DEVELOPMENT OF MACHINERY FOR TRADITIONAL FOODS -A

CONTINUOUS CHAPATI (INDIAN UNLEAVENED FLAT BREAD)

MACHINE

Dr. B S SridharDepartment of Food Engineering

CSIR-CFTRIMysore – 570 020

• Chapatis are the traditional staple diet of large segment of Indian population & many Asian countries

• Great demand exists for hygienic and large scale short time production of these types of foods to cater to the need of industrial canteens, institutional kitchens, railway canteens, hospitals, mid-day meal schemes and mass feeding centres

• Mechanizing the preparation of chapatis as Ready-to-Eat and Easy-to-Carry foods for marketing in unit packs similar to bread has enormous commercial potential due to growth in industrialization & mushrooming of nuclear families in present times as well for facilities for cooking are limited and practically non-existent

• Many machines available for continuous production of chapatis are not suitable due to inherent defects like dough stickiness, complicated cleaning and non -uniformity in quality

Prelude

CONTINUOUS CHAPATI MAKING MACHINE

The machine has a chapati forming unit and a baking unit. The dough is extended into a sheet and punched to obtain discs. The discs are baked in a three tier oven where it is heated by conduction on both sides before exposing to the flame via a mesh conveyer to obtain puffed and baked chapatis. Sizes of chapatis: 150 - 200 mm dia. and 1.2 -1.5 mm thickness; Capacity – 1200 chapatis/h

• Avoidance of manual handling of the dough eliminating human factors and making the entire operation hygienic

• Higher production capacity than any other systems and the chapatis produced are of uniform quality, diameter and thickness

• Continuous operation with provision of material recycling eliminating separate re-handling of the dough

• Versatile, high tolerance for variation of moisture content, fat and type of flour

• Easy control of baking temperature and residence time depending on thickness and moisture content

• Hygienic design and construction – No stickiness of the dough to any part of the device The parts of the machine can be easily dismantled and assembled so that contact parts can be cleaned and inspected regularly

Innovative features

• There is reduction in the cost of chapatis and savings in labour accrues indirectly as the consumption of raw material as well as labor for the preparation of chapatis can be optimised while large quantities are prepared.

• Energy efficient and is designed for continuous operation. Due to mass production, there is significant reduction in energy consumption

• Unit does not need skilled persons for operation A single operator is enough to prepare and feed the dough continuously and operate the machine

• Low cost machine, needs low investment and less floor space. No pollution

• Increased production rates and brings in hygiene into chapati preparation by eliminating human factors

Operational Excellence

• Promotes the spirit of self employment and entrepreneurship among rural and urban women of the developing countries and growth of small and medium scale entrepreneurship (SME) since the present development elevates the operation of chapati preparation form home scale to industrial scale

• Reduction of drudgery – Housewives need more time in the current social environment. The machine offers ready- to-eat and easy-to-carry chapatis, saving time and drudgery in the preparation of chapatis

• The various sectors benefiting from the development include: Industrial canteens, Institutional kitchens, Large hotels, Mass feeding centres and Small & Medium Scale Entrepreneurs. The system is energy efficient and is designed for continuous mechanized operation. Due to mass production, there is significant reduction in energy consumption and cost

• In times of natural catastrophes and calamities like, Earthquakes, Cyclones, Famines & Tsunami like disasters where large mass feeding is essential & in times of war this machine can put to good use to prepare huge quantities hot chapatis in a lesser time under hygienic conditions

Self reliance aspects

• Licensee(s) / beneficiary utilizing /benefitting from the development are 6 in number at present with a licence fee – Rs. 1,000,00 (Rs. One lakh only)

• The machine has been sold to many industries and organizations across India by the licensees including export to Middle east countries Some important buyers include MTR, WIPRO, Mysore Paper Mills Ltd., INS Vendirutti, Kochi, Mata Amritanandamayi Mutt, Ramakrishna Ashram students' hostel and school, South western Railway workshop canteen, Karnataka Police academy, Mysore many colleges and Hospitals across India. The estimated value of annual output/benefit derived by a one of the licensees amounts to Rs. 2,01,55,940 (Rupees Two Crore One Lakh Fifty Five Thousand Nine Hundred and Forty Only)

• The machine offers ready- to-eat and easy-to-carry chapatis, saving time and drudgery in the preparation of chapatis thus promoting the spirit of self employment and entrepreneurship amongst rural and urban populace including jail inmates. Recently central prison, Bangalore planned to hit market with plan to hit market with 1,000 ready-to-eat chapatis per hour (Ref: Bangalore Mirror, July 15, 2013, Page 6)

• Machine was put to good use during Tsunami, Gujarat Earth quate and Uttrakhand Floods relief activities. Ready-to-eat chapatis were prepared from the indigenously developed chapati making machine, on a large scale ranging from30,000 to 1,50,000 numbers and sent to various relief centres, significantly contributing to the spirit of societal mission of the self and organization.

Impact of the development

• Five different models based on the principles of extrusion, rolling and cam assisted pressing mechanisms and technology to increase shelf life of chapatis to 10-12 days has been developed; Capacity variants – 600 - 3000 chapatis/h

• In times of war and natural catastrophes and calamities like, Earthquakes, Cyclones, Famines & Floods where large mass feeding is essential this machine can be put to good use to prepare huge quantities hot chapatis in a lesser time under hygienic conditions with quality comparable to home made chapatis

• The machine can be used in large industrial canteens, institutional kitchens, railway stations, hospitals and midday meal scheme centres, where large quantity of chapatis are required to be produced in a short time and served fresh and hot to the consumers

• Housewives need more time in the current social environment, requiring them also to take up jobs. The machine offers ready- to-eat and easy-to-carry chapatis, saving time and drudgery in the preparation of chapatis and can be preserved & consumed as such where cooking facilities are limited and non-existent

• The chapatis produced from the machine can complement as ‘Food Aid’ to meet the global crisis of malnutrition, tackling extreme poverty and hunger ensuring that all citizens can afford the cost of basic nutrition

Future readiness

Different models of chapati making machine developed (Capacity :60 – 3000 per hour)

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• M/s Neoconcept Enterprises

• Acharya Institute – Bangalore, • Air Force Technical College, Bangalore. • Biocon India Ltd., - Bangalore. • BMS College – Bangalore. • Deloitte Consultancy, Hyderabad. • Ghousia College of Engg, Bangalore, • Intuit India Product Development Centre,

Bangalore. • INS Mandovi, Goa. • IISST - Trivandrum, 2machines. • MVIT College, Bangalore, • New Baldwin Residential School, Bangalore. • Om Shanti Dhama Gurukul, Sangam -Bangalore • RNS Institute – Banglore. • REVA Institute - Bangalore, • Sri Ramakrishna Vidyalaya– Bangalore &

Mysore. • Sri Venkateshwara Education Society, Bangalore. • Siddaganga Institute of Technology, Tumkur. • Sri Siddhi Vinayaka Residential School,

Kundapur, Udupi. • Shaheen college, Bidar. • Shranabasaveshwar residential School,

Gulbarga, • Sapthagiri Egg College, Bangalore. • 1Sri Channabasveswara College, Bhalki Bidar. • Tata Consultancy Services, Hyderabad. • Vydehi Institute of Medical Sciences, Bangalore

Customer list of some licenseesM/s Durai Engineering Products • Avinashalingam Deemed University, Coimabatore • Subaramaniam Catering Service, Tenkasi• Durooverseas Trading House, Coimbatore• Mohan Food Industries, Mangalore • Hotel Geetham, Pondicherry • KSB Pumps Limited, Coimbatore • INS Vendirutti, Kochi• Kongu Engg. College, Erode • St. Michaels Engineering College,• Sivaganga• South Western Railway Workshop, Mysore • Police TrainingAcademy, Mysore

M/s Vasanth Engineering Works

• Amritanandamayi Mutt, Kollam• Wipro Technologies, Bangalore• MTR Food Products, Bangalore • Link Middle East Ltd. Dubai• Elite Breads Pvt Ltd. Thrissur• Ashok Leyland Limited, Hosur• The Hindu Canteen, Chennai• The Mysore Paper Mills Limited Bhadravathi• Laxmi Enterprises, Goa• Ajit Insutreis, Bangalore• Taj Industreis, Pune• Ittina Community Kitchen Limited, Bangalore

Commercialization and Societal Activities

Chapatis prepared Uttrakhand relief victims

Commercialization and Societal Activities

A movie clipping showing the working of the machine at a staff cafeteria

Click on the video clipping to play