Thursday, May 26, 2022
outlook business
Vidya Herbs

Expanding Coffee Verticals

The company has expanded its coffee vertical with a state-of-art Instant Coffee Plant to enable the direct control of all analysis from procurement, production till dispatch of product.

Expanding Coffee Verticals
K.Shaymprasad, Founder Chairman, Vidya Herbs Pvt Ltd

Kodimule Shyam Prasad, the founder and managing director of Bangalore based Vidya Herbs Pvt Ltd, is one of the leading manufacturers of herbal and botanical extracts, which achieved  export sales of over Rs. 1000 crore last year,  a 30% increase over the previous fiscal year. The company hopes to maintain the growth momentum in the coming years with its upcoming expansion in instant coffee, decaf coffee and probiotics.

A post-graduate (gold medalist) in natural chemistry, Prasad started his career as a chemist in a pharmaceutical company in 1990 but quit his job after five years to turn an enterpreneur as he wanted to apply his knowledge of Natural Product Chemistry in business. Thus began his journey of first starting a trading firm for the buying and selling of botanical extracts. But in 2004, he eventually ventured into manufacturing by setting up Vidya Herbs in a small manufacturing facility on a 10,000 sq ft land.

Over the last 18 years, Vidya Herbs has diversified to include new products in its portfolia. Employing over 600 people across its six factories - five in Karnataka and one in Khammam, Telangana,  the company is in the process of setting up new plants to ramp up production. it takes pride continuously upgrading processes in the manufacturing plants to meet stringentquality demand, while investing more than 3 to 4 % of its expenses in research and development to improve production systems and products.

An inspirational leader, Prasad lays considerable emphasis on quality right from raw material to finished products. His commitment to nature has been intrinsic to all its manufacturing processes and extracts since the beginning. With its global presence, Vidya Herbs provides extracts from the best ingredients nature offers to companies worldwide.

“Success is not a destination. Success is a Journey. I never dreamt about success, I worked for it,” says Prasad, a first generation entrepreneur. “Tenacity, strategic thinking, staying passionate and focused on obtaining goals I set for myself, is the primary reason for my business success. If I could do one thing differently, it would be to listen to my instincts.”

K.Shaymprasad, Founder Chairman, Vidya Herbs Pvt Ltd
 

Insta Coffee

Vidya Coffee is situated at Chikmagalur with its own coffee estates, integrated coffee processing plant, spray dried roasting plant, Instant coffee plant & coffee extraction plant with the capacity of over 20000 MT/Annum in the heartland of Indian coffee which is a part of Western Ghats.  Coffee is grown under 3 tiers of shade and has a unique ecosystem. Several fruits and spice crops like Pepper, Cardamom, Citrus, Vanilla, Silver Oak are grown along with Coffee. In less than two years, this modern facility, with a plant of 20,000 MTS per year capacity, has helped the company emerge as the top insta coffee exporter in the country in 2021-22. Plans are afoot for further expand the coffee handling and processing capacity.

For instance, the company has expanded its coffee vertical with a state-of-art Instant Coffee Plant with an inbuilt modern laboratory to enable the direct control of all analysis from procurement, production till dispatch of product. Insta blends are the combination of beans of different origins in order to get a good balanced blend.

Following the “Berry To Cup” concept, the coffee processing plant has been built to have minimum / no manual intervention from the time of feeding. The company has invested in the latest whether it is machines from Buhler India (German technology) for cleaning of raw green coffee, world famous coffee roaster Leogap of “Probat” (Brazil), aroma recovery system from Flavourtech, Australia, or stainless steel insulated columns (percolators) for coffee extraction. In addition, the plant has an evaporator system and spray drier tower from one of the reputed suppliers in India. In the case of instant coffee, the company has invested in upgraded technologies like freeze dried coffee powder. Among the new expansion projects are  Probiotic and Decaffeine units being set up in Hassan Pharmaceutical SEZ. The facilities will help the company broaden its portfolio in the coming years.

Instant – or soluble – coffee is made from coffee beans that have been roasted and ground. The ground beans are then extracted with hot water to recover the coffee flavour and aroma. The process is similar to using a coffee percolator at home. The coffee extract is then dried in one of two ways: spray-drying and freeze drying.

Vidya Coffee has begun the spray-drying process which involves sprayed into a stream of hot air at the top of a tall cylindrical tower. As the droplets fall, they dry, becoming a fine powder by the time they reach the bottom. The powder may then be texturised into granules to facilitate dosage and dissolution. The quality of the aroma and flavour are preserved due to the very fast drying occurring during this process. Spray-drying is the most commonly used drying process.

The next project proposed to be launched soon is to start freeze-drying under which the coffee extract is frozen to about – 40°C and cut into granules. The frozen granules are then dried at low temperature and under vacuum. The quality of the aroma and flavour are protected by the very low temperature and gentle drying conditions. Finally, the soluble coffee is packaged into either glass jars or sachets.

Green Coffee

The company has been working continuously to bring in value added coffee products in the market. One of its new products is the green coffee extract CGA-7, now primed for the US market. Formulated for metabolic health benefits, CGA-7 is standardized to have high-purity chlorogenic acid. Results of a study conducted by the company and peer-reviewed in SAGE Open Medicine journal, indicated that the CGA-7 usage helped to significantly decrease body weight, body mass index, fat mass, and percentage in body fat compared to the placebo group.

Brewed Coffee

For brewed coffee lovers, Vidya Coffee offers ready-to-use, specially formulated, rich, coffee decoction that is concocted into perfection by coffee experts.

Decaffeinated extractions

The company’s is expected to be launched by May end once the new plant set up in Hassan comes into production with a vide range of production capacity. The market for decaffeinated Extraction drinks, which typically contain the original caffeine content has been growing rapidly worldwide.

Probiotics

The company is on course to soon start manufacture of probiotics, which are live bacteria and yeasts that have a wide range of therapeutic benefits and are being used to modulate immunity, lower serum cholesterol, treat atherosclerosis and arteriosclerosis, rheumatoid arthritis, cancer, etc. Increased commercial interest in exploiting the proposed health attributes of probiotics has contributed significantly to the growth and expansion of this market sector.

Extraction Facility

Vidya Herbs is in the process of ramping up its capacity for herbal extraction, herbal and spices products using new technologies and further upgrading the quality testing process. The company’s facilities have already been approved by the USFDA after site inspection of their herbal extract manufacturing facility in Bangalore.

Chilli extraction and Oleoresin unit

Last year Vidya Herbs’ Chilli extraction and Oleoresin unit in Mahabubabad, Telangana, spread over 16 acres, became operational. Chilli oleoresin is a kind of oily liquid extracted from chilli. Its main components are capsanthin and capsorubin.

Marketing and research

Recipient of several awards in the Agriculture, Research and Dietary Supplement category, Vidya Herbs takes pride in delivering research-based natural products to improve the quality of life. Given the company’s large production capabilities, 3 extraction facilities, customised manufacturing and offices around the world, Vidya Herbs is able to provide quick and reliable services. Its turmeric extract product – Puremeric Stain Free Tech was awarded the Gold Innovation award at the International Spice Conference 2019 for the innovative product developed by the in-house team.

Vidya Herbs believes in playing a positive role in the community it is involved in, and greatly values social and environmental impacts for the future generations. Sustainability is closely linked to its core business practices. Vidya Herbs’ CSR activities are largely in the villages and other remote areas.

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