Transcript Product/Process

PROJECT OPPORTUNITIES FOR SETTING UP OF FOOD PROCESSING
INDUSTRIES – TECHNOLOGIES FROM CFTRI
By
P.M.Badgujar
Head
CFTRI Resource Centre
MUMBAI
Central Food Technological Research Institute,
Mysore – 570 020
Model Food Chain
Agricultural Production
Processing and Manufacturing
Transport & Distribution
Food Service and
Catering establishment
Household Food
Preparations
Street Food Vending
Operations
Consumption
2
Advantage India for food processing
Abundant and large variety of farm produce due to diversified
(26 types of ) climatic conditions
Largest Livestock Population
3rd largest food producer in world
Largest producer of pulses
Leading producer consumer of milk and milk based products in world.
5th in poultry production.
Ranks Second in production of wheat, rice & groundnut and fourth in
coarse grains
Second largest producer of fruits & vegetables.
Abundant skilled & unskilled work force at cheaper cost
Leading Producer of coconut, cashewnut, ginger, turmeric & black pepper.
India confronts a situation in which the surplus
and the starvation exist together. Uneven
distribution, wastage and spoilage of food mainly
contribute to such an anomaly.
Prof. M. S. Swaminathan, Chairman, National
Commission on Farmers (India) “Having
mountains of grains on one side and hungry
millions on the other, by 2020, the demographic
divide, economic divide and the nutritional divide
will widen unless we address them with our
existing technologies.”
Lack of proper Post-harvest infrastructure &
adequate supply chain result in losses of harvested
farm produce worth approx. Rs. 30000 crores
annually in the country.
To improve farmer’s economy & save nation’s
wealth, need of the hour is to build sustainable
supply chains to link the farmer to the processing &
marketing centres and also to develop integrated
post-harvest technology & infrastructure.
FOOD PROCESSING INDUSTRY & SOCIOECONOMIC
DEVELOPMENT
High Priority Area ( Thrust Area)
Labour intensive (Employs 18 – 20% labour force) ,
offer major employment opportunity
Optimal utilization of agro resources
Highly decentralized small & Cottage scale industries Dominate,
Predominance of primary processing units
Enhancement of farmer’s economy, improvement in quality of life of
rural
Contributes to food security and price stabilization
Constraints for food industrial growth
• Raw material availability (price, suitability,
consistency )
 Higher logistics cost
 Large number of marginal farm holding
 Huge gap between farmgate price & price to
consumer (80%)
 Varietal suitability for processing & price /
yield factor.
MOFPI Vision 2015 document (2005)
targets
 Increase level of processing of perishables from 6
to 20% (3 times)
 Increase value addition from 20% to 35%
 Increase India’s share in global food market from
1.5% to 3% by 2015
Favourable market drivers for
packaged processed foods
• 1.1 billion population base with 1.6%
annual population growth, who spend over
50% income on food
• 350 million urban middle class with its
growing purchasing power
• Changing food habits (preference to
convenience, processed food)
• Growing need for convenience foods due to
urbanization
•Increasing proportion of urban working
women, growing organized retails.
•Shift on house hold expenditure on Cereals,
Pulses, edible oils, salt, sugar, spices  declined.
Milk & milk products, meat, egg & fish, fruits,
vegetables & beverages  increased
•Increased food safety and hygience
consciousness. Growing health & wellness
consciousness.
•Paradigm shift of joint families to nuclear
families .
•Emergence of wide range of innovative, safe
and reliable quality branded foods.
Product modification matching to Consumer
demands
• Products having lesser synthetic ingredients, preferably no
additives
 Foods & ingredients healthier for him
 Local flavour & taste at modest price
• Existing product modified to address lifestyle disorders
like obesity, hypertension, diabetes, heart ailments, etc
(Health & wellness based products)
Lowsugar, low fat, reduced calorie, low sodium foods
Probiotic enriched diary products & baby foods
 Products having much needed essential nutrients
 Nutritient & nutraceutical enriched food products
Examples Fruit juices/ beverages (Tropicana / Real), Sport
drink (Gatorado), Hifibre biscuits, Flaxseed biscuit (Benne
Vita)
Multigrain biscuits, Low sugar / sugarfree products
(confectionary, beverages, ice-cream)
Nutrichoice Diabetic Friendly Essentrals
XXX Energy drink Cereal bar (Horlick, Nutirbar) Mother
Horlicks, Junior Horlicks, Complan Memory, Amaze Brain
Foods
Ingredients used- Omega-3, Vitamin B1 & B 12,
antioxidants, protein ingredients, vital minerals and
phytochemicals such as Ginko bilola, brahmi extracts,
carotenoids, fibres, probiotics.
Causes of food deterioration
• decomposition by microorganisms
(bacteria, yeast and moulds)
• self-decomposition of the food (by
enzymatic biochemical reactions and
chemical reactions like oxidation)
• damage by insects, pests, rodents and other
animals, mechanical causes, etc.
METHODS OF FOOD PRESERVATION
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Reduction of water activity a)Drying and Dehydration
b)Preservation by adding sugar c) Preservation by salt
High temperature processing
Low temperature preservation (refrigerated/cold
storage)
Freezing preservation
Preservation by using chemical preservatives
Adjustment of pH/ Acidity
Oxygen removal
Preservation by hurdle technique
Radiation preservation
Packaging
PROCESSED FOOD PRODUCTS/ TECHNOLOGIES
CEREALS :
• PRIMARY PROCESSING OF FOOD GRAINS (CLEANING, GRADING,
DESTONING, POLISHING, PACKAGING),
• DRY MAIZE MILLING (GRITS, GERMS)
• WET MAIZE MILLING (STARCH & ITS DERIVATIVES)
• GRAIN FLOURS (WHEAT, JOWAR, BAJARA)
• MINI RICE MILL
• SHELF STABLE OPTIMALLY MILLED BROWN RICE
• PARBOILED RICE, QUICK COOKING RICE, CURING OF NEW
PADDY
• CEREAL FLAKES (RICE, JOWAR,
WHEAT,MAIZE,RAGI)
• RTE LOW FAT FLAKED SPICY MAIZE/CORN
SNACKS
• FLAKED JOWAR RTE LOW FAT SWEET &
SAVOURY SNACKS
• PUFFED CEREALS
• MAIZE CHIPS
• RAGI DECORTIVATION / ENZYME RICH FLOUR
• RAGI BASED MURUKKU / CHKALLI
• MULTIGRAIN BASED FORETIFIED SNACK
WHEAT MILLING / BAKERY PRODUCTS
Biscuit formulations: Salt/Sweet, Nutro, Cocoa, High Protein, Whole
wheat flour, Cardamom flavour, Onion flavour, High fiber, Wheat
germ, Sunflower grits, Low sodium, Therapeutic, Sugar free
Bread: production ( Several varieties - Brown, Plain, Sweet, Milk, Whole
Wheat, Fruit, High fiber, Ragi, Bajra, Sugar free ).
 Buns : Plain, Sweet, Fruit, High Protein
Honey based Bakery Products : Biscuit, Bread, Bun, Cake
High protein Upma Mix
Composite Ragi rusk, Sugar free rusk, High Protein rusk, Cake rusk,
Sugar free cake rusk
Bar cake, Sugar free cup cake, Eggless cake, Sugar free layer cake
South Indian Parotta
High protein ready to eat burfi
Whole wheat flour, Paustik atta , fortified atta
Shelf stable Chapati
Composite vermicelli based on millet flour
PULSES
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MINI DAL MILL
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IMPROVED DAL MILL
•
VERSATILE DAL MILL
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MODERN DAL MILL
•
GOTA SEPARATOR
•
PROCESSED BESAN FOR SEV / BOONDI
•
PAPAD (PULSES / RAGI)
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LEGUME BASED READY-TO-FRY SNACKS
•
QUICK COOKING, GERMINATED AND DEHYDRATED PULSES
•
DETOXIFICATION OF KESARI DAL
OILSEEDS / PROTEIN BASED :
• OIL (EXPELLING/ GHANI/SOLVENT EXTRATION) &
DEOILED CAKE,
• DEHULLING OF SUNFLOWER / SESAME
• HEAT RESISTANT WHITE SESAME SEEDS
• NUTRI OIL BLENDS
• LOW FAT HIGH PROTEIN SNACK FOODS
• AFLATOXIN DECONTAMINATION OF OILS
•EDIBLE GRADE OILSEED FLOURS (GROUNDNUT,
SOYABEAN)
•PROTEIN ISOLATES/HYDROLYSATES
•SOY DAL, SOYMILK, SOY CURD, SOY PANEER, SOY
NUGGETS,SOY LECITHIN, BLAND SOY PROTEIN
CONCENTRATE
•NUTRO CRISPO (SWEET AND SAVOURY )
•PEANUT BUTTER
CEREALS, PULSES, OILSEEDS
• ENERGY FOOD
• INFANT FOODS (HIGH PROTEIN, OPTIMISED 12%
PROTEIN, LACTOSE FREE
• LOW COST MALTED WEANING FOOD
• INSTANT READY MIXES (GULAMJAMUN, UPMA,
HIGH PROTEIN UPMA, IDLI, VADA, DOSA, CAKE,
EGGLESS CAKE, CHAKLI, JILEBI, MADDUR VADA,
PAKODA, PAYASAM, DOUGHNUT, MUSHROOM
SOUP, MULTIGRAIN SWEET, PUJABI HALWA,
BOMBAY HALWA, SOYA BASED SAMBAR,
FERMENTED AND DEHYDRATED READYMIX FOR
IDLI AND DOSA
•IDLI, DOSA, CHAPATI, VADA (MACHINE MADE)
•FRIED TRADITIONAL SNACK FOODS (SWEET,
SAVOURY)
•INSTANT TRADITIONAL FOODS (RASAM, SAMBAR,
PONGAL, PULIOGURE, EMLI POHA,
•PUFFED CEREALS/PULSES (FLUIDISED ROASTER)
•EXTRUDED SNACKS (READY TO EAT, READY TO
COOK, READY TO FRY, LOW FAT / LOW CALORIE)
• RTE LOW FAT SNACK LIKE CHAKLI
• LOW FAT EXPANDED SNACKS
• CEREAL BAR
• CHIKI : PLAIN, FORTIFIED
• FOOD FOR DIABITIC
FRUITS AND VEGETABLES PROCESSING
• India Second largest producer of fruits &
vegetables in the world with low levels of
current yields
• Mostly consumed fresh
• Less than 2% is processed with appropriate
raw material availability as constraint
• Farmer, the base of economy, gets much lower
returns due to too many intermediataries
between farmer and consumer
•Need to Establish farmer<-> processor
linkages
Fruit & Vegetable Processing in India
• Fresh consumption 96% Processed – 4%
• Processing, Cottage scale -70% medium
& large scales -30%.
TECHNOLOGY FOR FRESH FRUITS AND VEGETABLES
• Pre and Post Harvest Technology Protocols for Export of Fruits by
Sea
Mango – Alphonso, Banganapalli, Kesar, Neelum
Banana – Dwarf Cavendish
Pomegranate – Ganesh Variety
• Mango Ripening – Accelerated Process
• Antifungal Paste for Banana
• Wax Emulsion – Formulation and Use
• Minimally Processed Vegetables
MINIMALLY PROCESSED VEGETABLES UNDER MAP
Ash gourd
Coriander leaves
Mint leaves
Beet root
Curry leaves
Okra
Beans
Cucumber
Onion
Bitter gourd
Drumsticks
Plantain
Carrot
Field Beans
Ridge gourd
Cabbage
Fenugreek leaves
Snake gourd
Cauliflower
Green peas
Spinach leaves
Cluster beans
Green chillies
Tomato
Coccinia
Knol-khol
Turnip
FLOW DIAGRAM FOR THE PRODUCTION OF
MINIMALLY PROCESSED VEGETABLES
FRESH VEGETABLES
Sorting, Washing
Preparation (Removal of inedible portions)
Cutting (Manually or using a cutting machine)
Treatments (Minimal treatments with safe chemicals)
Surface drying (Preferably in a mechanical drier near ambient temperature)
Weighing, filling into pouches and sealing
Filling the pouches into secondary package
Cold storage
MINIMALLY PROCESSED VEGETABLES
FRUITS
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POST- HARVEST PROTOCOL (MANGO, BANANA, POMEGRNATE)
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FRUIT PULPS/JUICES AND CONCENTRATES (CHEMICALLY
PRESERVED, BOTTLED, CANNED, ASEPTICALLY BULK PACKED,
FROZEN)
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RTS FRUIT BEVERAGES (BOTTLES, TETRAPACK) : MANGO, PINEAPPLE,
GUAVA, LITCHE, CARROT, SUGARCANE, GINGER TEA, HONEY BASED,
NUTRI BEVERAGE / MIX FRUIT AND VEGETABLE, JUICE BASED
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CLARIFIED FRUIT JUICES
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SQUASHES, SYRUPS, CORDIALS, NECTARS, CRUSHES
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FRUIT CEREAL FLAKES
•
FRUIT JUICE POWDERS (MANGO, BANANA, ORANGE, LIME, AMLA,
TOMATO)
•
DEHYDRATED PRODUCTS (SUN DRIED, OVEN DRIED, VACUUM
DRIED, ACCELERATED FREEZE DRIED, OSMO-DEHYDRATED) – RAW
MANGO , GRAPES , AMLA, BER, JACK FRUIT, WHOLE LIME, CITRUS PEELS,
ONION POTATO, GREEN CHILLIES, DRUM STICK, BITTER GOURD,
CAULIFLOWER, CABBAGE, CARROT, BEANS
•JAMS, JELLIES, MARMALADES
•CANDIES & PRESERVES (AMLA, PAPAYA, GINGER,
SWALLOW ROOT CASHEW APPLE )
•PICKLES & CHUTNEYS.
•SAUCES & PASTES
•BRINE PRESERVED FRUIT PIECES (MANGO, LIME)
•FRUIT BARS & TOFFEES
•PECTIN
•PAPAIN
•POMEGRANATE / CUSTARD APPLE/ FIG/ JAMUN/AMLA
PRODUCTS
•DIPPING OIL FORMULATION FOR GRAPE DEHYDRATION
•WAX EMULSION / ANTIFUNGAL PASTE
•AMLA PASTE
•DATE SYRUP CONCENTRATE
•HONEY BASED FRUIT SPREDS
VEGETABLES:
• INSTANT PICKELS, STRAINED BABY FOOD,
• DEHYDRATED VEGETABLE (SLICES, FLAKES,
CUBES, POWDER)
• CANNED/ BOTTLED VEGETABLES (IN BRINE,
CURRIES)
• GRAVY PASTES FOR INDIAN CUISINES
• SOUP POWDERS
• CARROT JUICE BEVERAGES
• MINIMALLY PROCESSD VEGETABLES PACKED
UNDER MAP.
• READY TO EAT FOODS (MEALS) IN RETORT
POUCHES
• MUSHROOM CULTIVATION AND PROCESSING
• TOMATO PRODUCTS (PUREE, PASTE, KETCHUP,
CHUTNEY, )
• POTATO PRODUCTS (CHIPS, POWDER, FRIED
WAFERS)
FLOW DIAGRAM FOR THE PRODUCTION OF FRUIT JUICES
FRESH JUICE
pH adjustment
Heating to 900c
Filling into clean, sterilized hot bottles
Sterilized crown corks
Crown corking
Pasteurization at 850 C for 25 to 30 minutes
Air cooling, packing & storage
BOTTLED FRUIT JUICES
FLOW DIAGRAM FOR THE PRODUCTION OF
RTS BEVERAGE, SQUASHES, SYRUPS AND CORDIALS
FRUIT JUICE
Mixing with sugar syrup, citric acid, essence &
colour
Mixing with sugar syrup, citric acid, essence
colour and preservative
Homogenization
Filling into 750 ml
bottles
Heating to 87 C, filling into
sterilized hot bottles (200 ml)
R. O. Sealing
Crown corking
SQUASHES, SYRUP &
CORDIALS
Pasteurization at 85 C for 25-30
min
Cooling
RTS BEVERAGES
READY –TO-SERVE BANANA BEVERAGE
CLARIFIED BANANA JUICE/ JUICE CONCENTRAE
SUGAR SYRUP ADDITION
COLOUR + FLAVOUR ADDITION
MIXING / BLENDING
HOMOGENIZATION
FILLING IN CLEAN BOTTLES AND CAPPING
PROCESSING IN BOILING WATER
COOLING AND STORAGE
CAPACITY OF SUGGESTED UNIT :
5000 BOTTLES(200ML) /DAY
TOTAL PROJECT COST : Rs. 25 LAKHS
LIQUID FRUITS (CLARIFIED FRUIT
JUICE)
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Substitute fro synthetic soft drinks.
Pulpy fruits like Banana, Guava etc. can be processed
Banana
Washing & Peeling
Cutting & Pulping
Heating
Partial cooling
Enzyme treatment
Filtering
Hot filling into bottles
Pasteurization
* Optional – Concentration to 70oBrix
CAPACITY OF SUGGESTED UNIT : 300 KG/DAY
TOTAL PROJECT COST : Rs.15.75 LAKHS
ASEPTICALLY PACKED BANANA PULP
RIPENING BANANA FRUIT
RIPE AND SOUND BANANA
WASHING & PEELING
PULPING
HOMOGENIZATION
DESEEDING
DEAERATION
PASTEURIZATION
COOLING
ASEPTIC FILLING
STORAGE
CAPACITY OF SUGGESTED UNIT : 3 MT BANANA / HOUR
TOTAL PROJECT COST : Rs.1011 LAKHS
FROZEN BANANA PULP / CLARIFIED JUICE / CONCENTRATE
RIPE BANANA FRUITS
WASHING & PEELING
PULP / JUICE EXTRACTION
STANDARDIZATION AND HEATING (PASTEURIZATION)
FILLING IN PE BAGS IN VERTICAL POCKETS
MULTI-PLATE CONTACT FREEZING AT -32o C
FROZEN STORE (-28o C)
CONTAINER PACKAGING
TRANSPORTATION IN REFRIGERATED CONTAINER
DISTRIBUTION IN COLD CHAIN
CAPACITY OF SUGGESTED UNIT :
30 MT BANANA / DAY
TOTAL PROJECT COST : Rs.633 LAKHS
INDIVIDUALLY QUICK FROZEN OF IQF
BANANA SLICES
RIPE BANANA
WASHING & PEELING
SLICING
IQF FREEZING AT -32o C
FROZEN STORAGE
CONTAINER PACKING
TRANSPORTATION IN REFRIGERATED CONTAINER
DISTRIBUTION IN COLD CHAIN
Dehydration of Fruits & Vegetables
FRESH FRUIT /VEGETABLE
Sorting & Washing (manual / mechanical)
Preparation(manual or mechanical)
Blanching
(for vegetables)
Treatments
Dehydration
Packing
DEHYDRATED PRODUCT
SPRAY-DRIED / DRUM –DRIED / VACUUM SHELF
–DRIED BANNANA POWDER
BANANA PULP
MIXING WITH FUNCTIONAL ADDITIVES
HOMOGENIZATION
SPRAY DRYING / DRUM DRYING / VACUUM SHELF DRYING
SIZE REDUCTION AND SCREENING
DEHYDRATED BANANA POWDER
PACKAGING AND STORAGE
CAPACITY OF SUGGESTED UNIT :
1 MT PRODUCT /DAY
TOTAL PROJECT COST : Rs.389 LAKHS
FRUIT BARS
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Nutritious and ready to eat product with good shelf life
Marketed as confectionery items
Banana
Washing & Peeling
Cutting & Pulping
Mixing with other ingredients
Heating pulp
Partial cooling and addition of preservative
Spreading in trays
Drying & Cutting
Packing & storage
CAPACITY OF SUGGESTED UNIT : 250 KG/DAY
TOTAL PROJECT COST : Rs.25 LAKHS
DEHYDRATED WHOLE LIME
Lime Fruit
Washing
Pre-treatment
Dehydration
Dehydrated whole lime
Packaging & Storage
Capacity : 10 MT lime/day
Project Cost : Rs. 45 lakh
SPICES & PALANTATION CROPS
• SPICE POWDERS (CHILLI, TURMERIC, CORIANDER)
• SPICE OILS(PEPPER, GINGER, CARDOMOM)
• SPICE OLEORESINS (PEPPER, GINGER, TURMERIC,
CHILLIES)
• GRAVY PASTE FOR DIFFERENT INDIAN CUISINE
• CASHEW APPLE CANDY
• TAMARIND PRODUCTS (PULP, PASTE, JUICE
CONCENTRATE, POWDER, KERNEL POWDER,
CANDY, GREEN TAMARIND SPICE MIX )
•GINGER PRODUCT (DRIED GINGER, CANDY & PRESERVE)
•SUGARCANE –BOTTLED JUICE / SPREAD BIOPRESERVATION OF RTE SUGARCANE CHUNKS
•NEERA BOTTLING
•COMPOUNDED ASAFOETIDA
•ENCAPSULATED FLAVOURS
•NATURAL FOOD COLOURS (BEET ROOT, SAFFLOWER,
KOKUM, GRAPES, ANNATO, CHILLI, TURMERIC)
•SPICE MIX FORMULATIONS (SAMBAR, RASAM, PULAO)
•INSTANT GRAVY MIXES – DEHYDRATED/PASTES
•SPICE PASTES (GINGER, GARLIC)
•GARLIC- FLAKES, POWDER, PICKLE, OIL.
•CORIANDER DAL
•DESICCATED COCONUT
• COCONUT SPREAD AND COCONUT DIETARY FIBER
• VIRGIN COCONUT OIL
• VALUE ADDED COCONUT PRODUCTS : INSTANT
ADJUNCT MIX, INSTANT FILLING MIX, COCONUT
RICE MIX, COCONUT BITES
•CASHEW PROCESSING- FRIED & FLAVOURED NUTS /
SPREAD
TECHNOLOGIES FOR MEAT, FISH AND POULTRY
Pork
- Ham, Becan, sausage, pickle, dehydrated, canned
Sheep / Goat - Sausages, kabab, pickle, frozen curry, canned, sap
cube, sausage casing , Meat Burger, Meat wafers,
Beef
- Sausage, corned beef
Fish
- Wafer, sausage, frozen curry, marinated paste, pickle
Poultry
- Dressed chicken, curried, kabab, pickle, chicken wafer,
shelf stable biriyani, kabab mix & titbits, marinated
tandoori sausage, sandwich spread, soup mix, frozen
curry, soup cube, egg loaf,
Instant Gravy Mixes ( Dehydrated) - Multi purpose gravy, Biriyani,
Tandoori, Kabab, Meat preparations fish preparations
FOOD BIOTECHNOLOGY EMERGING AREAS
• Production of Natural colourants from plant sources
• Spirulina production for health foods & pharmaceuticals.
• Production of Phycocyanin from Spirulina Spp.
• Production of Xanthan gum
• Cultivation Botryococcus Braunii, Dunaliella (β carotene rich algae)
• Clarification of fruit juices through microbial enzymes
• Low lactose infant food
• Detection kits- Pesticides, Aflatoxins
• Biogas generation using fruit and vegetable wastes
• Biosensors- Glucose, Sucrose, Lactic acid, Pesticides, Tea
• Alcohol (banana, cashew apple, mahua, grapes, tapioca )
• Enzymes – pectinase,amylase,amyloglucosidase,phytase
• Vinegar generation
• Production of Fructooligosacharides (syrup & powder)
FOOD MACHINENARY DESIGNS
Indigenous machinery for traditional foods : Idli, Dosa, Vada,
Chapati, Papad, Jilebi
Combined IR and hot air heating system for food processing
Forming and frying machine for foods
Roaster : vibro fluidised bed, hot air
Devise for pneumatic dough extrusion & cutting of dough into Geometric shape
Leaf cup and plate making machine
Laddu molding machine (Besan, Rawa & Similar )
Sheeting and cutting device for chikki and similar products
Hand operated lemon cutting device
Dry maize milling plant
Infrared heating of Cashew kernels for testa removal
Hot air popping machine
Sugarcane deskinng machine
Sugarcane juice extractor
Shitting and cutting device for chikki and similar products
CONTINUOUS CHAPATI MAKING MACHINE - DESIGN
FROM CFTRI
•
Chapati or Roti is a popular traditional food in the Indian diet.
•
The developed machine which can cater to the large requirement
of chapatis in a short span of time.
Capacity
:
600 - 800 Chapathi’s/hr
LPG Consumption
:
3Kg/Hr
Power
:
7.5 HP
Size of Chapati
:
160mmdia/1.5 thickness
Machine dimension
:
6Mx1Mx2M
AUTOMATIC IDLI MAKING MACHINE - DESIGN FROM
CFTRI
•
CFTRI, Mysore has developed an
automatic continuous idli making machine
with a capacity to produce 1200 idlis per
our. The machine is the first of its kind. It
can continuously produce ready to eat /
serve idlis, untouched by hand
CONTINUOUS DOSA MAKING MACHINE - DESIGN
FROM CFTRI
All operations in the Dosa making from batter dispersion, depositing and
spreading on the hot plate to toasting /
roasting & oil application are
organized in a systematic way. At the
end of the pre-determined residence
time, the hot Dosas are rolled and
discharged.
Capacity : 400 Dosas per hour
Food
Material
Inlet
Hot air
recirculation 70%
Food
Material
Outlet
Fresh air
30%
Combustion chamber
LPG Flue + Fresh air
LPG
Cylinders
 Wheat,
soji,
greengram and jowar
as well as Snack foods
( vermicelli, corn
flakes and fryams)
roasted
with
satisfactory results.
INTEGRATED
HOT AIR
ROASTING
MACHINE
Automatic Continuous Urd Vada Making Machine
SPOUTED BED ROASTER
Chaff Separator
Hopper
Hopper
Blower
Feeding
Blower
Conveyor
Roasting
Chamber
Conveyor
Receiver
Control
Panel
COMBINED INFRARED AND HOT AIR HEATING SYSTEM
Product/Process:
Machine for dehydration of fruits
And vegetables.
Process/Technology:
The conventional drying systems are either batch type or energy
intensive systems. The combined infrared and hot air heating system
utilizes the synergistic effect of electromagnetic radiation and hot air
for the dehydration of vegetables. The conveyorized system could be
used for continuous operation. The versatile system could be used for
the other thermal processes such as blanching and roasting with
suitable minor modifications in the system. The prototype has a
capacity of 15 kg/h of raw vegetables.
Approximate price per machine: Rs. 15 lakh (400 kg/h of raw material)
CIRCULAR LEMON CUTTING MACHINE
Product/Process:
Machine for cutting of lemons
in to four pieces.
Process/Technology:
Washed lemons are transferred into the tray of the lemon cutting machine. The
lemons flow into the pockets of the centralizing disc due to the gradient of the inlet
chute. The centralizing disc carry/move the lemon against the cutter. The whole
lemon is cut into four pieces when the centralizing disc carrying the whole lemon
moves against the cutter. The lemons cut to four pieces are dropped on to the outlet
chute, when the centralizing disc moves away from the cutter. The outlet chute will
discharge the cut lemon into the tray/vessel. A geared motor drives the centralizing
disc.
Approximate price per machine: Rs 25,000/-
Other process control tools
Pest control programme is one of the important activities in the entire
production and process as pests pose a threat to the entire system, right
from incoming raw material to storage of finished goods.
Installation of fire-control and alarm systems & periodic inspection and
maintenance thereof.
Aircurtains maintain the constant interior temp of cold room chambers /
icecream chambers These high-velocity airflow air curtain block entry of hot
air, insects, dust, dirt, fumes by creating invisible curtain of high pressure air
when the doors are open.
Metal detection and seperation systems
CIP (Clean-in Process) systems
ORGANIC FOODS
Organic foods (Product of farming system avoids
use of man made fertilizer, pesticides, growth
promotor) it relies. After 3 yrs such treatment, first
produce is ‘Organic’.
‘Organic’ product – Min 95% organic agri
ingredients. e.g. Corn flake
Made with organic ingredients –Min. 70% Organic
agri. Ingredients e.g. ketchup, grape wine
Selection criteria for food
packaging system :
 Packing requirements of food product
 Barrier, strength and product
compatibility properties of packaging
system
 Intended shelf-life
 Cost
Package forms
Metal
Glass
Plastic
Wood
Paper
Flexible
Semi-rigid
Rigid
Different
forms
Al-Foils
Composites
Laminates
Coextruded films
Coatings
Primary
Secondary
Tertiary
•
Retailer’s margin 15% in India against 2% in
US
•
Wholesaler’s margin 15% in India against 4%
in US
•
10% processed F&V consumed by 70% of
population (rural/small towns);
60% by 4 metropolitan cities and
30% in state capitals and other big cities.
• Good scope for processing units both for local
markets and export
Marketing Pattern of Processed
Fruit & Vegetable Products in
India
Sector
 Institutional
 House holds &
housewives
 Export
Market Share
(Value based)
40%
40%
20%
Food Issues
Sensory,
Physical,
Kinesthetic
and Other
dimensions
Quality
Safety
Nutrition
Microbiology,
Additives,
Contaminants,
Toxins,
Environmental pollutants,
Adulterants
Macro&
micro- nutrients
67
FOOD SAFETY is an important issue
globally. Food manufacture needs to
assure safe & quality food at
affordable & competitive price to the
consumer. Food safety & quality
encompasses the entire food chain
starting from farm products on to
processing transportation &
distribution, till consumption.
FOOD STANDARDS
A. Safety Standards
B. Quality Standards
A - Gives protection to health of consumers
Minimum quality requirements as laid down under
“Prevention of Food Adulteration Act, 1954 and Rules
thereof, 1955”.- This will be replaced by Food Safety &
Standards Act shortly.
* Mandatory
B - To improve the quality at the manufactures level
and encourage the food industry BIS, Agmark, FPO
etc.,
* Voluntary
69
Nutrition Information Panel
Nutrition Facts:
Mandatory
components
(underlined)
and
voluntary components – to be declared in the
following order:
 Total calories
 Calories from fat
 Total fat
 Saturated fat
 Transfat
 Cholesterol
 Sodium
 Potassium
Conti…
70
Contd…
 Carbohydrates
 Dietary fibre
 Sugars
 Protein
 Vitamin A
Percent of Vitamin A as Beta-carotene
 Vitamin C
 Calcium
 Iron
 Other vitamins and minerals
71
Govt. Support through various promotional
agencies.
-
Capital Investment subsidy
R&D Support
Quality Control Support
Market development assistant
Export incentives
Establishment of Food Parks, Food Clusters, Agri
Export Zone
- Cold Chain Incentive Schemes
- Storage infrastructure
TECHNOLOGY TRANSFER FROM CFTRI
Identification of the CFTRI technology by the entrepreneurs
Payment of premium to CFTRI by the entrepreneurs
(remittance by DD favouring Director, CFTRI, Mysore.
Signing of License Agreement
Technical dossier to the Licensee
Demonstration of process know-how, at CFTRI, Mysore
Participation of two authorized representatives in the
demonstration-cum- training
One to one discussion with the concerned faculty and
quality control procedure
USER ORIENTED SERVICES OF CFTRI
• Analytical and Quality Control for Food Industries
• Industrial Consultancy to Industries
• Contract Research for Product Development and TroubleShooting in Food Processing Sectors
• Sensory Assessment and Consumer Acceptance Studies
• Packaging Materials Testing & Food Packaging Assistance
• Need Based Bibliography in Food Science and Technology
• D P R for Establishing Food Industry/Food clustres
• HRD & Training
Analytical Capabilities
• Physico-chemical and microbiological analysis of processed and
primary foods as per FPO,PFA, BIS, AGMARK, FDA-USA and
Codex specification/ guidelines
• Nutrition facts (FDA, Codex, EEU, ICMR/DGHS)
• Additives (Preservatives,colours, sweetners, antioxidants)
• Food Contaminants (Toxic metals, Pesticide residues, Mycotoxins)
• Vitamins and Minerals
• Sensory Analysis (quantitative descriptive analysis, product
positioning) odour porfile, texture profile)
• Microbiological analysis
• Packaging materials(incl. migration tests for food grade nature)
• Shelf-life studies
Mail
:
Head
CFTRI Resource Centre
Bhavan’s College
Campus, Andheri (W)
Mumbai – 400 058
Telephone
:
022 - 26231599
Fax
:
022 – 26231599
E-mail
:
[email protected]
Web Site
:
www.CFTRI.com
Head Quarter
:
CFTRI, Mysore – 570 020
Director
Telephone
:
0821 -2514534 / 2515101
Fax
:
0821 - 2515453
E-mail
:
[email protected]
P. M. BADGUJAR
CFTRI Resource Centre
Bhavan’s College Campus,
Andheri (West), Mumbai
Mobile No: 9821118996
E-Mail: [email protected] ;[email protected]