INNOVATIVE PROCESSES AND MACHINERY FOR FOOD PROCESSING August 19-20, 2013 Two day training programme Kolkata

Dr. H Umesh Hebbar, M.Tech., Ph.D. Principal Scientist, Department of Food Engineering CSIR- CFTRI, Mysore, India

About CFTRI ..Processes ….Products …..Machinery

About CFTRI……  One Stop Centre for Food Science and Technology • Premier Food Research Institute established in 1950. • One of the constituent laboratories of CSIR, Govt. of India • Mandate to develop cost-effective, bio-friendly food processing technologies, with total concern for food safety, health, nutrition and environment. • 17 R&D departments, 14 supporting departments and 3 Resource Centers • Around 500 scientific/supporting staff , 150 Research Fellows Certifications and Accreditations • ISO 9001 Quality Management System • ISO 14001 Environmental management System 12/18/2014 • ISO 17025 NABL Accreditation

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CFTRI Portfolio………. Pre/Post-harvest protocols for extension of shelf-life Disinfestation, handling, packaging of Fruits Technologies for shelf-life extension Minimal processing, Fumigation, Thermal/non-thermal processing, Biotechnological approach, Packaging Development of products Convenience foods – RTE, RTC, Easy to prepare, Designer foods – Low GI, Low Fat, Low Calorie, Geriatric Functional/Speciality Foods –Pro-biotic/pre-biotic Equipment development Traditional Indian Foods, Improved efficiency, nonconventional energy source s Basic research Biochemistry, Nutrition, Cell culture, Biotechnology, Nanotechnology 12/18/2014

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Other Activities………… Consultancy assignments Industry sponsored projects

Imphal

Technology/Know-how transfer BR Hills

Turn-key projects

HRD activities Lucknow • M.Sc. Food Technology (2 years) • Certificate Course on Milling Technology (1 year) • Entrepreneur Development Programmes • Short-term Courses for Entrepreneurs (1-2 weeks) • Ph.D. Programme for Research Fellows • Project work for Under Graduate/Post-graduate students 12/18/2014

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Pilot plant

Automated Wheat mill

Analytical Lab

Facilities at CFTRI

Maize mill

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Sensory booth

Instrumentation facility

SS 6

Agricultural Production Scenario in Eastern/N-E India     

Fruits & Vegetables (Potato, Onion, Pea, Mushroom) Cereals (Rice, Maize, Wheat, Millets) Spices (Ginger, Chilli and Turmeric) Milk & Poultry products Sugarcane

 Mostly in small and medium scale industries  Scope for Value addition is high.  Value addition to these agri-materials is one of the potential areas of Industrial and Research importance

12/18/2014

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12/18/2014

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PRE/POST HARVEST PROTOCOLS  Post harvest technology protocols for Air cargo space and export of Mango variety Alphonso in uneconomical and exorbitant Reefer Container by ship. air freight charges (3 times).  Technology protocol for export of Banana variety dwarf Cavandish by ship. Orchard management pre harvest care with spray treatments to control fungal and insect damages to the fruit, optimum stage of maturity for harvest, desapping, handling, packing-house operations such as grading, washing, post harvest dip treatments, packing in specially designed CFB boxes, precooling, stacking in reefer containers, optimum storage temperature and humidity management inside the reefer container and post transportation ripening conditions.

12/18/2014

Shelf-life extension by 35 days for Mango and 42 days for banana

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Minimal Processing (MP) of Vegetables Preparation procedure generally includes processes such as washing, peeling, cutting, trimming, slicing, shredding, dicing and coring .

Simple and Cost effective

 Generates gainful employment

 Maintains freshness and quality  Render vegetables in convenient and "Ready-to-cook form".  Bulk reduction for better storage, easy transportation and packaging

 Extends shelf-life by 3-5 folds  At rural and urban level

        

Ash gourd Beetroot Beans Bittergourd Carrot Cabbage Cauliflower Cluster beans Coccinia

     

 Boosts export of vegetables

 

 Renders 60% value addition



 Low cost technology

Coriander leaves Curry leaves Cucumber Drumsticks Field beans Fenugreek leaves Green peas Green chillies Knol-khol

        

Mint leaves Okra Onion Plantain Ridge gourd Snake gourd Spinach leaves Tomato Turnip

Controlled/Modified atmosphere storage Pretreated fruits

• Concentrations of Oxygen, Carbon di-oxide, Nitrogen • Temperature • Humidity

Dehydration of fruits and vegetables Removal of moisture leads to reduction in Water activity Microbial activity Enzyme activity

Slices, Shredding, Powder

• Ultimately results in shelf-life extension

Reduction in density, storage space and transportation cost

Osmotic-hot air dehydration Osmotic dehydration followed by hot air drying at lower temperatures

Jack fruit slices

Amla segments (sweet and salted) Pineapple slices Mango slices Vegetables

Electromagnetic radiation assisted drying Conventional Heating H M

EMR Heating W M H

H

Case hardening

M

M

W

H = Heat, M = Mass, W = Waves

Rate of Heat and Mass transfer is more Reduces drying time Improves product quality

Near Infrared (NIR) heater Air vent NIR heat sources Material bed

• • • • •

Wavelength: 1.1-1.3 μm (max.) Power: 6 kW Max. temperature: 220⁰C Operation: Continuous/batch Heating: Top & Bottom

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INFRARED PROCESSING OF CASHEW KERNELS FOR TESTA REMOVAL – AN ALTERNATIVE TO ‘BOURMA’ DRYING RAW NUTS ROASTING SHELLING

24 h

BOURMA

DRYING PEELING ~1 h

GRADING PACKING

IR INTERMITTENT HEATING

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ADVANTAGES  Reduced processing time (80% over Bourma)  Higher yield of ‘White Wholes’ (5-6%)  No ‘Scorched kernels’(2% in Bourma)  Elimination of ‘High Cooling’ step

 Lower processing cost (20%)  Easy to scale up  Continuous process with minimum labor requirement

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COMBINED IR AND HOT AIR DRYING

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Air Vent 90.2°C

IR Heat Sources

Control Panel

Temperature Sensor Conveyor Air Heater Air Duct

Blower

SYNERGISTIC EFFECT OF HOT AIR AND INFRARED 1911

Infrared Drying Reduced drying time (43%) Higher rehydration moisture (6-7%)

Higher carotenoid retention (88%) Better cell structure

COMBINED RF AND HOT AIR DRYING

Energy efficient dryer 27.12 MHz

Higher product thickness

VEGETABLES

Self regulating system

SPICES HERBS

Ideal for finish drying

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Basil leaves

Dill greens

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MW-Convective drying

BATCH

 Reduction in drying time by ~40%  Retention in volatile oil by ~20%

 Improved color values

CONVEYORIZED 23

Solar Drying The indirect drier has three main components: external air heater drying room (or cabinet) with its trays air circulation and evacuation device with eventual recycling.

Cardamom dryers Natural Convection dryers on the filed itself Solar dryers for increased energy conservation 24

Vibro Fluidized Bed Dryer/Roaster Food Material Inlet

Hot air recirculation 70%

Food Material Outlet

Fresh air 30%

Combustion chamber LPG Flue + Fresh air

LPG Cylinders

INTEGRATED HOT AIR ROASTING MACHINE

Comparison of HSD and LPG fired ovens Description

Type of oven

Diesel

LPG

Indirect

Direct

10,300 Kcal / kg

11,642 Kcal / kg

Fuel quantity

49.5 Kgs / per ton of Food

42 Kgs/ per ton of Food

Cost of Fuel

Rs 24.50 / Kg

Rs 22.50 / Kg

Rs 1213 / per ton of Food

945 / per ton of Food

Type of Heating Gross Calorific Value

Total Fuel Cost Saving of Fuel (cost) by converting diesel-fired oven to LPG fired oven.

15.15% (22.09 %)

 Endurance test conducted with wheat, soji, greengram and jowar.  Snack foods - vermicelli, corn flakes and fryams also roasted with satisfactory results.

INFRARED ROASTING OF GROUNDNUT SEEDS Overall Liking

80 70 60 50 L 40 30 20 10 0

Texture

Flavor

12 8

TI(Min)

Appearance/ Color

4 150

160

170

180

190

200

1

2

3

4

TE(°C)

Method of roasting

Product quality Compressive Oil yield strength (%) (N)

Temp.

duration

(ºC)

(min)

-

-

4.43

68.90

47.03

Drum

180

20

1.60

57.23

Sand

180

12

1.30

IR

180

8.0

0.87

Control

Moisture

5

6

7

8

Hedonic scale

(%)

Peroxide Value (meqO2/kg)

70.45

0.34

4.90

49.98

57.45

0.67

5.88

64.13

49.57

68.00

0.46

5.15

67.50

51.68

36.50

0.38

4.98

Lightness

(% w.b)

FFA

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Spouted Bed Roasting Hopper

Chaff Separator

Control Panel

Receiver

Spouted Bed Roaster mixing  Effective Gas-Particle contact facilitating HTST process.  Enhanced aroma and flavor  On line chaff separation and dust removal  Visual display arrangements helps in roasting bean color control

Membrane Processes Classification  MF, UF, NF and RO depending on pore size & trans-membrane pressure  Plate & Frame, Tubular, Spiral wound and Hollow fiber modules.  Scale-up is easy as they are modular.  Becoming more cost effective as material is imported now.  Polymeric and ceramic membranes 30

Membrane Processes Advantages  Low temperature and low pressure process  Low energy consumption

Disadvantages  Maximum achievable concentration  Membrane fouling  Concentration polarization 31

Keishing Foundation, Management of Tribal Areas (MATA), Litan, Manipur

View of the Buildings on the site

Orange & Pineapple juice concentrates • MATA plant first in India in membrane area by CSIR-DSIR-MFPI. • MF for clarification and concentration by evaporation. • Hot filling or HTST bag-in-barrel. • RTS (Ready-to-Serve) beverages are through tetrapack.

View of the process plant

Membrane system

Vaccum Evoparator

Pineapple and Orange products

Membrane processing of black tea extracts Black tea extract

Diafiltration (150%)

 50 fold extract (45 min, 90°C) TSS - 0.61%; PP- 0.348%  Conc. extracts – 2, 5 & 10%

Retentate MF/UF

Clarified black tea extract

Undesirable – cream components

• Protein • Pectin • Minerals - Ca

Primary quality criteria Low turbidity Low tea cream Original color

Desirable - Higher Soluble solids recovery  Polyphenols recovery TF/TR Catechins

• MF • UF • VCR

Membranes - 450, 200 nm - 25, 50, 100 & 500kDa -5

Membrane processing of Honey Membrane processing Feed

Micro-filtration (MF)

- (3 Membranes)

Retentate

MF

Permeate

Ultra-filtration (UF) – (5 Membranes)

Retentate

UF

Permeate

•Commercially

sterile honey without cloudiness or sedimentation

Vacuum Concentration

Vacuum Concentration

- Beverages

•Enzyme enriched honey - Nutritional

Filtered Enzyme Enriched Honey

Ultrafiltered Honey

Scheme for Membrane Processing

OMD Plate & Frame Membrane Unit 1

5 5

2

5

1. Ball Valve 2. OMD Plate and Frame Module 3

3. Feed Reservoir

4

4. Osmotic Agent Reservoir 5. Peristaltic Pump

Concentration up to 65°Bx 38

Hurdle Technology for Extending the shelf life  Hurdle Technology for extending the shelf life for a minimum of 6 - 8 weeks using Hurdle technology

Prepared idlies/dosa/paddu Placing them in pouches

Steam flushing

 Hurdle Technology used here rely on a mild heat treatment (65-95°C) followed by storage at chilled temperature ( 4.0

Analytical grade

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as fluorescent markers food colorants (Lina blue) in cosmetics pharmaceuticals immunological aspects

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Preparation of Crude Extract

Fully grown spirulina biomass

Washed with distilled water

Homogenization

Crude Extract

Centrifugation

Spirulina cells releasing phycocyanin during homogenization 53

Betalains-Current Practice  Fermentation to remove the sugar

 Wet grinding of whole beat and spray drying  Drawbacks • Large quantity needed to get hue • Tedious process

 Differential Partitioning of Betalains and Sugars using Aqueous two Phase Extraction

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Flowchart of the downstream processing of Betalains

Fresh beet root

Wash, peel, slice and grind with acidified water

Centrifuge at 12000 rpm to remove polyphenols

PEG Recovery

Betalains

Product (concentrated)

Sugar and other components

Fresh juice subjected to ATPE

Betalains powder Lyophilization 55

Value addition to food waste Apple pomace contains 18%starch,10% pectin, 25% insoluble and 7% soluble fibre, 1400mg phenolics & 392 mg flavonoids/100g dry wt. •Development of cereal flakes & bakery products like cookies, bun and muffin. Watermelon (Citrullus lanatus) rind: Citrulline of the rind is known for its ability to remove ammonia in the human body and is essential for excretion of oxidative waste processes. •Development of Watermelon rind tit bits employing osmo-dehydration technique

Bromelain from pineapple wastes

 Meat tenderization  Pharmaceutical applications

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Low calorie RTS fruit beverages, low glycemic RTS blended vegetable beverages, value added products

Karaunda Pumpkin

Shelf life of 45-90 days

Mulberry

Value added products from custard apple

Bio-functional beverage and jelly from debittered sweet orange (Citrus sinensis)

Sweet orange juice turns bitter, even at room temperature and on heating for pasteurization it further intensifies besides development of off-flavor Bitter principles:

Naringin Limonin

Beverage and jelly from Mangosteen (Garcinia mangostana) fruit rind

- mangostin

Retention of xanthones in processed products.

SPRAY DRIED PRODUCTS

 Honey powder Application: Dry mixes Advantages: Free flowing with honey flavor and color Long shelf life (PET/FOIL/LAMINATE) Higher honey content Patent:

Spray dried honey powder (DEL/419/01)

 Mango powder  Bael Powder  Encapsulated bioactive compounds

PRODUCTS FOR CHILDREN Energy Food – Multigrain Product - High Calorie - Fortified with nutrients - Dry mix for consumption - Preparation Products High Energy Biscuits – High Calorie

Fortified Products – Minerals, Vitamins

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Traditional Indian Foods • Non homogenous nature and their variations in recipes & shapes add to problems.

• Food material processing

properties

change

during

• Many of them derive standard conditions of serving. • To be operated on small batch capacities and hence scope for mechanization is limited.

• Technology and machine should go hand in hand

development

AUTOMATIC CONTINUOUS DOSA MACHINE

• Designed and Developed at CFTRI • 400 Dosa/h • LPG based system

• More than 800 units across India

AUTOMATIC CONTINUOUS IDLI MAKING MACHINE

• Capacity : 1200 Idlis/ h • Sensor Based Automatic Deposition • Synchronized Mechanical Scooping system

• Cleaning-In-Place (CIP) System • Electronic Counter • Hygienic and untouched by human element • Final Product of Uniform Quality

CONTINUOUS CHAPTHI MAKING MACHINE • Designed and Developed at CFTRI

• 1000 Chapatis/h • LPG based system • Forming, Baking and Puffing section

CONTINUOUS VADA MAKING MACHINE

Poory Machine (600 nos/h)

Automation for Safe Food Garlic Peeling Machine (100 kg/hr)

Laddu machine (2000 nos/h)

Wet /Dry Grinder ( 50 kg/h)

Pneumatic lemon cutting machine (2500 nos/hr)

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Jilebi Making System

Leaf Cup Making System

Murukku Making Machine

ACKNOWLEDGEMENTS Dr . KSMS Raghavarao

Dr. MN Shashirekha

Dr. M Madhava Naidu

Dr. K Ramalakshmi

Dr. K Vankatesh Murthy

Research Students

Prof. Samir Brahmachary, DG CSIR Prof. Ram Rajasekharan, Director, CSIR-CFTRI

Thank you