Aloe Vera Gel Manufacturing Business:
The following content is all about Aloe Vera Gel Manufacturing Business.
Aloe Vera Gel Manufacturing Business – Aloe Vera Cultivation
One of the most reward promising businesses is herbal industry which has a great demand both local and export potential in Aloe Vera plant based products. Aloe Vera is often referred as ‘The Miracle Plant’ because of its natural healing properties and it is an amazing medicinal herb grown worldwide. The plant has many medicinal properties and hence starting an aloe farm is going to be very prospering investment.
Growing Aloe Vera needs minimal care and growing habitat. It can be grown in all types of soils with less irrigation. The vital points to be taken into consideration before starting cultivation would be is the soil conditions and climatic conditions. When the answers are positive and convincing it is good to kick start aloe vera farm.
Aloe vera can be applied on the skin externally or can be taken as a juice internally. The rich gel inside the plant thick leaves has lot of minerals and the water content is almost 95%. Though water content is high it has 75 ingredients on which much research is going on to bring out many of its organic uses in both pharmaceutical and cosmetic industry. The aloe vera gel has nutrients as follows:
- Vitamins C, E, Beta Carotene, and B12.
- Minerals such as magnesium, manganese, zinc, copper, chromium, calcium, sodium, potassium, iron.
- Amino Acids.
- Sugars like long chain polysaccharides that help boost the immune system.
- Enzymes that help break down and digest food.
- Plant Sterols that act as powerful anti-inflammatory agents.
- Lignin that helps Aloe penetrate the skin.
- Saponins is a soapy substance with an anti-microbial effect.
- Anthraquinonesis a powerful natural painkiller.
- Salycylic Acidis anti-inflammatory, helps break down dead tissue.
Aloe Vera Gel Manufacturing Business – Choosing Aloe Vera Farming Site
Cultivation of Aloe vera is simple and easy to manage in growing. The land must meet the standard farming requirements such as soil fertility, irrigation facility, and weather conditions such as more sun light, warm to hot temperatures and less rainfall. In the initial stage a beginner can start planting 5000 saplings in an acre land with a part of it to construct house for aloe juice production.
Aloe Vera Gel Manufacturing Business – Feasibility Study of Aloe Vera Cultivation
Aloe Vera – Perennial, drought resisting, succulent plant.
Climate – Grows in hot humid conditions but sensitive to frost.
Rainfall – Requires 80 cm rainfall per year.
Soil – Grows well in all kinds of soils with proper soil drainage. For commercial growing sandy loam soil is much preferable.
The land or place you going to start aloe vera farming must meet all of the above site conditions.
Aloe Vera Gel Manufacturing Business – Aloe Vera Growing Process
The farmland must be propagated either by aloe vera sapplings or by root suckers. For commercial growing and planting of 5000 seedlings for an acre can be done by procuring from a commercial nursery or from a horticulture centre.
Land Preparation: Plow the land to loosen the soil for planting. Make the land free from weeds. Incorporate organic matter such as farm yard manure and compost and keep the soil slightly acidic.
Plant Spacing: To accommodate 5000 saplings, spacing about 30 x 30 inches in rows between plants must be maintained. It takes about two years for the plant to mature and be ready for harvest.
Aloe Vera Harvesting:The crop will be ready for harvesting from end of second year onwards. Harvesting can be done on quarterly basis in a year. On an average three leaves can be cut per plant so each plant can be harvested with 12 fully grown leaves in a year. So an acre land with 5000 plants can produce 60000 leaves annually that will come to 30000 to 60000 kilograms. Cut the leaves close to the stem and place the cut end of the leaf downwards in the troughs. The juice trickles down from the leaves rapidly and flows down and escapes from the trough holes.
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Aloe Vera Gel Manufacturing Business – Marketing of Aloe Vera leaves
Harvest leaves that are thick and fleshy at about 20 to 30 cm long. The color of the leaves can be green to greyish green in color. Small farmer who cannot have processing units can sell the leaves directly or through marketing agency to pharma companies or cosmetic industries, or traditional medicinal houses. There is much demand and there are agencies that buy aloe leaf for export. Small farmers can check sites such as exportersindia and indiamart websites to sell directly to end customers.
Aloe Vera Gel Manufacturing Business – Machinery in Preparing Aloe Vera Juice
The harvested leaves from the fields are brought into the manufacturing unit. The flesh of the leaf is rich in natural fibers, Minerals and Vitamins. The leaf pulp has so many remedies for skin, internal healing, cleansing and repair when taken as juice. To prepare aloe vera juice a farmer must be in a position to purchase and install these components:
- Aloe leaf washing tank.
- Leaf extractor.
- Pulp filter.
- Special juicer.
- Bottle filling and capping machine.
Processing must take place as soon as possible after harvesting ideally within 36 hours. Due to the perishable nature of the pulp or gel, leaves must be processed for juice at the earliest. The juices if not stored properly get degraded due to enzymatic and microbial activity and oxidation over a short period of time. The leaves are placed in washing tank with antimicrobial agent to remove dirt and surface bacteria. The leaves are thoroughly washed and dried. Therind or thorny edges of the leaf are sliced on both sides. The green leafy part is removed and the gel or pulp is collected and passed through a filtration cum homogenizing unit to get clear transparent juice. The juice is heated to 60 to 70° C and cooled rapidly to kill the microorganisms. There is no need for any chemical or preservative to be added because of heating and cooling of the juice. The juice then is sent for filling followed by capping and packing.
Aloe Vera Gel Manufacturing Business – Preparing Raw Aloe Vera Juice
This is the most common preparation of aloe vera juice by people having aloe vera in their backyard garden. The inner pulp from freshly cut leaf is collected by removing rind the green part of the leaf. The pulp is mixed with water and thoroughly mixed or crushed in a blender. The crude juice can be prepared with or without plants latex. It is recommendable to avoid the yellow gel. To avoid yellow gel cut part of the leaf base and allow the leaf to rest in slanting or vertical position allowing the yellow gel drain down followed by washing the leaf in water. In this preparation method the juice contains high concentrations of undesirable laxatives.
Aloe Vera Gel Manufacturing Business – Preparing Aloe Vera Leaf Juice
As the name suggest the juice is prepared from the entire leaf. The thorny side parts of the leaf along with top and bottom of the leaf are removed. The remaining part of the leaf along with rind is cut into slices and crushed and blender into slurry. Some may not prefer slurry soup, so it’s treated with enzyme cellulose which hydrolyzes polysaccharides and making it more soft and liquid product. Excessive enzyme treatment may result in loss of medicinal restorative properties in the juice. One report suggests over processing will lead to 50 to 90% breakdown of glucomannans in aloe vera leaf juice.
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After the enzymatic treatment the juice is subjected to a series of filtrations to remove rind particles and laxatives. The juice is passed through a depulping machine followed by sterilization of the juice. This pasteurization prevents degradation of the acetylated polysaccharides by exogenous and endogenous bacteria. The juice is freed from aloins A and B and other laxative compounds followed by decolorization with activated charcoal are employed. After undergoing such treatments the juice will be a clear watery liquid ready for consumption and marketing.
Aloe Vera Gel Manufacturing Business – Preparing Aloe Vera Inner Pulp Juice
In this production the same preliminaries of removal of grind and laxatives are undertaken at the initial stage followed by cleaning of leaf inner gel in cool water. This filleting process can be done in two ways; manually and mechanically. When properly done the inner pulp will be free from phenolic compounds such as aloins A and B and rind particles.
Separating of inner gel manually is recommended. In the initial stage the leaves from the farm are washed with an antimicrobial agent such as hypochlorite to remove dirt and surface bacteria. The thorny side edges are cut along the length on both sides of the leaf along with top and bottom part of the leaf. The pulp is manually removed by a sharp knife separating the pulp from the grind (green part of the leaf). While in mechanical process the leaves after washing with antimicrobial agents are manually fed into mechanical filleting and depulping machine. In the filleting process the leaves undergo culling, trimming and removing of the rind. The rollers in the machine must be properly adjusted when separating gel from the leaf. When rollers are pressed hard against the leaf the laxative compounds which reside in the vascular layer (between the grind and gel) are extracted and get mixed with the inner gel and if the rollers are pressed softly there is loss of inner gel will be left behind on the grind and gets discarded.
The extracted inner pulp is then washed in clear cool water to free from traces of yellow gel or laxatives. The slurry gel is passed through series of filtration to get of rind particles completely and laxatives such as aloins A and B. Decolorization of the juice with activated charcoal is employed. The juice is undergone pasteurization to remove traces of bacteria or any other microorganism followed by adding preservatives. The juice is now ready for packing.
Aloe Vera Gel Manufacturing Business – Processing of Aloe Vera Juice Step by Step
To generate Aloe Vera juice commercially from the farm produce (raw alove vera leaves) can be achieved as described step by step.
- Cleaning of raw materials.
- Filleting / Removal of leaf rind.
- Pulp Grinding.
- Enzyme Treatment.
- Series of Filtration.
- Filling and Packing.
Aloe Vera Gel Manufacturing Business – Cleaning of Raw Materials from the Farm: Matured Aloe Vera leaves which are harvested must be fleshy, undamaged, mold or rot free ones. Harvested leaves must be immediately processed for juice extraction; transportation of leaves from distant farms must be undertaken in refrigerated vehicles. Quick processing must be taken as all the active ingredients in the leaf are silently affected by season, climatic and soil variations. The decomposition of polysaccharides with natural enzymes takes place starting from six hours and the gel in the leaf gets contaminated with bacteria on the rind surface. This will affect the quality and production of Aloe Vera juice. The leaves are thoroughly washed in water along with antimicrobial agents in the washing tank.
Aloe Vera Gel Manufacturing Business – Filleting / Removal of Leaf Rind: In this stage the gel is extracted by removing the green rind. The leaf is cut vertically at the edges on both sides to remove the thorny edge. The lower bottom white part of the leaf base about one inch is removed with a sharp knife. The top rind is removed along with vascular bundles leaving the white jelly part (mucilage layer/gel) by a sharp knife followed by removing the bottom rind similarly. The green part or the rind, leaf base and thorny parts are discarded. The colorless gel or mucilage has the highest concentration of beneficial aloe ingredients though the gel contains more than 98%. The gel is washed in clean cool water thoroughly to get rid of latex (yellowish gel) and there is minimal bacterial contamination. In cases of mechanical gel extraction there are high possibilities of aloe juice tasting bitter at this stage as it is more prone to get mixed with latex and anthraquinones. Manual gel extraction is much preferable and recommended even though it is labor intensive.
Aloe Vera Gel Manufacturing Business – Pulp Grinding: The pulp or inner gel extraction operations must be completed within 36 hours from harvesting the leaves. The laxatives and anthraquinones are the ones that react on aloe gel degrading the quality by browning the aloe gel. After aloe gel is collected from extraction it is immediately sent for crushing or grinding. Grinding must be done with gel getting crushed evenly at room temperature. As the aloe gel is more prone to enzymatic browning during crushing or grinding the process must be done within 20 minutes.
Aloe Vera Gel Manufacturing Business – Treatmentof Aloe Vera Gel with Enzymes: Aloe Vera gel before processing is treated with Pectolytic enzyme for a long duration for preserving polysaccharides in Aloe Vera gel. Enzyme treatment is done at 50° C within 20 minutes time duration.
Aloe Vera Gel Manufacturing Business – Series of Filtration:In this phase of operation the Aloe Vera gel juice is filtered from rind particles and laxative compounds through a series of filtration.
Aloe Vera Gel Manufacturing Business – pH of Aloe Vera Gel Juice: The unpasteurized Aloe Vera gel juice must be acidic 3.0 and 3.5 range. The pH of the gel juice is treated with Vitamin C and citric acid as this will help improve the flavor of aloe gel juice and also helps avoid browning reaction. To improve the shelf life the Aloe Vera juice is treated with dearation process which helps in avoiding oxidation of ascorbic acid.
Aloe Vera Gel Manufacturing Business – Pasteurization: In order to destroy pathogens and microorganisms in the Aloe vera gel, the gel is passed through a high temperature short time treatment. The pasteurization treatment is undertaken at 90 to 95° C for one to two minutes and thisalso helps to avoid bad flavor in the juice.
Aloe Vera Gel Manufacturing Business – Aloe Vera Juice Cooling: This is an important process. After pasteurization the hot Aloe Vera gel juice is made to undergo flash cooling to less than 6° C within 12 to 15 seconds. This treatment will destroy bacteria and other microorganisms completely in the Aloe Vera juice.
Aloe Vera Gel Manufacturing Business – Filling and Packing of Aloe Vera Juice:This is the last processing stage in the preparation of Aloe Vera juice commercially. After pasteurization and cooling the Aloe juice is free from biological contamination, retains shelf life and maintains the right flavor for consumption. The finished juice in this stage undergoes through filling machine which fills bottles as desired from 50 ml to 1000 ml and above. Filled up bottles are moved to the next stage for bottle capping. The finished Aloe Vera juice bottles are collected and packed in labelled carton boxes by six, dozen and even single bottle packing.
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Storage: The Aloe Vera juice must be stored in relative humidity and temperature in the refrigerator for duration and product quality. Those two parameters will affect the shelf life of Aloe vera juice.
Aloe Vera Gel Manufacturing Business – Safety Measures in Aloe Vera Manufacturing
- Workers must be vigilant all the time especially at the rind removal/filleting stage while using knifes.
- Wear protective equipment.
- Protect your eyes as small fragment may cause serious complications.
- Wear ear protectors at place with high machine noise levels.
- Workers are advised to wear safety helmet, shoes while working.
- Any worker when sustained with an minor or major injury or not well while at work must be given first aid treatment and put the case on record.
- Workers and staff must be aware of do’s and don’ts when fire breaks out and be able to reach emergency numbers.
Aloe Vera Gel Manufacturing Business – Marketing of Aloe Vera Juice
- Small farmers can directly sell harvested leaves to Pharma companies, cosmetics companies and others that use Aloe Vera leaves as their raw materials.
- Establish a business deal for selling Aloe Vera Juice with retail outlets, suppliers and distributors or export to international markets either directly or marketing agency.
- Create an e-shop or retail outlet for Aloe Vera leaves or end products.
- Sell end products at various e-commerce portals by registering.
Bottom Line of Aloe Vera Gel Manufacturing Business:
Any one who can grow aloe vera on commercial scale start this business and start making money with proper marketing channel.