127609115 indian food processing industry

8/12/2019 127609115 Indian Food Processing Industry

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Food processing Industry

Group 2


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Food Processing Definition

Food processing is the set of methods andtechniques used to transform rawingredients into food or to transform food into

other forms for consumptionby humans oranimals either in the home or by the foodprocessing industry.

It involves of all intermediary processesbetween Farm to forkthat a product undergoes.


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Understanding FoodTechnology

Food technology is a collection of variousstandard applicationsas required for aproduct. Technology is just embedded into the

processes that make sure food isuncontaminated, and production is lookedafter as in normal industries.


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Benefits of food processing

Toin removal

!onger shelf"life

#asing marketing and distribution tasks Increase in off"season availability of foods

#ase in transportation of delicate

perishable foods across long distances de"activation of spoilage and pathogenic

micro"organisms


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Generically used Principles

High pressure processing (HPP)- Involves theapplication of very high pressures (up to 6 000times atmospheric pressure) to pre-packaged or

bulk liquid or solid foods$ in a hydrostatic press " Finds application injam$ jellys$ fruit juices$ processed

meat products

Pulsed electric fields processing- %sed mainly forcleaning and separation

"Finds application injuice$ dairy and beverages


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&ontd''

Osotic dehydration- (elps inreducing moisture content, thereby

increasing shelf life of foods

"Finds application in almost every)here

Processing !y radio fre"uencyelectric fields- %sedwhere thermalapplication is unfeasible owing to loss

of food quality or nutrition

"Involves radio fre uenc to sterili*eand


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#urrent scenario -Production

+2, cultivable land

compared to --,

)orld average

ll -+ major

climates in the)orld eist in India

/0 out of 01 soil

types eist in India

21 agri"climatic

regions

!argest livestock

population

!argest producer of

milk

!argest producer

cereals

econd"largest fruitand vegetable

producer

mong the top five producers )orld)ide

of rice$ )heat$ groundnuts$ tea$ coffee$

tobacco$ spices$ sugar and oilseeds.

unshine hours

and day length are

ideally suited for

round the year

cultivation

!ignificant "pportunity

#ndia as a global sourcing

hub


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#urrent $cenario -Processing

#ategory

% of processed oftotal production

fruits and vegetales 2.2 ,

3oultry 0,

4arine products 5,

4ilk products 6+,


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#urrent scenario -#onsuption

Food Consumption in Indi$ource& B' () * + #$O11111

,111,111

,1 1 1 1,1 1 1 1 ,

1 1 1 1

,1 1 1 1111

,111

,111

1

11

111

111

111

111

1111 1 1 1 1 1 1 1 1 e1 1 1 1 f1111 f1111 f1111 f1111 f1 1 11

C AGR: . %111


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egments of food processing

Fruits and vegetable processing

7airy Grain processing

4eat and 3oultry processing

&onfectionery


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89#:9I#; Industry si*e < =1 >illion %7

&ontributes 0.6, to India?s G73 @, share in India?s total industrial production

!arge gro)th potential < out of total agricultural produce$

currently only 2, is processed

ource A 48F3I )ebsite


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tructure of Indian Food

3rocessing Industry


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Fruits and vegetables


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ector Insights

Installed capacity of fruits B vegetablesprocessing industry has increased from -.-million tonnes in Canuary -@@6 to 2.- milliontonnes in 2110

The processing of fruits and vegetables isestimated to be around 2.2, of the totalproduction in the country

4ajority of processing firms are cottage$household and small"scale sector$ havingsmall capacities of up to 2+1 tonnes perannum


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Improvements required'

&onsumption of value added fruits B vegetables are lo)compared to primary processed foods$ fresh fruits Bvegetables.

The inclination to)ards processed foods is mostly visible inurban centres due to a high purchasing po)er

remarkable push can be given to this sector bystrengthening linkages bet)een farmers and food processors

The poor and )eak linkage bet)een farmers and markets$ as)ell as$ farmers and processing companies has brought aboutinefficiencies in the supply chain and encouraged theinvolvement of middlemen leading price rise to the products


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Government 3olicies for Fruits B

9egetables Do industrial license required for setting up Fruits B

9egetables 3rocessing Industries Eecept if it?s a-11, eport oriented unit

+-, F7I allo)ed for processing of tomatoes$

mushrooms B other fro*en vegetables$ fruits$ nuts$fruit"peel$ fruit jellies$ marmalades$ juices etc. ector is regulated by Fruit 3roducts 8rder$ -@++

EF38$ issued under essential commodities act

3roducts like pickles B chutneys$ tapioca sago andtapioca flour are reserved for eclusive manufacturein small scale sector

#port is freely allo)ed

$%!#& '"&!!#*+


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$%!#& '"&!!#*+

&*#./! F" F/#! %*

1+%$2!

&leaning

3eeling >lanching

3ickling

7ehydration


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9alue dded 3roducts From Fruits

and 9egetables Fruit pulps and juices Fruit based ready"to"serve beverages canned fruits and vegetables Cams quashes 3ickles &hutneys

7ehydrated 9egetables processed mushrooms curried vegetables


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Fruit beverages

/nfermented beverages

Fruit juices )hich do notundergo alcoholicfermentation

Include natural ands)eetened juices$ :T$nectar$ cordial$ squash$crush$ syrup$ fruit juiceconcentrate and fruit juicepo)der.

Fermented beverages

Fruit Cuices )hich

undergo alcoholic

fermentation by yeast

#.g. )ine$ champaigne$

port$ sherry$ tokay$

muscat$

nira and cider

#asily digestible$ highly refreshing$ thirst quenching$ appeti*ing andnutritionally far superior to many synthetic and aerated drinks.H


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quash

Fruit beverage containing at least 2+,fruit juice or pulp B /1"+1, total solublesolids

lso contains about -, acid B 6+1 ppmsulphur dioide or 011 ppm sodiumben*oate

It is diluted before serving. &ommercial usage " 4ango$ orange

and pineapple It can also be prepared from lemon$

bael$ papaya$ etc. using potassiummeta bisulphite E4 as preservativeor from jamun$ passion"fruit$ peach$plum$ raspberry$ stra)berry$ grapefruit$etc. )ith sodium ben*oate aspreservative.


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Flow-sheet for processing of

! beverages


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&ordial

It is a sparkling$ clear$ s)eetened fruit juice

from )hich pulp and other insoluble

substances have been completely removed.

It contains at least 2+, juice and 61, T$-.+, acid and 6+1 ppm of sulphur dioide.

uitable for blending )ith )ines.

!ime and lemon are suitable for makingcordial.


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F2"4&% F" '"&!!#*+

"F &"#%2


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Dectar

!r *o Fruits 5uice'ulp 7 .uantity of waterrequired (litre)

- 4ango 21 Juantity of finishedproduct Elitre < Juantity

of Ejuice Elitre K sugar Ekg

K acid Ekg used

2 3apaya 21

6 Guava 21/ >ael 21

+ Camun 21

0 mla mla pulp 21!ime juice 2

Ginger juice -

&ontains at least 21 per cent fruitjuice L pulp and -+ per cent total

soluble solids and also about 1.6 per

cent acid.

It is not diluted before serving.


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Fermented >everage" ;ine

>everage resulting

from fermentation by

yeasts of grape fruits

)ith properprocessing

lcohol content < = to

21 ,


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F2"4&% F" '"&!!#*+

"F 4#*


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5%8

4ade by boiling fruit pulp withsufficient amount of sugar to areasonably thick consistency

pple$ pear$ sapotaEchikku$

peach$ papaya$ carrot$ plum$stra)berry$ raspberry$ mango$

tomato$ grapes and muskmelon

It can be prepared from one kind

of fruit or from t)o or more kinds.

F "4&% F" '"&!!#*+


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F2"4&% F" '"&!!#*+

"F 5%8


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5223

emi"solid product preparedby boiling a clear strainedsolution$free from pulp$ afterthe addition of sugar and

acid. Fruits used for preparation

of jelly " Guava$ sourapple$plum$ papaya$

gooseberry$ pricot$pineapple$ stra)berry$raspberry.


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F2"4&% F" '"&!!#*+

"F 5223


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8%8%2% Fruit jelly in )hich slices of the fruit or its peel are

suspended. Generally used for products made from citrus fruits likeoranges and lemons in )hich shredded peel is used asthe suspended material.

&itrus marmalades are classified into"

9 5elly marmalade The follo)ing combinations give good quality of jelly

marmaladeA i. )eet orange E4alta and khatta or sour orangeE&itrus aurantium in the ratio of 2A- by )eight. hreds of4alta orange peel are used. ii. 4andarin orange and khatta in the ratio of 2A- by)eight. hreds of 4alta orange peel are used. Iii. )eet orange E4alta and galgal ECitrus limoniain the ratio of 2A- by )eight. hreds of 4alta orange peel

are used.

: 5am marmalade The method of preparation is practically the same as that

for jelly marmalade. In this case the pectin etract of fruit isnot clarified and the )hole pulp is used. ugar is addedaccording to the )eight of fruit$ generally in the proportionof -A-. The pulp"sugar miture is cooked till the T

content reaches 0+ per cent.


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+la=ed candy

&overing of candied fruits vegetables with a thin transparentcoating of sugar, which imparts them a glossy appearance

'rocess< &ane sugar and )ater E2A- by )eight are boiled in a steam pan at --6"

--/M& and the scum is removed as it comes up.< Thereafter the syrup is cooled to @6M& and rubbed )ith a )ooden ladle

on the side of the pan )hen granulated sugar is obtained.< 7ried candied fruits passed through granulated portion of the sugar

solution$ one by one$ by means of a fork$ and then placed on trays in a)arm dry room.< &an also be dried in a drier at /@M& for 2"6 hours.< 3acked in airtight containers after they become crisp


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&rystalli=ed candy &andied fruits vegetables when covered or coated

with crystals of sugar, either by rolling in finely

powdered sugar or by allowing sugar crystals todeposit on them from a dense syrup.

3rocess< The candied fruits are placed on a )ire mesh tray )hich is

placed in a deep vessel.

< &ooled syrup E=1 per cent total soluble solids is gentlypoured over the fruit so as to cover it entirely.

< The )hole mass is left undisturbed for -2 to -5 hours during)hich a thin coating of crystalli*ed sugar is formed.

< The tray is then taken out carefully from the vessel and the

surplus syrup drained off.< The fruits are then placed in a single layer on )ire mesh trays

and dried at room temperature or at about /@M& in driers.


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3ickles

The preservation of food in common salt orin vinegar is known as pickling.

8ne of the most ancient methods ofpreserving fruits and vegetables.

+ood appeti=ers, addto the palatability of ameal.

timulate the flo) of gastric juice and thus helpin digestion.

t present$ pickles are prepared )ith salt$vinegar$ oil or )ith a miture of salt$ oil$ spicesand vinegar.


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8% '%&?%+#*+8% '%&?%+#*+#*/!3#*/!3

I t d tiI t d ti


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/-

IntroductionIntroduction

High Hydrostatic Pressure (HHP) treatent is an athericdecontaination process hich consists in su!.ecting pac/aged foodto ater pressures fro 011 to 211 'Pa,

The pressure applied is isostatically transitted inside a pressure3essel,


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7iagram of the ((3 equipment7iagram of the ((3 equipment


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Food that can be ((3 treatedFood that can be ((3 treated

Solid foods, mainly vacuum packed

- Dry-cured or coo/ed eat products

- #heese

- Fish seafood arine products

- 4eady to eat eals sauces

- Fruits aralades 5 .as

- 6egeta!les

Liquid foods, in flei!le packa"in"

- Dairy products

- Fruit .uices

- 7utraceutical forulations


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//

Food that can not be ((3 treatedFood that can not be ((3 treated

Solid foods #it$ ai% included

- Bread

- 'ousse

&acka"ed foods in completely %i"id packa"in"

- n glass

- #anned

Foods #it$ a ve%y lo# #ate% content

- $pices

- Dry fruits

4ain technological effects of ((34ain technological effects of ((3


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/+

4ain technological effects of ((34ain technological effects of ((3

in meat productsin meat products

@ A!out colo%:

8 n fresh or arinated eat the iron in the yoglo!in changes

fro ferrous to ferric and glo!in is denatured& the red color is lost

' A!out tetu%e:

8 nhi!ition or stiulation of the proteolytic acti3ity in usclesacti3ityuscles (depending on processing conditions)

8 Proteins are partially denaturi9ed in products here proteins ha3e not

!een pre3iously odified !y other process& heating drying ferentation:

' A!out fats and lipids:

8 4e3ersi!le crystalli9ation

T d b f l E-T t d b f l E-


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/0

Treated beef samples E-Treated beef samples E-

Top vie) of the fresh and fro*en beef samples treated by ((3

T t d b f l E2T t d b f l E2


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/=

Treated beef samples E2Treated beef samples E2

#oo/ed saples& 3ie fro the top (a); 3ie of the inside(!)

Treated commercial beefTreated commercial beef


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Treated commercial beefTreated commercial beef

products samplesproducts samples

#oercial !eef products !efore and after HHP treatent

3 i f l ti f t th t3 i f l ti f t th t


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/@

3rocessing or formulation factors that can3rocessing or formulation factors that can

modify the effect of high pressure E-modify the effect of high pressure E-

@ (empe%atu%e:

8 High teperatures increase the effect of high pressure against

icroorganiss and eat coponents

8 $u!-9ero teperatures can protect fish products coponents

/eeping reasona!le icro!ial inacti3ation capacity/eeping capacity

' p):

8


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+1


modify the effect of high pressure E2modify the effect of high pressure E2

@ *acte%iocins:

8 $oe !acteriocins and specially nisin are 3ery effecti3e

co!ined ith high pressure e3en on Gra 8 !acteria

' +ate% activity:

8 =ith higher ater acti3ity ore effecti3eness of high pressure

processing !ut also ore reco3ery fro su! lethally in.ured

icroorganiss

3 i f l ti f t th t3rocessing or formulation factors that can


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+-


modify the effect of high pressure E6modify the effect of high pressure E6

@ &%ese%vatives:

8


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+2

>enefits of high pressure>enefits of high pressure

>dapted to saniti9e products here heat processing is

inappropriate (dry cured ha ferented eat products sliced

ready to eat eat products etc,)

>lternati3e to heat treatents to process foods inacti3ating

icro organiss #it$out c$an"in" t$e senso%y qualities o%t$e nut%itional values of foods

8th d t f hi h


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8ther advantages of high pressure8ther advantages of high pressure

6ery lo use of energy

7o residues& uses only tap ater

$afe for or/ers

>ccepted !y consuers and retailers

Does not produce

< ne) chemical compounds

< radiolytic by"products

3resent range of pressures3resent range of pressures


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+/

3resent range of pressures3resent range of pressures

availableavailable

3 i t t3rocessing temperatures


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++

3rocessing temperatures3rocessing temperatures

#conomic data#conomic data


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+0

#conomic data#conomic data

8"2 'roductivity (a) &ost (b)

4ave 6000;; -=1 kgLh 1$-@ N L kg

4ave 60009;0 /2+ kgLh 1$-/ N L kg

4ave 6000


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+=

Industrial motivations to use (ighIndustrial motivations to use (igh

(ydrostatic 3ressure treatment(ydrostatic 3ressure treatment

@ )i"$e% mic%o!iolo"ical safety

8 $ignificant reduction of the ris/s associated ith the

presence and groth of pathogens

8 >dditional preser3ation treatent applied to the

products after pac/aging

' *ette% senso%ial quality

8 $ignificant reduction of the sensorial ris/s associated to

the presence and groth of alteration icroorganiss

(fresher fla3our)

:easons for the industrial use:easons for the industrial use


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+5

:easons for the industrial use:easons for the industrial use

of ((3of ((3

Consume% satisfaction

8 Fresher fla3or

8 Healthy or con3enient attri!utes

' Le"al %equi%ements

8 4elated to food safety8 4elated to e?port regulations

' As a %eaction in f%ont a food c%isis

' (o meet costume%s specifications

' S$elf life etension

' Ima"e of innovative company

8 Both to retailers and end users

8 Producing safer and relia!le products

' (ec$nolo"y fully accepted !y consume%s

#amples of uses of ((3#amples of uses of ((3


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+@


ry-cured meatB



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01


&ooked meatB cooked ham$ roasted chicken$ turkey breast$ cooked

sausages



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0-


eady mealsB

8bstacles for the implementation8bstacles for the implementation


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02

pp

of ((3 E-of ((3 E-

@ Lo# level of pu!lic kno#led"e a!out t$e tec$nolo"y

' Attitude of t$e pu!lic administ%ations in -u%ope

8


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06

pp

of ((3 E2of ((3 E2

@ Reduced num!e% of supplie%s fo% equipments

8 'ore options a3aila!le ould encourage a ore acti3e ar/et

' &e%ception of economical %isk

8 Dou!ts a!out echanical and structural relia!ility (un.ustified)

8 $oe fear a!out the usual "uic/ o!solescence for the first

3ersions of industrial e"uipents

8 nitial high in3estent cost (ainly for !ig copanies ith need

for siultaneous purchasing of ultiple e"uipents)8 t e?plains hy the a3erage user of high pressure is a ediu

si9e copany anaged !y the oners

8 tAs necessary to offer to food copanies appro3ed protocols andprocess 3alidation ser3ices for different food atri?es


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>akery Industry

>akery Industry


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>akery Industry

8vervie)


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India < a 6111 &rore market and 6rd

largest producer of >akery products after

% and &hina.

3er capita consumption in our country is2.- g.$ compared to more than -1 kg in

the % and is -.@1 kg. in &hina.

>iscuits


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Industry 8rgani*ed A %norgani*ed sector is ++, A

/+, ratio. 'opular $randsB>ritannia$ 3arle$

3riyagold$ 7ukes$ ;indsor etc.

nnual 3roduction B Gro)thA#n 2akh 8

211+"10 -/.2@

2110"1= -0.-/211="15 -=.//

2115"1@ -0.+=

211@"-1 -5.2+

21-1"-- [email protected]

:00;-06 9A7

2110"1= -6,

211="15 -+,2115"1@ -1,

211@"-1 -/,

21-1"-- -+,


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ural-/rban penetration growth of

$iscuit

-. %rban 4arketA =+, to 5+,

2. :ural 4arketA +1, to 0+,


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Ingredients

a) 8aCor ingredientsB< 3rovide bulk to the product$ overall structure$ body etc. and

consist mainly of )heat flour Eheart of each recipe in bakery$sugar$ fat$ salt$ )ater$ egg Eoptional$ soya flour$ and starch.

a) 8inor ingredientsBroad categories are en*ymes$ emulsifiers B stabili*ers$preservatives$ chemical improvers$ nutritional ingredientsEvitamins$ minerals$ fibers$ s)eeteners$ flavors$ etc.


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Ingredients concentration


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3rocess


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3re"4iingA


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>akingA

< >iscuits are then baked in large baking ovens

O pre"described temperatures for a pre"

decided amount of time.< Through steam etractors$ the steam is

etracted from the output.

aking time and baking temperature is ofutmost importance.

< Then proceeded to cooling.


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&oolingA< &ooled for a particular amount of time in cooling

conveyors.

3ackagingA< >iscuits are fed into packing machines in

continuous stacks )ith the help of auto feeders.>iscuits are fed into packing machines incontinuous stacks this is achieved through

stacker )hich converts free flo)ing biscuits intouniform achieved through stacker )hich convertsfree flo)ing biscuits into uniform stacks.

4ajor functioning of


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4ajor functioning of

packaging-. 3rotect from mechanical damage in transit

and loading and unloading processes.

2. 3rotect from any loss of moisture or any

foreign odour contamination.6. !egal compliance for values and ingredients

for customers.

/. dvertisements.

9arious packing


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9arious packing

machines

(ori*ontal flo)

rap machine

:oll )rapping

machine

Types of


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Types of

packaging

'1& rays !hrink wrapped

3lant


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3lant

!ayout


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Food and regulatory measures

pproval additives

(&&3$ G43 EGood 4anufacturing

practices$ G(3 EGood (ygienic

practices

ociety for Indian >akers recently issued

>& of FIH

>& of


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>& of

FIH

#ducate the staff on the ct #hibit food safety posters in the factory

:emove epired date goods because it is a healthrisk and provide clean and proper uniforms

&onduct medical eamination for all

;hite)ash premises periodically

%se processed )ater for manufacture

Take special attention in preparing the labels Take effective pest control measures and

mandatory use of gloves


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Trade related aspects

>ports< The eport market comprises of south"east sian

countries EThailand$ 3hilippines$ Tai)an$ and4alaysia$ Depal$ >angladesh$ ri !anka$ and3akistan$ %$ and frican countries E>ra*il$&hile$ and 3eru and rab countries.

#mports< Food ingredients and ra) materials are being

imported from countries like &hina$ France$

Germany$ %$ >ra*il$ Tai)an$ Italy$ Turkey$&hile$ and the Detherlands.

&h ll d 3 t


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&hallenges and 3rospects

/norgani=ed sectorBa. !ocal manufacturers )ith numerous local

brands cater to the populous segment.

b. !o) margins$ high level of fragmentation are the

main features in the bakery industry.c. 9olumes$ brand loyalty and strong distribution

net)orks are the main drivers of gro)th. "rgani=ed sectorB

a !o) margins of profit due to escalatingprices of major ra) materials$ particularly)heat flour$ vegetable oil$ sugar$ and milk.

127609115 indian food processing industry

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