White Paper Food Processing1 8
White Paper Food Processing1 8
White Paper Food Processing1 8
S.No Topic
1 Executive Summary
13
Case Study:
1. Amul
2. Lijjat Pappad
D’Essence Consulting
[email protected]
022-28347425
303, Aar Pee Center, 11th Road,
MIDC, Andheri (E), Mumbai-400093
EXECUTIVE SUMMARY
Food processing involves any type of value addition to agricultural or horticultural produce and
also includes processes such as grading, sorting, and packaging which enhance shelf life of food
products. The food processing industry provides vital linkages and synergies between industry
and agriculture.
The Food Processing Industry sector in India is one of the largest in terms of production,
consumption, export and growth prospects. The government has accorded it a high priority, with
a number of fiscal reliefs and incentives, to encourage commercialization and value addition to
agricultural produce, for minimizing pre/post harvest wastage, generating employment and
export growth.
The idea of India is gradually changing as number of countries showing interest to invest in
India is increasing. In fact it is observed that India has displaced the US as the second most
favoured destination in the world for FDI after China.
Food industry is one of the key sectors which is the mainstay of Indian economy because of its
high share in employment and major contribution to GDP. At present the food processing sector
employs about 13 million people directly and about 35 million people indirectly. The food
market in India is estimated at over Rs. 9,100 billion and accounts for about two third of the total
Indian retail market.
India's food processing sector covers a wide range of products fruit and vegetables, meat and
poultry; milk and milk products, alcoholic beverages, fisheries, plantation, grain processing and
other consumer product groups like confectionery, chocolates and cocoa products, Soya-based
products, mineral water, high protein foods etc.
Looking into some of the key facts, India has largest irrigated land in the world. India produces
annually 105 million tonnes of milk (highest in the world), 150 million tonnes of fruits &
vegetables (second largest), 485 million livestock (largest), 230 million tonnes food-grain (third
largest), 7 million tonnes of fish (3rd largest), 489 million Poultry and 45,200 million eggs.
Food processing industry is currently growing at around 14%. The industry received FDI
totalling Rs 9450 million in 2009-10. However, India’s share in export of processed food in
global trade is only 1.5 %; whereas the size of the global processed-food market is estimated at
Rs. 190 trillion and nearly 80 per cent of agricultural products in the developed countries get
processed and packaged.
India has set itself a target of doubling its processed food production by 2015, and will set up 10
food technology parks during the next year with a view to achieving this. According to the India
Food and Drink Report by research analysis firm Research and Markets, by 2012, India’s
processed food output is likely to grow by 44.2 per cent to touch Rs. 4,505 billion, while
packaged food sales will increase by 67.5 per cent to reach Rs. 1,085 billion. On a per capita
basis, per capita packaged food spending is expected to grow by 56.5 per cent to Rs. 903 by
2012.
Opportunities in Food Processing in India
• Diverse agro-climatic conditions • Increasing literacy, rapid
lead to a wide-ranging and large raw urbanization and rising per capita
material base suitable for food income resulting in rapid growth and
processing industries in India. changes in demand patterns. This is
Currently a very small percentage creating great opportunities for
(less than 2%) of these is processed exploring the large hidden markets.
into value added products, leaves An average Indian spends about 40
opportunity to explore in the sector. % of household expenditure on food
• One of the biggest emerging items.
markets, with more than 1 billion • Demand for processed /convenience
population and 250 million strong food is constantly increasing.
middle class sets a large consumer • Cheaper workforce availability can
base within the country. be effectively utilized to setup large
• India is the seventh largest country, low cost production bases for
with extensive administrative domestic and export markets.
structure and independent judiciary, • Liberalized policies with specific
a sound financial & infrastructural incentives for high priority food
network. Stable and flourishing processing sector provide very
democracy is also an opportunistic favourable environment for
attribute of the country. investments and exports in the
sector.
Challenges in Food Processing
• Unprocessed foods are susceptible to and attractive packaging, and at low
spoilage by biochemical processes, incremental costs.
microbial attack and infestation. The • The challenges for the food
right post harvest practices such as preservation, distribution and
good processing techniques, and processing sectors are diverse and
proper packaging, transportation and demanding, and need to be addressed
storage (of even processed foods) on several fronts to derive maximum
can play a significant role in market benefits. Presently, the
reducing spoilage and extending organizations addressing the
shelf life. educational and R & D requirements
India has access to several natural resources that provides it a competitive advantage in the food
processing sector. Due to its diverse agro-climatic conditions, it has a wide-ranging and large
raw material base suitable for food processing industries.
The chart above describes the process i.e. the Entire Value Chain for a Private Entrepreneur
from Demand Estimation to Consumption. Government i.e. Central as well as State government
along with its agencies supports the farmer and processing units to encourage this sector.
The Stages involved in the value chain are:
5.2
5.9
7.4 8.8 Education and
7
7.6 recreation
10.4 13.1
8 Apparel
20.3 21.3 20.1
Healthcare
Housing &Utilities
34.6 31.5 34.4
Transportation
35%
Grocery
EXTENT OF SHARE OF
SIZE – OUTPUT GROWTH
SEGMENT PROCESSING ORGANIZED KEY SEGMENTS
/ VALUE RATE (%)
(%) SECTOR (%)
Raw fruits & vegetables,
Fruits &
Rs 1687.5 Cr. 02 48 pulp, canned fruits and 20
Vegetables
pickles
Marine fisheries, frozen
2.33 million
Fish 12 - products, minced fish 20
tonnes
products
Milk Rs 58.5 Cr. 37 15 Butter, Ghee, Cheese etc. 15
6.4 million
Meat & Poultry 01 05 Cattle, Buffalo & poultry 10
tonnes
Packaged Rs 9000 Cr. - 80 Noodles, vermicelli & pasta 08
Fruit based & carbonated
Beverages Rs 697.5 Cr. - 77 27
drinks
Staple Food - 50 Salt, sugar, Flour, Bread 85
Source: Investment commission of India,2009 and www.ibef.org
Fruits & Vegetable Processing:
• India produces the widest range of fruits • However less than 2 per cent of the total
and vegetables in the world. vegetables produced in the country are
• It is the second largest vegetable (100 commercially processed, as compared to
million tonnes) and fruit (50 million nearly 70 per cent in Brazil and 65 per
tonnes) producer accounting for 8.4 per cent in USA.
cent of the world’s fruit and vegetable • India’s installed capacity for fruits and
production. vegetable processing
• The share of Fruits and Vegetable exports increased from 1.1
(In Cr. Rs.)
organised million tonnes in
F&V Processed F & V
sector in fruit 1993 to 2.77 million
1523.25 2214.90 2580.30 3555.00 4517.55
processing is 2209.05 2298.15 2589.30 3060.00 3134.25 tonnes in 2007.
estimated to • About 20 per
be nearly 50 2005-06 2006-07 2007-08 2008-09 2009-10 cent of processed
per cent. Source: APEDA fruits and vegetables
• Fruit production in India registered a are exported.
growth of 3.9 percent over the years • Major products exported include fruit
whereas the fruit processing sector grew pulps, pickles, chutneys, canned foods,
several times faster at 20 per cent over concentrated pulps and juices and
the same period. vegetables.
• The total area under fruit cultivation is • Fruit exports registered a growth of 16
estimated at 4.18 million hectares and per cent in volume and 21 per cent in
7.59 million hectares under vegetable value terms in 2006-07.
cultivation. • Mango and mango based products alone
constitute 50 per cent of the exports.
Milk Processing:
• Indian stands first in the world in terms • The market for dairy products is
of milk production. expected to grow at 15-20 per cent.
• The current size of the Indian dairy
Some private players includes Hatsun,
sector is Rs.3133.5 billion and has been
Heritage, Modern ,Paras, Dynamix, Parag
growing at 5 per cent a year.
and Metro ,also FMCG players like
• The dairy sector
Nestle,Danone
Exports of Dairy Products
ranks first in terms (in Cr. Rs.) & Britannia all
of processed foods 947.25 980.86
of which sell
with 37 per cent of 507.15 510.75
402.68 liquid milk and
the produce being
manufactures
processed.
2005-06 2006-07 2007-08 2008-09 2009-10 value added
• The organised
Source: APEDA products like
sector processes an
milk powder,
estimated 20 percent of the total milk
ghee, butter, cheese, curd and butter milk in
output in India.
small quantities.
• There are 676 dairy plants registered
with Government of India, which come • Taking Dairies to the Next stage:-
Besides debt, private equity has become a preferred source of raising funds in dairy sector.
PE funds are supported by liberal FDI policies. PE funds include investment from International
Finance Corporation in Modern Dairy (North India), Actis in Nilgiri Dairy (South India), Motilal
Oswal Private Equity in Parag Milk Foods.
Fish Processing:
• India has large marine product and cent (3.9 million tons) came from marine
processing potential with varied fish resources.
resources along the 8,041 km coastline, • Fish processing is mostly targeted for
28,000 km of rivers and millions of export markets.
hectares of reservoirs and brackish
Exports of Marine Products (in Cr. Rs.)
water.
• India is the third largest fish producer in 9597.78
8338.18 8545.90 8588.83
7398.95
the world and second in in-land fish
production.
• The Fisheries sector in India has been
2005-06 2006-07 2007-08 2008-09 2009-10
classified into marine, inland and Source: MPEDA
• India has the largest number of livestock • Most of the animals in India are not bred
population in the world accounting for for meat. Animals generally used for
50 per cent of buffaloes and 16 per cent production of meat are cattle, buffaloes,
of the goat population. goats, sheep, pigs and poultry.
• Meat production is Rs.625 million and a • Only 11 per cent of the buffalo
Meat export is Rs.5.2 million. population, 6 per cent of the cattle, 33
per cent of the sheep and 38 per cent of
Exports (in Cr. Rs.)
Meat Processed Meat Poultry the goat population is culled for meat.
2488.5 3007.35 5602.05 7069.95 7606.35
• Consumption per head of both fresh and
processed meat is very low at 1.5 kg
2.205 6.255 13.86 10.395 10.26
289.8 290.25 472.5 431.55 398.7 compared with world average of 35.5 kg.
2005-06 2006-07 2007-08 2008-09 2009-10 • Indian poultry meat market is
Source: APEDA
approximately Rs. 105.0 billion.
• Indian broiler industry has seen a rapid • The total size of this market is estimated
growth in the last few years - CAGR of at Rs.16,650 million by value and 85,000
more than 10 per cent a year since 1998. tonnes by volume.
• White beverages account for 65 per cent
of the market and brown beverages
Beverages: The beverages market constitute the remaining 35 per cent.
primarily consists of non-alcoholic and • India is the largest producer of tea in the
alcoholic beverages world accounting for 28 per cent of the
total global production, at 857 million
Non – alcoholic beverages kgs.
• Tea production in India has been
• Non-alcoholic beverages can be broadly
growing at 1.2 per cent per annum and
classified into carbonated drinks, non-
India is the fourth largest exporter of tea
carbonated drinks and hot beverages.
in the world with estimated exports of
• The market for carbonated drinks in
Rs. 18886.8 million in 2007-08.
India is worth Rs.75 billion while the
• India is also the fifth largest producer of
juice and juice-based drinks market
coffee accounting for 4 per cent of the
accounts for Rs.12.5 billion.
total production in the world.
• Growing at a rate of 25 per cent, the
• Nearly 75 per cent of India’s production
fruit-drinks category is one of the fastest
is exported and coffee exports stood at
growing in the beverages market.
Rs. 29,315 million in 2007-08.
• Sports and energy drinks, which
currently have a low penetration in the
Indian market, have sufficient potential
to grow. Alcoholic beverages
• They are considered a socially-
• The market for alcoholic beverages has
acceptable alternative to alcoholic
been growing consistently.
beverages. Hot beverages include health
drinks such as white beverages and • The market for wine in India was
brown beverages such as tea/coffee as growing at over 25 per cent per year.
Integrated supply chain and scale • The country has only 3600
slaughterhouses, 9 modern abattoirs and
of operation
171 meat processing units, and a limited
• Even though India ranks second in number of pork-processing units.
production of fruits and vegetables, • This is one of the reasons penetration of
nearly 20 to 25 per cent of this processed meat is extremely poor at 1
production is lost in spoilage in various per cent in India.
stages of harvesting. • These figures indicate both the need for
• The major problems are poor quality of scale, and the potential or growth offered
seed, planting material and lack of by the sector.
technology.
• Quality produce lead to investment in Processing Technology
technology and ability to sustain a long • Currently most of the processing in India
gestation period for harvest. is manual.
• It also results in better quality of • There is limited use of technology like
processed food. So we need to establish pre-cooling facilities for vegetables,
backward integration like contract controlled atmospheric storage and
farming to improve quality of produce. irradiation facilities. This technology is
• Nearly 90 percent of the food processing important for extended storage of fruits
units are small in scale so not able to and vegetables in making them
exploit the advantage of economies of beneficial for further processing.
scale. • In case of meat processing, even with the
presence of over 3600 licensed
slaughter-houses in India, the level of • India has a large untapped customer base
technology used in most of them is and even a small footprint in the
limited, resulting in low exploitation of domestic market would enable the player
animal population. to gain significant volumes.
• Bringing in modern technology is an • Acceptance in the domestic market and
area that existing as well as new hence higher penetration is driven by the
investors in the sector can focus on, this following factors:
will make a clear difference in both
Competitive Pricing
process efficiencies as well as quality of
Consumers of processed foods are extremely
the end product.
price sensitive even a small change in
Increasing penetration in pricing can have significant impact on
TERMINAL
MARKET
AGGREGATORS FOOD
FARM INPUTS ANCILLARIES FOOD RETAILING
AND LOGISTICS PROCESSORS
CONTRACT
FARMING
In recent days trend has been towards integration and collaboration across players in the value
chain, to garner mutual benefits. Such integration is initiated by manufacturers, who are looking
to integrate backward to establish linkages with farmers and logistics provider. This led to two
new models emerging in the sector – Contract farming and Terminal markets.
Contract Farming
Contract Farming is an agreement between the food processor (contractor) , who is typically
a large organized player, and the farmer, whereby the farmer is contracted to plant the
contractor ’s crop on his land. He also agrees to harvest and deliver to the contractor a quantum
of produce, based upon anticipated yield and contracted acreage at a pre-agreed price.
The food processor provides inputs in terms of technology and training to the farmer, to improve
the yield and quality of the produce.
This results in a win-win situation that generates a steady source of income for the farmer and
eliminates supply shocks and assures good quality farm inputs which are crucial for the
processor.
The Government of India has been actively encouraging contract farming endeavours. The
National Agricultural Policy envisages that ‘private sector participation will be encouraged
through contract farming and land leasing arrangements to allow accelerated technology
transfer, capital inflow and assured market for crop production ’.
Terminal Markets
A Terminal market is a central site, often in a metropolitan area, that serves as an assembly and
trading place for agricultural commodities. Here there are different options for disposing off the
produce. It can either be sold to the end consumer, or to the processor, or packed for export, or
even stored for disposal at a future date. It thus offers different options to farmers under a single
roof.
Typically, terminal markets operate on a hub and spoke model where the markets form the hubs,
and are linked to different collection centres (spokes) that are located close to the production
centres. The typical value chain structure for a terminal market, as well as the key activities and
corresponding infrastructure requirements at each level, are depicted in the figure below:
Food Parks
Food Parks are comprehensive industrial
estates for food-processing units where the
industries would have the provision of
common facilities like cold storage, cold
chain, effluent treatment plant, warehousing,
power connection, water facilities, sewage
etc.
has identified the food processing sector as a 25% of profits for the next five years) for
high priority area and has given a number of setting up of new agro-processing industries
fiscal relief and incentives to encourage to process and package fruits and vegetables
commercialisation and value addition to (F&V). Export earnings are exempted from
items under an export obligation in selected removed. Peak rate of customs duty has been
Food parks: In a bid to boost the food food parks across the country.
Private investment has been one of the key drivers for growth of the Indian food industry. As we
know food processing industry has been allowed 100 % FDI it has shown substantial growth
which can be observed in the chart:
Industry estimates the total amount of investments in the food processing sector in the pipeline
for the next three years is about Rs. 1,150 billion.
• South Korean confectionery giant, Lotte • Conglomerate Reliance Industries Ltd has
Group, also has plans to set up a invested US$ 1.25 billion in a dairy
with a focus on the beer market. Through solutions provider, Wincanton, for its
its recent acquisition of US brewing giant efforts focussed on India’s mass grocery
now also owns A-B's Indian subsidiary, • Dairy major and ice cream specialist,
• Italian confectionery company, Ferrero India's US$ 500 million snack food
Organic Food
• Organic food ensures high food quality, desire to ingest specific foods or
which other conventional foods cannot beverages for the purpose of preventing
because it costs about 20% more than and wellness concerns offer the best
• Fabindia has ventured into the organic • No wonder healthy food is becoming a
Organics with no preservatives or colors and affluence have made health food
food store chain has exclusive stores in • In recognition of these trends, food
Hyderabad, Bangalore and Pune. Godrej marketers in the country have introduced
Basket, is also looking into the growth of the health food market.
Food as Control
Overseas Players
Company Logo Company Products Brief about the company
• The parent company Unilever holds 51.5%of
HUL’s Equity
• India’s largest FMCG Company with
Biscuits, Instant
Hindustan leadership in Home & Personal care products
coffee, Tea, Instant
Unilever
drinks, Jam, Syrups, and Food &Beverages
Ltd
Salt, Wheat flour-atta,
• HUL’s brands so reach across 20 different
categories with combined volumes of about
4mn tons and sales of US$ 2.17 billion
• In 2002, with a turnover of Rs 3 billion, • The member sisters are free to choose
exports worth Rs 100 million, 62 the work they like, rolling papads, or
branches and 40 divisions all over the packing, or preparing the dough.
country, and 42000 members, the Sri • Payment is made on a daily basis. The
Mahila Griha Udyog Lijjat Papad supervisors constantly check for the
(SMGULP) was a women's quality and weight of papads.
entrepreneurial success story in India. • SMGULP inculcates in its members, "a
• From humble beginnings in a thickly commitment to earn a legitimate income,
populated locality of Mumbai in 1959, honesty, and not snatching the fruits of
SMGULP has come a long way. another person's income" and adherence
• The organization gained recognition to quality. Stringent rules of cleanliness
through its most famous product- Lijjat and purity are maintained.
papad. In addition to papads, SMGULP • The whole manufacturing process is
manufactured other household products open to inspection by anybody. A well
like spices, bakery products and laid formula is strictly followed to obtain
detergents. products of a fixed standard of taste,
• A look at any of the branches of color and size.
SMGULP gives the feel of an efficient • In March 1959, seven semi-literate
entrepreneurial set up. women from Gujarat came together to
• The key to SMGULP's success lies in supplement their family incomes and
the feeling of oneness that it creates. create a sustainable source of
• Women above 18 years of age can employment with the skill they knew -
become members of SMGULP by cooking.
signing a pledge of devotion to the • They started out on the terrace of a large,
organization. old, residential building called Lohana
• At SMGULP, workers are referred to as Niwas in Girgaum, a thickly populated
co-owners and the women who work area in south Mumbai. This is where the
there are referred to as sisters. seven housewives, bored and confined to
their homes, saw an opportunity to set up the end of the third year more than 300
an organization 44 years ago. women were rolling papads.
• These women borrowed Rs 80 from • SMGULP is a symbol of the progress of
Chaganlal Karamsi Parekh, a member of women in developing countries like
the Servants of India Society and a India. It took the organization 43 years
social worker. The women commenced to grow from a 7-member team, to one,
business by selling papads. which has 42000 members.
• Within 3 months there were 25 women • The organization not only aims at the
joined them and within 6 months they economic empowerment of women, it
were able to reward themselves with half also seeks to raise the standard of living
gram of gold each with the profit they of women.
had made. • SMGULP has taken a major step
• The group used considerable publicity towards eradicating evils like poverty
through word-of-mouth publicity and and illiteracy.
articles in vernacular newspapers. • Such an organization also forms a vital
• By the second year of its formation, 100 link between social development and the
to 150 women joined the group, and by advancement of rural women.
D’ESSENCE is a full service Boutique Management Consulting firm incorporated in 1998. We assist
Corporate, Mid-Sized Owner Managed Companies and Government Organizations to Build, Grow and
Remain Competitive.
Our highly professional and qualified team includes Management Graduates, Engineers, Accountants,
and Economists who analyze and present a “fresh perspective” to your business.
Chandni Sahgal: Managing Consultant Shahid Tanwar: Project Leader Sachin Chavan: Project Leader
+91 9820075332 +91 9833854580 +91 9967588598
[email protected] [email protected] [email protected]