2 shows apple pulp maker machine.
Oak Barrel
Oak barrel is used to store apple pulp and juice for fermentation process to take place. Oak barrel would normally be imported.
Plastic and metal barrels are not used in fermentation process because they can react with acids and disturb the fermentation
process; therefore, oak barrels are preferred. Apple cider goes through subtle2 chemical changes throughout the time it is stored in
the oak barrel. Each oak barrel has a storage capacity of 500 liter. However, for the proposed project, each barrel is to be filled at
90% so as to leave 10% open space for sufficient air flow required for fermentation. Figure shows an oak barrel.
Electric Hand Mixer
It is a tool for mixing apple pulp and juice in the oak barrel. The proposed business will use it to mix apple pulp
and juice to ensure that pulp remains completely submerged during the fermentation process. It is made of
stainless steel. Its electricity power is 950 W, paddle size of 120 mm, paddle length of 590 mm and a speed range
of 350-700 rpm3. Figure 4 shows electric hand mixer.
Pulp Presser Machine
Pulp Presser machine can press juice from fruits like apples, grapes, pomegranate etc. Pulp presser machine consumes low energy and has a compact
structure which results in high efficiency. The proposed business will use it to compress mixture of apple pulp and juice comes out from barrels placed
in fermentation area, so as to extract maximum juice from the mixture. It is made of stainless steel. Its required electricity consumption is 3,000 Watts
and the capacity of this machine is 500 kg/hour. Figure shows pulp presser machine.
Juice Filtration Plant
Filtration plant is used for achieving clear filtration quality for apple cider. After filtration, refined apple cider is
obtained which is ready for packing. The capacity of Juice Filtration Plant is 500 liter/hour of unpurified juice.
It is made of stainless steel. Its power requirement is 750W. Figure 6 shows juice filtration machine.
Bottle Filling and Capping Machine
This machine will automatically fill and cap white vinegar and apple cider bottles of different sizes of 100 ml4 to 1,000 ml. Its capacity
is to fill and cap 50 bottles/minute. The electricity requirement of this machine is 3,800 Watts. Its material is made up of stainless
steel. Figure 7 shows bottle filling and capping machine for white vinegar and apple cider.
Labeling Machine
The proposed business will use this machine to glue labels on produced apple cider and white
vinegar bottles. Its power is 250W and it can label 50 bottles/minute. Figure 8 shows labeling
machine for white vinegar an apple cider.
Boiler Machine
The proposed business will use a gas operated boiler for boiling apple cider. Its capacity is 500 Liter/hour. Its power
consumption is 500W. It starts quickly and achieves high temperature in short time. Figure 9 shows boiler machine.
White Vinegar Generator Machine
White vinegar generator machine will be used it for preparing white vinegar. Addition and mixing of raw
materials required for white vinegar will take place in this machine. It has a capacity of 200 Liter/hour. It is
made of stainless steel. Its power consumption is 500 W. Figure 10 shows white vinegar generator machine.
Large Tubs & Trolley (500Liter)
These tubs are used for moving apples from cutting department to crusher department. These are aging resistant and easy to
clean. These tubs have a capacity of 500 Liter and are made of linear low-density polyethylene (LLDPE) material. Figure 11 shows
large tubs.
Plastic Tub (500L)-For Washing
Proposed business will use plastic tubs for washing apples. The size used by
proposed business is 500 Liter. Figure 12 shows plastic tub.
Electronic Moveable Weighing Machine
This machine will be mainly used for weighing apples. It has a capacity to weigh up to
500kg. Its power consumption is 25W. Figure 13 shows electronic moveable weighing
machine.
Electricity Generator (Diesel)
Electricity generator will be used to ensure uninterrupted production in case of any power
outage. Capacity of generator for the proposed business would be 125 KW. Figure 15 shows
generator.
Water Filtration Plant
Water filtration plant will be used for filtering the water, which will be used in white vinegar
and apple cider preparation. Its capacity is 1000 Liter/hour and weight is 35 kg. Its power
consumption is 25W. Figure 16 shows water filtration plant.
Process Flow of Production Unit of Apple Cider
The process flow of production of apple cider is shown in Figure 22.

Procurement of Weighing of Apples Washing Extracting and

Apples Raw Materials and Cutting Transferring Apple
Pulp

Cooling and Adding water and Separating Fermentaion of

Filtration of Apple Boiling of Apple Juice from Pulp Apple Pulp
Cider Cider

Quality Check Packing of Apple Delivery and

Cider Payment
 Unit Cost (PKR) Total Cost (PKR)
Cost Item No.
White Vinegar Generator Machine (200 Liter/Batch)
1 750,000 750,000
Electronic Movable Weighing Machine (500 Kg)- Apple Cider
1 250,000 250,000
Weighing Scale (100 Kg)-White Vinegar 1 75,000 75,000
Automatic Fruit Cutting Machine (500 Kg/Hour) 1 350,000 350,000
Large Tubs (500 Liter) (For Washing) 5 20,000 100,000
Trollies (500 Liter) 4 60,000 240,000
Alcohol Refractometer 5 22,000 110,000
Water Filtration Plant 1 250,000 250,000
Digital Automatic pH Meter 5 5,000 20,000
Brix Hydrometer 5 5,000 25,000
Mannual Drum Lifter (500Kg) 1 70,000 70,000
Apple Pulp Maker Machine (500 Kg/Hour) 1 2,000,000 2,000,000
Pulp Presser Machine (500 Kg/Hour) 1 1,000,000 1,000,000
Juice Filtration Machine (500 Liter/Hour) 1 500,000 500,000
Bottle Filling and capping Machine (50 BPM) (100ml-1000ml)
1 1,500,000 1,500,000
Labeling Machine (for Both) 50BPM) 1 1,500,000 1,500,000
Oak Barrel (500 Liter) 50 150,000 7,500,000
Electric Hand Mixer 4 15,000 60,000
Boiler Machine (500 Liter/Hour) 1 2,200,000 2,200,000
Generator (125 KW) 1 4,000,000 3,500,000
Water Suction Pump (1.5 Hp) 1 100,000 100,000

Total Cost (PKR) 22,600,000

Initial Investment for Establishment of Value Addition Unit /
Plant

1. Land & Infrastructure :

2. Apple Processing Line with Accessories:

3. Machinery

4. Furniture & Fixture

5. Office Equipment and Accessories

6. Human Resources:
 Production Scope & Supply Chain
• Apple Production: 700 Thousand Tons (2021-22):
• Post Harvest waster @ 25% : 175 Thousand Tons
• The major share is consumed in fresh form
• Meager amount of value added products:
• Value Added Products: Jam, Jelly, Juice, Apple Cedar, Apple Vinegar, Pomace etc.
• Shin Kolu or Golden Delicious variety of apple is preferred.
• Tehsil Mangocher in Kalat, Gulistan in Killa Abdullah and Hurramzai in Pishin have the highest

proportion of Shin Kolu/Golden Delicious apple

• Value addition contribute towards reducing postharvest losses and increasing the economic value of

produce.
• Marketing Venues: Local, National and Export
Demand of Value Added Products
Consumption of Processed Fruit Products by Number of HH

Processed Fruit & Vegetable Products Mo. of User HH % of Total HH

Jam 80 100
Jelly 43 54
Mango Juice 61 76.25
Orange Juice 31 38.75
Apple Juice 27 33.75
Pickles 76 95
Source: Estimation of Demand for processed Fruit and Vegetable Products in Hyatabad, Peshawar. (2007)
Sarhad Journal of Agriculture
Cost of Typical Value Addition Unit
Table Apple Value Addition Unit (210 MT)
Description of Item / Work
A-1 Type of Machinery / Equipment Quantity No. Cost Rs.
1 Juice Extractor 1 6,000,000
2 Pulp Machine 1 1,200,000
3 Slicing Machine 1 4,400,000
4 Steam Jacketed Kettle 1 700,000
5 Mixer / Grinder 1 700,000
6 bottle washing and Filling Machine 1 5,000,000
7 Baby Boiler 1 1,500,000
8 Cap Stealing Machine 1 1,800,000
Stirrers, SS Utensiles, Burner, Wighing scales, Hand
9 L.S 700,000
gloves
10 Knives, tools, material handling equipment L.S 450,000
11 Testing Equipment / Chemiclas L.S 500,000
Sub- Total Rs. 22,950,000
Other Cost Typical Value Addition Unit
Description of Work / Item Unit Cost (Rs.)
A-2 Other Machinery
Solar Tube Well (Pishin) Variable with location &
1 11.00
1 discharge
Sub-Total Rs. 11.00
A-3 Furniture & Fixtures
1 Tables 3 0.10
2 Executive Chairs 3 0.75
3 Visitor Chairs 10 0.25
4 AC 2 0.225
Sub-Total Rs 0.35
A-4 Office Equipment / Machinery
1 Laptop Computer 1 0.15
2 Desktop Computers 2 0.09
3 Computer Printers 3 0.09
4 Photocopier 1 0.20
5 Water Dispenser 2 0.025
6 Fax Machine 1 0.025
7 Vehicles 2 9.00
8 PTCL L.S. 0.02
Sub-Total Rs. 9.42
Other Cost Typical Value Addition Unit
Description of Work / Item Unit Rs. (Mln)
A-5 Human Resource (Yearly)
1 Production Manager / Executive (Year) 1 1.80
2 Quality Control Specialist / Chemist 1 1.80
3 Skilled Workers 2 1.20
4 Semi-Skilled Workers 4 1.44
5 Accounts / Administrative Officer 1 1.44
6 Electrician 1 0.60
7 Mechanics 1 0.60
8 Reception 1 0.48
9 Cleaner 3 1.08
10 Driver 2 0.84
11 Security Guards / Watchmen 3 1.26
Sub-Total 12.54
A-6 Office Building
1 Land Acquisition (Kanal) 2 2.00
2 Office Building
3 Processing Hall
4 Ware house
5 Boundary hall
6 Rest room
Sub-Total 13.02
Sensitivity Indicators / Challenges
Small Farmers (< 5 acres) : 80%
• Quetta, Pishin K. Saifullah, K. Abdullah, Kalat: 32%, 64%, 59%, 32% & 19%
• Small Farmers are capital scarce: high post-harvest losses 20-30% apple (small
sized or injured fruit) is wasted that further depresses their profit margins
• Highly dependent on Arhtis / Commissions agents

Suppliers
• Raw Material for Value Addition: fruits, sugar, pectin, additives, preservatives,
food colors etc.
• Packaging Martial: Plastic / Glass jars, pouches, labels, cardboard boxes for
outer packing and adhesive tapes

Compliance of Quality Control Standards

• National and International production and Packaging quality Control standards

Marketing Competition in terms of Price

• Local, National & International brands / smuggled items