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

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About CFTRI……

• 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

12/18/2014

One Stop Centre for Food Science

and Technology

Certifications and Accreditations

• ISO 9001 Quality Management System

• ISO 14001 Environmental management System

• 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, non-

conventional energy source s

Basic research

Biochemistry, Nutrition, Cell culture, Biotechnology,

Nanotechnology

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Other Activities…………

Consultancy assignments

Industry sponsored projects

Technology/Know-how transfer

Turn-key projects

HRD activities

• 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

Imphal

BR Hills

Lucknow

12/18/2014

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SS

Facilities

at CFTRI

Pilot plant

Automated

Wheat mill

Maize mill Sensory booth

Instrumentation facility

Analytical Lab

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Agricultural Production Scenario in

Eastern/N-E India

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

Fruits & Vegetables (Potato, Onion, Pea, Mushroom)

Cereals (Rice, Maize, Wheat, Millets)

Spices (Ginger, Chilli and Turmeric)

Milk & Poultry products

Sugarcane

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Post harvest technology protocols for

export of Mango variety Alphonso in

Reefer Container by ship.

Technology protocol for export of

Banana variety dwarf Cavandish by ship.

Air cargo space and

uneconomical and exorbitant

air freight charges (3 times).

PRE/POST HARVEST PROTOCOLS

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, pre-

cooling, stacking in reefer containers, optimum storage temperature and

humidity management inside the reefer container and post transportation

ripening conditions.

Shelf-life extension by 35

days for Mango and 42

days for banana

Preparation procedure generally includes processes such as washing, peeling, cutting, trimming, slicing, shredding, dicing and coring .

Minimal Processing (MP) of Vegetables

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

Boosts export of vegetables

Renders 60% value addition

Low cost technology

Ash gourd

Beetroot

Beans

Bittergourd

Carrot

Cabbage

Cauliflower

Cluster beans

Coccinia

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

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

Pretreated fruits

Dehydration of fruits and vegetables

Removal of moisture leads to reduction in

Water activity Microbial activity Enzyme activity

• Ultimately results in shelf-life extension

Reduction in density, storage space and transportation cost

Slices, Shredding, Powder

Osmotic-hot air dehydration

Jack fruit slices

Amla segments (sweet and salted)

Pineapple slices

Mango slices

Vegetables

Osmotic dehydration followed by hot air

drying at lower temperatures

Electromagnetic radiation assisted drying

Conventional Heating EMR Heating

H W

M M H M M

H Case hardening

W

H = Heat, M = Mass, W = Waves

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

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Near Infrared (NIR) heater

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

Material bed

NIR heat sources

Air vent

INFRARED PROCESSING OF CASHEW KERNELS

FOR TESTA REMOVAL – AN ALTERNATIVE TO ‘BOURMA’ DRYING

RAW NUTS

ROASTING

SHELLING

DRYING

PEELING

GRADING

PACKING

~1 h

24 h

BOURMA

IR

INTERMITTENT HEATING 16

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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

ADVANTAGES

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COMBINED IR AND HOT AIR DRYING

1911

Air Vent

Temperature Sensor

Air Duct

Air Heater Blower

Control Panel

Conveyor

IR Heat Sources 90.2°C

SYNERGISTIC EFFECT OF HOT AIR AND INFRARED

Infrared Drying

Reduced drying time (43%)

Higher rehydration moisture (6-7%)

Higher carotenoid retention (88%)

Better cell structure

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VEGETABLES

SPICES

HERBS

27.12 MHz

COMBINED RF AND HOT AIR DRYING

Energy efficient dryer

Higher product thickness

Self regulating system

Ideal for finish drying

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Dill greens

Basil leaves

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MW-Convective drying

CONVEYORIZED

BATCH

Reduction in drying time by ~40%

Retention in volatile oil by ~20%

Improved color values

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.

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Cardamom dryers

Natural Convection dryers

on the filed itself

Solar dryers for increased

energy conservation

INTEGRATED HOT AIR

ROASTING MACHINE

Combustion chamber LPG Flue + Fresh air

Food

Material

Outlet

Food

Material

Inlet

Hot air

recirculation 70%

Fresh air

30%

LPG

Cylinders

Vibro Fluidized Bed Dryer/Roaster

Comparison of HSD and LPG fired ovens

Description Type of oven

Diesel LPG

Type of Heating Indirect Direct

Gross Calorific Value 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

Total Fuel Cost Rs 1213 / per ton of

Food

945 / per ton of Food

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.

27

0

10

20

30

40

50

60

70

80

L

150 160 170 180 190 200

4

8

12

TE(°C)

TI(Min)

1 2 3 4 5 6 7 8 9

Hedonic scale

Overall

Liking

Texture

Flavor

Appearance/

Color

INFRARED ROASTING OF GROUNDNUT SEEDS

Method of

roasting Temp.

(ºC)

duration

(min)

Product quality

Moisture

(% w.b)

Lightness Oil yield

(%)

Compressive

strength

(N)

FFA

(%)

Peroxide

Value

(meqO2/kg)

Control - - 4.43 68.90 47.03 70.45 0.34 4.90

Drum 180 20 1.60 57.23 49.98 57.45 0.67 5.88

Sand 180 12 1.30 64.13 49.57 68.00 0.46 5.15

IR 180 8.0 0.87 67.50 51.68 36.50 0.38 4.98

Hopper

Spouted Bed Roasting

Chaff Separator

Receiver

Control

Panel

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

Spouted Bed Roaster

Membrane Processes

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

Classification

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Membrane Processes

Low temperature and low pressure process

Low energy consumption

Advantages

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Maximum achievable concentration

Membrane fouling

Concentration polarization

Disadvantages

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

Membranes

• MF - 450, 200 nm

• UF - 25, 50, 100 & 500kDa

• VCR - 5

50 fold extract (45 min, 90°C)

TSS - 0.61%; PP- 0.348%

Conc. extracts – 2, 5 & 10%

Black tea extract

Retentate

Clarified black tea extract

Diafiltration (150%)

Primary quality criteria Low turbidity Low tea cream Original color

MF/UF

Undesirable – cream

components

•Protein

•Pectin

•Minerals - Ca

Desirable - Higher Soluble solids

recovery

Polyphenols

recovery

TF/TR

Catechins

Membrane processing of Honey

Membrane processing

Micro-filtration (MF)

- (3 Membranes)

Ultra-filtration (UF)

– (5 Membranes)

•Commercially sterile honey without cloudiness or

sedimentation

- Beverages

•Enzyme enriched honey

- Nutritional

MF

UF

Feed

Retentate Permeate

Vacuum

Concentration

Retentate Permeate

Vacuum

Concentration

Filtered Enzyme Enriched Honey

Scheme for Membrane Processing Ultrafiltered Honey

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1

2

3 4

1. Ball Valve

5. Peristaltic Pump

3. Feed Reservoir

2. OMD Plate and Frame Module

4. Osmotic Agent Reservoir

5 5

OMD Plate & Frame Membrane Unit

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Concentration up to 65°Bx

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

Hurdle Technology used here rely on a mild heat treatment (65-95°C) followed by storage at chilled temperature (<10°C) for safety and preservation.

Hurdle Technology for Extending the shelf life

Prepared idlies/dosa/paddu

Placing them in pouches

Steam flushing

Heat sealing

Racking

pasteurization

Refrigerated storage (3-4° C)

Value added products from Ginger

• Bleached ginger

• Unbleached ginger

• Salted ginger

• Ginger preserve

• Ginger candy

• Ginger paste

• Ginger powder

• Ginger oil

• Ginger oleoresin

(CH3)n

O OH

HO

CH3 O

GINGEROL

C17H26O4

n = 6

n = 8

n = 10

Fresh ginger

Drying

Powdering

Steam distillation

Spent Drying Ginger oil

Solvent Extraction

Desolventization

waste Oleoresin

Preparation of Ginger Oleoresin

TURMERIC COOKING

Polishing

Fresh Rhizomes

Harvested lot

Pre-cleaning

Separation of fingers & bulbs

Cooking in water (40-60 min)

Heaping

Spreading for sun drying

Polishing & Bagging

Traditional processing of turmeric

Production of Turmeric Powder

Fresh turmeric rhizomes

Grading/separation

Slicer/dicer

Turmeric slices

Drying

Dried turmeric slices

Powdering

Turmeric Powder

Down stream processing time for

production of hygienic Turmeric

powder starting from freshly

harvested turmeric rhizomes is

very low (with in 24 h) compared

to traditional methods, which

takes minimum of 25-30 days.

Higher curcumin and volatile oil

content in the finished product1

Patent “A process for

production of turmeric powder from fresh turmeric rhizomes 250/del/2013” filed

Primary processing of chilli

• Harvesting at near ripe red stage

• Indoor heaping for full colour development

• Solar/ shade drying- 8-15 days

• Improvements in drying

• Processing of paprika

Value added products from chilli

• Chilli powder

• Chilli oleoresin

• Chilli seed oil

• Chilli paste

• Chilli colour • High pungency chilli oleoresin

• Capsaicin

Production and Processing of Oyster Mushrooms

a) A technology for the Large scale production and processing of Oyster (Pleurotus species) Mushrooms has been developed and transferred to entrepreneurs, which involves

Culture & Spawn

Large scale production

(Urban & Rural Models)

Mushroom dehydration

Pickle & Sweet Chutney

Canning

Instant mushroom soup mix.

b) Plantation crop wastes like fresh coffee pulp and coir fibre waste are also used substrate and yields are at par with that on rice straw (more than 100% BCE).

c) Mushroom produced without any fungicide/pesticide and hence, can be regarded as “Organic Food”

Desiccated Coconut Powder

Spray Dried Coconut Milk Powder

Coconut Dietary Fiber

Tender Coconut Beverage

Coconut Spread

Virgin

coconut oil

Coconut Protein Powder

VALUE ADDED PRODUCTS FROM COCONUT

VCO Technology transferred to more than

30 entrepreneurs

Processing of Sugarcane Juice Beverage

Storage

Sugarcanes

Crushing

Filtration

Pasteurization

Cooling

Bottling / canning

Aseptic filling

Commercial sterility upto 120 days at RT

Commercial sterility upto 150 days at RT

Pretreatment

Hygienic Crusher

Sugarcane Juice Spread

Pretreatment

Crushing

Filtration

Processing

Filling

Cooling

Storage

Sugarcanes

Stability 120 days

Sugarcane Juice Concentrate & Powder

Sugarcane

Crushing

Filtration

Sugarcane Juice

Sugarcane juice Concentrate (120 days)

Sugarcane juice Powder

Concentrate (Vacuum) with additives

Dehydration with additives

Kakambi & Jaggery

Sugarcane

Crushing

Filtration

Sugarcane Juice

Kakambi (20 days)

Two stage evaporation

Jaggery (160 days)

Evaporation under vacuum

Purity = A280

A620

Purity Grade Cost per mg

(in US $)

0.7 Food grade 0.13

1 – 3.9 Reactive grade 1 – 5

> 4.0 Analytical grade 15

Phycocyanin

Applications as fluorescent markers

food colorants (Lina blue)

in cosmetics

pharmaceuticals

immunological aspects

Phycocyanin

Is a blue colored phycobiliprotein obtained from

Spirulina platensis and has high commercial value

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Preparation of Crude Extract

Fully grown spirulina biomass

Washed with distilled water

Homogenization

Spirulina cells releasing phycocyanin during homogenization Centrifugation

Crude Extract

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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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Fresh beet

root

Wash, peel, slice and grind

with acidified water

Centrifuge at 12000 rpm to

remove polyphenols

Fresh juice

subjected to

ATPE

Product

(concentrated)

Betalains

powder

Betalains

Sugar and other

components

Lyophilization

PEG

Recovery

Flowchart of the downstream processing of Betalains

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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

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Bromelain from pineapple wastes

Meat tenderization

Pharmaceutical applications

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

Shelf life of 45-90 days

Karaunda

Mulberry Pumpkin

Value added products from custard apple

Bio-functional beverage and jelly from de-

bittered sweet orange (Citrus sinensis)

Limonin

Naringin

Sweet orange juice turns bitter, even at

room temperature and on heating for

pasteurization it further intensifies

besides development of off-flavor

Bitter principles:

- mangostin

Beverage and jelly from

Mangosteen

(Garcinia mangostana) fruit rind

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

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Energy Food – Multigrain Product

- High Calorie

- Fortified with nutrients

- Dry mix for consumption

- Preparation Products

High Energy Biscuits – High Calorie

Fortified Products – Minerals, Vitamins

PRODUCTS FOR CHILDREN

• Non homogenous nature and their variations in

recipes & shapes add to problems.

•Food material properties change during

processing

• 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 development

should go hand in hand

Traditional Indian Foods

• Designed and

Developed at

CFTRI

• 400 Dosa/h

• LPG based system

• More than 800 units

across India

AUTOMATIC CONTINUOUS DOSA MACHINE

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

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Poory Machine

(600 nos/h)

Garlic Peeling Machine (100 kg/hr)

Pneumatic lemon cutting machine (2500 nos/hr) Wet /Dry Grinder

( 50 kg/h)

Automation for Safe Food

Laddu machine (2000 nos/h)

Murukku Making

Machine

Jilebi Making System

Leaf Cup Making System

ACKNOWLEDGEMENTS

Prof. Samir Brahmachary, DG CSIR

Prof. Ram Rajasekharan, Director, CSIR-CFTRI

Dr . KSMS Raghavarao

Dr. M Madhava Naidu

Dr. K Vankatesh Murthy

Dr. MN Shashirekha

Dr. K Ramalakshmi

Research Students

Thank you