1. INDUSTRIAL VISIT
PROJECT REPORT ON
MAPRO FOODS PVT
LTD
B Y AY U S H K U M A R
2 1 2 3
S T. X AV I E R ’ S C O L L E G E , R A N C H I

2. INTRODUCTION
• Located around the idyllic hill-town of Panchgani in Western India, Mapro Foods
manufactures Fruit Jams; Fruit beverage concentrates – Crushes and Squashes; and
Fruit Bars. With an annual processing capacity of around 30 thousand MT, Mapro is a
market leader in Western India. The company has grown organically over the last five
decades with sustained profitability. Known for its quality and innovation, Mapro has
been built on its founder’s philosophy of developing products that are wholesome,
nutritious, value-for-money, and imaginative.
• It was our pleasure that we all got an opportunity to visit Mapro Foods Private Limited
situated at Wai, Mahabaleshwar on 13th Oct 2019.
• The manufacturing facilities are certified with ISO 9001:2000 and HACCP by BvQi

4. HISTORY
• In 1959, Kishore Vora started operations in small room, as a home business with a
mutually beneficial relationship with the farmers to make strawberry jam for product
sales. This eventually led to the launch of the Mapro brand in 1978.

5. • Mapro set up a fruit processing unit at Gureghar with 12 permanent employees and
also involving remaining villagers into farming. Mapro provided the farmers technical
guidance and also guaranteed to buy their produce. The region has the highest
produce of strawberries in India and constant increase in tourist inflow over time.
Tourist recognition led to the development of the MAPRO GARDEN which is the
popular identity of Gureghar among tourists now.
• Gureghar or Mapro Garden is host to the annual Strawberry Festival. Mahabaleshwar
contributes to 85% of the total strawberry produce in India and about 80% is
consumed fresh. The Strawberry Festival encourages the strawberry cultivation in the
belt.

6. COMPANY’S OBJECTIVE
• 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
• Mapro will develop, produce, package and sell food products, with high regards for
safety, nutrition and taste, which they can confidently give to the customers by
implementing and continually improving quality management system and food safety
management system to meet and exceed customer’s expectations.

7. MILESTONES
• 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

8. MANUFACTURING PROCESS
• Inspection – When the fruit arrives at the plant, it is inspected for
quality, using color, 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 & 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
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.

9. • Pasteurizing – 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 DE juicer 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.

10. • Filling the jars –Pre sterilized 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 color, ripeness, and taste as guide. Fruit that
passes inspection is cleaned, crushed, and pasteurized. Next, the premeasured
is cooked with added sugar and pectin until it reaches the appropriate thickness and
taste. Then it is vacuum-packed in jars and labelled. Metal caps are then vaccumed
sealed on top. The process of filling the jars and vacuum packing those forces all of
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.

11. MANUFACTURING PROCESS

15. PRODUCTS CATEGORIES
• Mapro produces a no. of items ranging from jams, jellies, crushes, syrups, etc. Their
leading products is Rose syrup, made from rose petals and their extracts. The
manufacturing process for most of their products is similar only differing in the types
of fruits used and the variations in cooking temperature and pectin ratio.
 Fruit Sweets With Real Fruit Jam
• These soft fruity and jelly sweets are 100% vegetarian as they are made with pectin and
fruit extracts. They contain no Gluteen. Contain nutritious fruit juice and instant energy
.
• Fruity sweets
• Jelly sweets
• Falchoos
• Jelly cubes
• Fruit pebbles

17. JAMS
• A whole range of delicious fruity jams are produced by Mapro units in Panchgani and
Wai. These jams are made with certain specific fruits and fruit pulps .the various types
include:
• Mango
• Orange marmalade
• Strawberry
• Pineapple
• Raspberry
• Mix fruit

18. SYRUP
• Syrups are made with pure contents for the exclusive natural flavours and properties.
The syrup recepies are balanced to allow use in sherbats, milkshakes, faloodas, and
even ice-cream toppings.
• Rose syrup
• Khus syrup
• Thandai syrup
• Mahakool syrup
• Strawberry syrup
• Kesar syrup
• Pineapple syrup

19. SQUASH
• Mapro squashes with their high fruit content are terrific for Sherbats and fruit punch.
• Orange squash
• Lemon squash
• Lemon barley squash
• Strawberry squash
• Lemon ginger squash
• Strawberry cordial
• Pineapple cordial

21. ICE-CREAMS
• Mapro does produce ice –creams on a large scale. It is only produced and supplied at
the mapro garden in Panchgani.
• Strawberry(People’s favourite)
• Mango
• Pineapple rose
• Chocolate
Almonds
• Honey(sugar free)

22. CRUSH
• Ideal with milkshakes, ice-creams, puddings, deserts and now even sweats. This
bestseller makes milkshakes thicker and ice- creams richer.
Strawberry crush
Litchi crush
 Alphanso mango crush
 Mango crush
 Kiwi crush
 Kokum crush
Pineapple crush
THIS IS THE NEW RANGE OF THE PRODUCTS OFFERED BY MAPR

23. SWOT ANALYSIS OF MAPRO

24. STRENGTH
1. 1. Wide product
range .
2. 2. Good product
quality with 45%
fruit content in
the products.

25. WEAKNESS
1. 1. Fresh fruits
are perishable
in nature .
2. 2. Limited
presence in
the country .

26. O P P O RTUNITIES
1. 1. Growing
market in
India.
2. 2. Online
Marketing.
3. 3.
International
expansion.

27. THREATS
1. 1. High
dependence on
weather for
good raw
materials.
2. 2. Availability of
substitute
products.

28. OBSERVATION
• 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 labor 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 1,18,000 metric tones 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 laborer employed as well.
• · This company 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.

29. 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
chocolate desert toppings.

30. CONCLUSION
• It is easy for the manufacturing units to get a regular and steady supply of units.
• The overall process is completed in a matter of minutes. There is a good blend of
human and machine resources. At no point of production is there wastage of time.
• Hygiene levels are upto the mark. There is no scope for spoilage on account of
unhygienic conditions.
• The free space in the factory could be used up for more machines in order to
increase production.
• The bottles sterilization with the help of machines help in saving a lot of time.

31. MAPRO GARDEN