Transcript CENTRE OF EXCELLENCE on Sorghum Report- NFSM on Coarse Cereals- Hyderabad(AP)
Annual Report 2015-16 Centre of Excellence (CoE) on Sorghum Dr B Dayakar Rao, PI & Team ICAR- Indian institute of Millets Research
Rajendranagar, Hyderabad 500 030
www.millets.res.in
Centre of Excellence on sorghum @ IIMR
INNER VIEW
Objectives of CoE on Sorghum
1.
To strengthen post-harvest entrepreneurship development
training programmes for stakeholders
2.
To facilitate Linkages between producers, entrepreneurs with consumer markets
& major private players for large scale commercialization
3.
Creation of awareness on nutritional superiority of sorghum based value
added multi grain products
4.
To develop novel value added traditional, non-traditional, RTE/
convenient foods & enhance shelf life of the sorghum products
Entrepreneurship Development
Training programs: Title: Empowering stakeholders through value-added processing & commercialization of sorghum/millets technologies
•
Duration: 2 Days × 4 trainings
•
Each batch consisted of 50 trainees
•
Trainees profession: entrepreneurs, prospective farmers, NGOs, KVKs and government servants etc.
States and date of trainings:
1.
2.
Tamil Nadu : 11 & 12 th August 2015 Maharashtra: 22 & 23 rd September 2015 3.
Andhra Pradesh and Telangana: 13 &14 th October 2015 4. Karnataka: 10 -11 th March, 2016
Participants in two days entrepreneurship training program @ IIMR
Upgradation of Skills - Tie up with private entrepreneurs
Version 1 Version 2 Version 3 Jowar Roti-making machines
Jointly developed in association with private entrepreneur
Features Operation by Space Required Capacity Version 1
Foot More 40 rotis/hr
Version 2
Hand Less 50-60 rotis/hr
Version 3
Hand Less
Version 4 Version 4
Hand Very less 80-100 rotis/hr 50-60 rotis/hr
Speed Cost
Low d (150 rpm) Rs 25 K medium (200 rpm) Rs 12 K High (250 rpm) Rs 10 K Medium (200 rpm) Rs 7 K
Commercialization of value added products
• • • Entered three MoU’s M/s Azure Edge Ventures – Nutri Bee for the technology licensing of gun puff sorghum M/s
e Fresh
M/s Harsha Agri Bio Park for technology licensing of
Idli Rawa
• • • • • Revenue generated from commercialization: Total SKU (Stock Keeping Unit): 15590 SKUs Total Quantity (Kg): 108.81 quintals Value: Rs. 5 lakhs License Fee from two MoUs: Rs. 1.5 lakhs Total revenue generated: Rs 6.5 lakhs
Launching of novel eatrite products
• Three products were commercially launched by Dr T. Mohapatra, DG, ICAR at IIRR • • • Jowar Instant Upma mix Jowar Instant Pongal mix & Millet Rawa
Industrial Interface meet @ CoE on Sorghum
• • • • Organized by CoE on Sorghum at IIMR, Hyderabad on 20th Feb. 2016 Showcasing of value added technologies developed by CoEs on Coarse Cereals under DAC.
Participated by important dignitaries, scientists, scholars, entrepreneurs and other stakeholders (50) from all over the country.
Exhibitions stalls were put up by Centres of Excellence of various coarse cereals and other
entrepreneurs Exhibition inaugurated by Shri D.P. Malik @ Industrial Interface Meet Mr. Amitabh Tewari, GM- Parle Agro Ragi Malt Vending machine
Industrial Interface meet
@ CoE on Sorghum • • • • • •
IIMR – address R&D issues jointly with the industry in enhancing shelf life Private players - Parle, ITC foods and Bambino industries has vowed to launch few millets products
Private players to work in close collaboration with IIMR and other CoE's
DAC - agreed to increase their efforts in popularizing various value added sorghum/millet commodities
Incubation facility development - at IIMR in one year time for handholding them.
Small millets Milling unit will be devised with the help CIAE
and private entrepreneurs
One day Consultative meet on enhancing sorghum exports
@ Pune
“Enhancing utilization of sorghum for export opportunities” 30th July 2015 • • 50 stakeholders participated Enhancing supply chain to promote export-ready cultivars. • Enhancing Industry competitiveness by technology transfer Market Development: • Commodity based campaigning for industries, • promotion and publicity, • branding consultancy and retailing to be addressed
Eatrite sales outlet @ IIMR
Inaugurated by Dr. J.S. Sandhu, DDG (Crop Science) on 6 th August 2015
7.5 tons of Eatrite products supplied to Future Retail Limited (Big Bazaar)
Popularization- Organized Eatrite stall
• Put up sorghum product stalls in following Exhibitions • At Farmer’s day at IIOR & IIRR Hyderabad on 12 th Sept. 2015 and 7 th Nov 2015.
• At HICC, Novotel complex, Madhapur , Hyderabad on 27 th -29 th Oct. 2015 for National seed congress.
• At Golden Jubilee celebration of IIRR, Hyderabad on 5 th Dec. 2015 • • • At National Seminar held at NAARM on 13-14 Dec. 2015 Organic Millet Fest 2015 at Nellore Millet Fest, 2016 at Guntur sponsored by DAC • • At Krishi Unnati Mela, IARI , Delhi from 19 to 21 st Consultative meeting at VAMNICOM, Pune on 30 Mar. 2016.
th July 2015 • Institutional Visits- Through mobile van to NAARM, IIRR and IIOR and more than 30 Road Shows
Dr T. Mohapatra, DG, ICAR and Shri Radhe Mohan Singh, Union Agril minister @ Krishi unnati Mela 2016 Eatrite stall @ Golden Jubilee celebration of IIRR
Exhibitions, Fairs & Road Sh
ows
At Millet Festival 2016 @ Guntur
Exhibitions, Fairs & Road Sh
ows contd..
Eatrite stall @ National Seminar - NAARM Eatrite stall @ Millet Fest 2015 - Hyderabad Eatrite stall @ Krishi Unnati Mela 2016 - IARI Eatrite stall @ VAMNICOM, Pune Eatrite stall @ Millet Festival 2016 - Nellore
Millet Rath-
activities Fabricated mobile van for promotional
Latest Version
Popularization through Media (Newspaper)
Awareness & sensitization
• • • •
Stream of visitors COE Dr. T. Mohopatra, DG, ICAR Renuka Chowdary, Ex-MP Ibrahim El Dukan DG, ARC Sudan International and National Students
• Brought out a special technical bulletin on Nutritional and Health benefits of Millets
• Brought out a technical bulletin on New Technologies on Millet Value added Foods developed @ CoE on sorghum
Novel recipes and other products
Various products developed from Sorghum Products Traditional products Milling products Extruded products Baked products
Novel recipes - Traditional Products
• Recipes of Sorghum Bhakarwadi, Sorghum Boondi Laddu, Sorghum Samosa, Sorghum Parboiled Wada, Sorghum Pancake and Sorghum based Sharbat were developed.
Sorghum
Boondi Laddu
Sorghum
Bhakarwadi
Sorghum Pancake Sorghum Based
Sharbat
Novel recipes - Traditional Products Contd..
Sorghum
Samosa
• • • • • • Pure sorghum indigenous traditional foods are fiber rich Beneficial for all age groups.
Easy to prepare Have high organoleptic acceptability Rich in magnesium, zinc, iron, dietary fiber and protein Utility as breakfast food and evening snacks Sorghum Parboiled
Wada
Enhancing shelf life of suji through pre-processing of Sorghum grain
• • • • •
Developed and standardized of pre-processed sorghum grain (soaked, roasted and pulverized)
Pre-processed sorghum grain took less time for cooking and Grain was separated after cooking Resulted in improvement of end product textural properties.
Semolina made from pre-processed sorghum can be used to make Khichidi, upma and idli. Fine Semolina
Cooking quality of the preprocessed grain S.No
1 2
Rawa Grain type weight (g)
Whole Sorghum grain Pre processed Sorghum grain 50 50
Water absorption (ml)
400 300
Cooking time (min) End product weight after cooking of grain (per 100 g)
25 20 233 246
Observation
Sticky texture Separated grain
Enhancing shelf life of suji through pre-processing of Sorghum grain contd..
• • • Semolina made from pre- processed sorghum was packed in MET pouches at ambient conditions Highly nutritious and renders good shelf life.
Shelf life was up to five months for all three semolina 0 15 45 60 75 90 105 120 135 150 165
Shelf life analysis of semolina from pre-processed grain Fine Semolina Medium Semolina Coarse Semolina Days Water activity
0.211
0.254
0.259
0.334
0.346
0.362
0.377
0.412
0.435
0.548
0.644
Alcoholic acidity Water activity
0.031
0.032
0.041
0.042
0.053
0.064
0.079
0.083
0.088
0.115
0.174
0.202
0.214
0.229
0.325
0.336
0.349
0.369
0.425
0.468
0.564
0.687
Alcoholic acidity Water activity
0.032
0.039
0.044
0.045
0.057
0.069
0.076
0.079
0.086
0.107
0.125
0.221
0.216
0.252
0.322
0.358
0.371
0.387
0.453
0.474
0.586
0.621
Alcoholic acidity
0.031
0.036
0.043
0.045
0.051
0.067
0.074
0.084
0.089
0.113
0.134
Medium Semolina Coarse Semolina
Development and standardization of sorghum based Extruded Snacks (RTE)
Extruded Snacks
• Prepared using twin screw hot extruder and extruded through a round die.
• Variants available masala coated, chocolate or essence based • Utility as breakfast cereals and evening snacks Sorghum Semolina (Rice: Ragi: Wheat: Corn - Flour) Conditioning Extrusion and Cutting Water Drying Extruded Snacks Packaging
Process flow chart for production of ready-to-eat (Extruded snacks) products
Extruded Snacks Hot Extruder
Trials for standardization of sorghum based Extruded Snacks (RTE)
• • RTE extruded snacks Formulations with blends based on sorghum in different proportions were developed The parameter of screw frequency - 32 Hz constant and temperature was changed,
No. Of Trials TRIAL 1 TRIAL 2 Ingredients
Corn Flour Rice Flour Wheat Flour Sugar Flour Salt Water Corn Flour Rice Flour Wheat Flour Salt Water
%
59.00
10.00
25.00
4.00
1.50
10.00
70.00
10.00
18.00
1.20
10.00
In g/ml Heater Zone
2360 g HEATER 3 400 g HEATER 4 1000 g 160 g 60 g 400 ml 2800 g 400 g 720 g 48 g 400 ml HEATER 3 HEATER 4
Heater temperature
120 0 C 140 0 C 140 180 0 0 C C
Result
Conducted trial without sorghum flour to test the suitability of other flour combination for extruded product Increased composition of corn and heater temperature obtained better quality snacks
Sorghum based Extruded Snacks (RTE) contd..
No. Of Trials TRIAL 3 TRIAL 4 Ingredients
Corn Flour Rice Flour Sorghum Flour Wheat Flour Salt Water Corn Flour Rice Flour Sorghum Flour Wheat Flour Salt Water
%
54.00
10.00
25.00
10.00
1.00
10.00
40.00
10.00
40.00
9.00
1.00
12.00
In g/ml
1080 g 200 g
Heater Zone
HEATER 3 HEATER 4
Heater temperature
140 180 0 0 C C 500 g 200 g 20 g 200 ml 800 g 200 g HEATER 3 HEATER 4 140 180 0 0 C C
Result
Incorporated sorghum flour reduced corn percent from recipe obtained more tasty product 800 g 180 g 20 g 240 ml The product obtained was having good texture and crunchy
Sorghum based Extruded Snacks (RTE) contd..
No. Of Trials TRIAL 5 TRIAL 6 Ingredients
Corn flour Rice flour Jowar rawa Wheat flour salt Chana dal flour Jowar Rawa Ragi Corn Flour Rice Flour Wheat Flour Salt Baking Powder
%
22.72
13.6
45.45
7.72
1.36
9 50 22 15 5 5 1.5
1.5
In g/ml
500g 300g 1000g 170g 30g 200g 1100g 484g 330g 110g 110g 33g 33g
Heater Zone
HEATER 3 HEATER 4 heater 3 heater 4 Water 13 264ml The trial 6 was found to be of best quality 125 155
Heater temperature Result
The product with this combination was having best quality in terms of taste and texture.
120°C 150°C The product with this combination was crispy and was having best quality in terms of taste and texture.
Sorghum based Extruded Snacks (RTE) contd..
10 11 12 13 1 2 3 4 8 9 5 6 7
• • • It was found that formulation requires moisture addition of minimum 12%. Fine semolina was found suitable for extruder snacks Shelf life was of sixth months.
Shelf life analysis for sorghum hot extruded snacks (per 100g) S.No
Days
15 30 45 60 75 90 105 120 135 150 165 180 195
Moisture content (%)
7.43
6.91
6.91
6.21
7.21
6.23
7.43
6.91
6.91
6.12
7.71
7.53
7.56
Water activity Alcoholic (aw) acidity
0.211
0.214
0.219
0.224
0.329
0.330
0.435
0.454
0.559
0.664
0.666
0.686
0.687
0.041
0.041
0.041
0.042
0.042
0.042
0.045
0.045
0.061
0.094
0.095
0.105
0.119
Nutrient composition for sorghum hot extruded snacks (per 100g) Nutrient Energy(Kcal) Protein (g) Fat (g) Dietary fibre (g) Quantity
356 12.9
4.08
12.88
Masala Coated Extruded Snacks
Development and standardization of sorghum based Extruded Flakes (RTE)
Extruded Flakes
• Prepared using twin screw hot extruder • Round die and flattened in a roller flaker • Variants available masala coated, chocolate or essence based • Utility as breakfast cereals and evening snacks Sorghum Semolina (Rice: Wheat: Corn - Flour) Conditioning Water Extrusion Roller flaker machine Extruded flakes Packaging
Process flow chart for production of ready-to-eat (Extruded flakes) products
Extruded Flakes Hot Extruder Roller Flaker
Standardization of sorghum based Extruded Flakes (RTE) Contd..
Formulations for preparation of Sorghum rich Extruded flakes
• • • T3 blend - best quality in terms of taste and texture. The extrudates are - dried & coated with essence or spice mix. T3 blend gave higher yield of 78% at 20 Hz screw frequency.
Ingredients / Blends T1 (Control) T2 T3 T4 T5 *T6 *T7 Sorghum Idli rawa (%)
55 60 80 82 84 91 97
Corn flour (%)
27 27 8.5
6.5
4.5
4.5
1.5
Rice Flour (%)
11.5
6.5
5 5 5 3
Wheat Flour (%)
5 5 5 5 5 0
Salt (%)
1.5
1.5
1.5
1.5
1.5
1.5
1.5
*
Blends did not give desired flakes product
Standardisation of extruder screw frequency Trial No 11 12 13 14 15 1 2 3 4 5 6 7 8 9 10 Blends
T1 (Control) T2 T3 T4 T5
Extruder
Screw Frequency (Hz) 12 18 20 12 18 20 12 18 20 12 18 20 12 18 20
Roller flaker
Flakes (%) 87 88 88 65 66 71 62 65 78 71 76 84 65 79 85 Un flaked (%) 13 12 12 35 34 29 38 35 22 29 24 16 35 21 15
Chocolate flavored Extruded Flakes Water (%)
15 15 15 15 15 15 15
Sorghum based Extruded Flakes (RTE) contd..
• • • • It was found that formulation requires moisture addition of 15%. Rich in protein and dietary fibre Fine semolina of sorghum found suitable for extruder flakes. Shelf life is six months
Nutrient composition for sorghum hot extruded snacks (per 100g) Shelf life analysis for sorghum hot extruded flakes (per 100g) S.No
8 9 10 11 12 13 5 6 7 1 2 3 4 Days
15 30 45 60 75 90 105 120 135 150 165 180 195
Moisture content (%)
6.12
6.23
6.43
6.68
7.11
7.12
7.34
7.54
7.56
7.57
7.86
7.89
7.91
Water activity (aw)
0.2011
0.2056
0.2088
0.2103
0.2256
0.2285
0.2355
0.3377
0.3544
0.4561
0.5382
0.6181
0.6322
Alcoholic acidity
0.032
0.038
0.042
0.042
0.042
0.042
0.042
0.042
0.048
0.063
0.085
0.108
0.112
Nutrient Energy(Kcal) Protein (g) Fat (g) Dietary fibre (g) Quantity
356 13.90
1.40
14.88
Optimization conditions for sorghum puffs production using puff gun machine
• • • •
Sorghum Puffs
Prepared using gun puffing machine The M 35-1 yields highest percentage of puffs (70%) at 21% moisture Variants available masala coated Utility as inflight and evening snacks Whole Sorghum Grading Dehulling Dehulled grain Conditioning Gun puffing Sorghum puffs
Process flow chart for production of Sorghum puffs
Development trails of Sorghum Puffs Trial no.
1 2 3 4 5 Moisture (%)
16 18 21 25 27
Pressure (M. Pa)
0.8
0.8
0.7
0.7
0.7
Puffs (%)
35 38 70 42 24
Pops (%)
35 40 20 21 23
Un-puffed grain (%)
30 22 10 37 53
Sorghum Puffs
Trials for standardization of sorghum puffs contd..
• • • • Parboiled Sorghum grain yielded the least and dehulled highest amount of puffs. Addition of 1% salt to the grain during conditioning improved yield The puffs are rich in dietary fibre The shelf life was found to be 3 months .
Nutrient composition for sorghum puffs (per 100g) S. No 01 02 03 04 05 06 Parameters
Protein (%) Fat (%) Dietary fibre (g) Ash (%) Carbohydrates (g) Energy (Kcal)
Sorghum Puffs
11.9
3.02
13.88
1.6
64.6
333.18
Trial No Shelf life analysis for sorghum puffs (per 100g) Days 0 15 45 60 75 90 105 Water activity
0.231
0.254
0.259
0.264
0.266
0.2864
0.2975
Alcoholic acidity
0.04
0.04
0.06
0.09
0.105
0.112
0.129
1 2 3 4 5 Masala Sorghum Puffs Standardization trails of Sorghum Puffs for increase in recovery
Grain
Treatments
Moisture (%)
Popping (%) Expansio n ratio Coefficient of Expansion
Native Sorghum Decorticated Sorghum Decorticated Sorghum (1% salt) Parboiled decorticated Sorghum Parboiled Sorghum 21 21 20 21 21 12.31
63.54
99.33
60.22
38.51
1.2
6.36
7.69
5.1
3 2.1
8.3
10 5.6
3.3
Development and standardization of sorghum based composite base for Pizza
• • • Sorghum based pizza base T5 formulation was highly acceptable Packed in HDPE pouches at ambient conditions Shelf life of 5 days
Formulations of Sorghum composite pizza Ingredients / Blends Control T1 T2 T3 T4 T5 *T6 Sorghum flour (%)
0 10 20 30 40 50 60
Fine Wheat flour (%)
95 85 75 65 55 45 35
Yeast (%)
1.5
1.5
1.5
1.5
1.5
1.5
1.5
Salt (%)
0.5
0.5
0.5
0.5
0.5
0.5
0.5
Fat (%)
2.5
2.5
2.5
2.5
2.5
2.5
2.5
Sugar (%)
0.5
0.5
0.5
0.5
0.5
0.5
0.5
Flour (Sorghum: fine Wheat) Sugar, Fat, Yeast and Salt Mixing Kneading Baking Cooing Cutting Packaging
Process flow chart for production of Sorghum based composite pizza
Mean Score of Sensory evaluation of Sorghum composite pizza bae 5 4 3 2 1 0 Control T1 Colour Flavour T2 T3 Texture Formulations Taste After taste T4 T5 Overall acceptability
Sorghum Composite Pizza base
Other Achievements
Applied for request for examination (RFE)-for two patent applications
• Process for preparing sorghum flakes from • sorghum grains Device for preparing unleavened sorghum pancakes
Disseminated knowledge on sorghum processing cum promotional and marketing to:
• 100 students/scholars • • • • • • • 100 women 225 trainees (Prospective farmers, NGOs, entrepreneurs) Several government servants 27 NGOs 34 dignitaries from national & international organizations 22 scientists Above 100 visitors
Budget utilization
•
Funds Released Rs 21.7
•
Expenditure Rs 17.3 lakhs
•
Percent utilization = 80 %
Work plan for the year 2016-17
1. To liason and build up commercial linkages (enter 2 MoU's with prospective entrepreneurs & horizontal expansion) 2.
Impact Assessment of sorghum and millet commercialization 3. Handholding of EDP & conducting four National training programmes
I.
Tamil Nadu II.
Andhra Pradesh III. Karnataka IV. Maharashtra V.
Telangana
4. To develop and standardize 4 recipes
– Extruded product development trials with different sorghum recipe combinations. – Estimation of water activity, moisture of fat content of 62 sorghum cultivars 5.
Creation of Awareness on Nutritional superiority of sorghum based value added products Additionally, 1 meetings/conferences …..
Way Forward
Horizontal expansion Replication Upscaling of existing commercialized technologies &
Exploring more business tie-ups with Nestle, Parle Agro Foods, Bambino to engage in commercialization of targeted products in volumes
Creating aggressive awareness strategies with communication plans such as advertisement and through celebrities
To establish more linkages with line departments of state governments
Mainstreaming millets in public funded welfare programmes
Technology incubation for handholding at IIMR and a mini commercial scale millet processing facility