Mapro Factory

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
 Industry Profile
The Fast Moving Consumer Goods (FMCG) Industry,
alternatively called as CPG (Consumer Packed goods) industry
primary deals with the production, distribution and marketing
of consumer packaged goods. The FMCG is those consumables
which are normally consumed at a regular interval. Some of the
prime activities of FMCG industry are selling, marketing,
financing, purchasing etc. The industry also engaged in
operations, supply chain, production and general management.

FMCG industry economy

The competition among FMCG manufacturers is also growing
and as a result of this investment in FMCG industry is also
increasing. Specifically in India, where FMCG industry is
regarded as the fourth largest sector with total market size of
US$ 13.1 billion.
 Company Profile
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.

Product Profile
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 mango 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.

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.
.

Manufacturing Chocolate
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.

Managerial structure
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.

Customers and competitors

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.
  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.

Objective of the Project

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.

Observations and Findings

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

and fruit sweets in India.