module i - plantation crops

53
Module I Plantation Crops E .P. Banuu Priya Assistant Professor Kongu Engineering College

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Page 1: Module I - Plantation Crops

Module I

Plantation Crops

E .P. Banuu PriyaAssistant Professor

Kongu Engineering College

Page 2: Module I - Plantation Crops

Importance of plantation crops

• Plantation crops are high value commercial crops

• Economic importance

• Export potential

• Employment generation (app. 0.5 million people)

• Poverty alleviation (rural sector)

• Ministry of Agriculture - Coconut, cashewnut, cocoa, arecanut, oil

palm and palmyrah

• Ministry of commerce - Tea, coffee and rubber

Page 3: Module I - Plantation Crops

Cashew nut

• Cashew is brought from Brazil to India by the Portuguese • Initially cultivated to arrest soil erosion and sea winds

• India was the first country to enter the global cashew trade.

• The country processes about 1.18 million tonnes of cashew

• 1959 – 150 mills; 2008 – 3500 mills

• Organized - 46 % ; Unorganized – 54 %

• Annual demand - 1.5 million tonnes, only a half of which is met by the

existing production.

Page 4: Module I - Plantation Crops

Cashew (Anacardium occidentale L.)

• India is the largest Producer, Processor and Exporter in the world ?

1960 1970 1980 1990 2000 until 20120

200000

400000

600000

800000

1000000

1200000

Top production - cashew nut

Mozambique Nigeria Vietnam India

Cash

ew P

rodu

ction

(MT)

Page 5: Module I - Plantation Crops

Contd..

• India imports - raw in-shell cashew from Congo, Tanzania, Indonesia and

Thailand (Zheng, 2012)

• India exports processed nuts to USA, UK, Japan, Netherlands, Australia,

Canada and Germany (Directorate-General of Commercial Intelligence and

Statistics, 2011).

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• “zero cholesterol nut”

Nutrition Composition

Protein - 21.2

Carbohydrates - 22.0

Fat - 47.0

Rest is total Minerals (Calcium, Phosphorus, Iron), Moisture and total Fiber

(in 100 g of cashew nut)

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Parts of cashew fruit

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Ripening stages of cashew

 

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Processing of cashew• Raw material

• Cleaning• Grading• Drying • Storage

• Conditioning• Roasting or steam cooking• Decortication (wooden mallets or cutting)• Separation of kernel• Kernel drying• Peeling• Grading and packaging

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Over view of processing

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Raw cashew nutsFreshly harvested cashew

nuts (initial m.c. 25%)

Cleaning (Rotary screen)

Grading

Sun drying

(2-3 days till 8-9% m.c)

Storage (gunny bags – 8-9 %)

Page 13: Module I - Plantation Crops

Methods of processing

Page 14: Module I - Plantation Crops

Cleaning

• Manual cleaning – sand, stones, dried cashew etc., are removed• Hand sieves (0.95 cm mesh)

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Conditioning• Washed by dipping the nuts in cold water in a tank

• Heaped on the floor are covered with moist gunny bags

• Water is sprinkled over the heaps periodically to keep the nuts in wet condition and

allowed to absorb moisture gradually

• Conditioning with moisture ensures quality of the final product

• Over humidification – desert grades

• Under humidification – scorched grades

• Steam cooking/roasting

• Oil recovery will be less and breakage of kernels would be more if the nut has not

absorbed sufficient amount of water

Page 16: Module I - Plantation Crops

Roasting

Purpose - carefully separate the kernel without CNSL contamination - less breakage

• Open pan• Drum drying (unconditioned)• Oil bath roasting

Page 17: Module I - Plantation Crops

Open pan roasting

• Used by traditional cashew processors in India.

• This technique is very simple with minimal equipment requirements.

• Requires skill and judgement in order to prevent the nuts from burning.

• The roasting pan is an open circular mild steel dish, measuring 2 to 2.5 feet in

diameter, supported over an open fire.

• Between 1 and 1.5 kg of raw nuts are placed on to the heated pan at a time.

• The nuts are heated on the pan, with constant stirring, in order to prevent burning

• As the nuts heat up, the CNSL is exuded onto the pan

Page 18: Module I - Plantation Crops

Open pan roasting

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Drum roasting• An improvement on the open pan roaster was the development of a drum

roaster, within which the cashew nuts are roasted.

• Nuts without any conditioning are fed into a rotating drum, heated initially to red hot to allow the shell of the nut to ignite and burn

• Drum is tilted at an angle (15-20°) over the fire and rotated during heating to prevent the nuts from burning

• During rotation, nuts pass through the cylinder and out of the opposite end of the drum.

• Duration of the roasting process can be regulated by changing the speed of rotation of the drum.

• Takes about 3-5 minutes and the drum is rotated by hand

• Rate of shelling and out turn of whole kernel is higher

• Cylinder is covered in a hood connected to a chimney which draws the black smoke upward into the atmosphere and makes it less unpleasant for the operator

Page 20: Module I - Plantation Crops

Drum roaster fired from a furnace below

Page 21: Module I - Plantation Crops

Oil bath roasting• Consists of a rectangular vessel and embedded in brick work and

heated by a furnace – shell is used as fuel• Conditioned nuts are passed through a bath of heated cashew nut

shell liquid (CNSL) maintained at a temperature of 175-220°C (190°C) for about 1-2 minutes

• Small (18 – 22 cm) -90 sec• Medium (23 – 25 mm) – 100 sec• Large (26 – 35 mm) – 110 sec

• Screw or belt conveyor is operating inside the bath of liquid• Roasting time is adjusted by the speed of the conveyor• During the passage, the shell gets heated , rupturing the cell walls

and releasing the shell liquid• Nuts are conveyed through a suitable outlet to a centrifuge – residual

oil is removed • Oil recovered from the roaster and centrifuge is filled into drums.

Page 22: Module I - Plantation Crops

Mild roasting• Conditioned grains are mild roasted for 20-25 min to remove

surface water• Loosens the kernel from the shell • After roasting, the nuts are spread on the floor as a thin layer for

cooling and later sent for shelling

Page 23: Module I - Plantation Crops

Shelling

• Roasted nuts are placed on a flat surface and cracked with a wooden mallet

• Efficiency - 10 nuts/min• 8 h shift - approximately 30 kg of raw nuts – 7.5 kg kernel• Cooling – 2-4 h

Page 24: Module I - Plantation Crops

Kernel drying – “BORMA”

• Purpose – to peel the testa from the kernel• Temperature – 60-70°C• Time – 6-7 h• Final m.c – 3.5 – 4%• Borma ovens are fired – shell or CNSL removed cake • Natural draft stack – 13-15 cm • Cooling

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Borma or Tray dryer

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Peeling

• The peeling process involved removal of testa from the kernel with the help of sharp knife (made of bamboo).

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Rehumidification

• Exposed to humid air• m.c – 5 %

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Grading• Grading operation is important since it is the last opportunity for

quality control of the kernels.

• Grading system is known as the American Standard, which is also incorporated in the Indian Government export criteria.

• Kernels are categorized on the basis of colour and condition.

• Peeled cashew nuts can be classified into between 11 and 24 grades. These are roughly divided into three groups: white whole, white pieces and scorched grades.

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GradingS.NO GROUPS SPECIFICATION

1 White wholesW180 (super large)W210 (large)W240W280W320W450

Between 120 and 180 kernels per lb (266-395 per kg) 200 and 210 kernels per lb (395-465 per kg) 230 and 240 kernels per lb (485-530 per kg) 270 and 280 kernels per lb (575-620 per kg) 300 and 320 kernels per lb (660-706 per kg) 400 and 450 kernels per lb (880-990 per kg)

2 White piecesButtsSplits

Pieces

Small piecesBaby bits

A kernel broken cleanly across the section of the nut.Kernel which has broken down the natural line of cleavage to form a cotyledon.

A kernel which has broken across the section but does not qualify for a butt and is above a specific size.

As above but smaller.Very small pieces of kernel which are white in colour.

3 Scorched gradesWholes

Butts

Whole kernels that have been slightly scorched during the process but are otherwise sound. These are not graded according to size.Butts that have been scorched.

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Packaging

• Graded kernels are packed in square tins of 25lb capacity• After filling and weighing - 65 cm vacuum and filled with CO2

• Tins are carefully tested for leaks after a day’s storage. • Then they are packed in cartons• Flexible packages - polyethyene and polypropylene • filled with 33.3% vacuum and 66.7% CO2 (1:2 ratio of CO2:N2)

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Semi - mechanical• Grading of raw nuts (before roasting)• steam roasting (instead of open pan or drum or sun or oil-bath

roasting) • cutting (instead of shelling)

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Grading

• 3 groups – small, medium, large.• Depending on size, nuts may require different timings for roasting• Vibratory screens / calibrator

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Steam roasting process

• The steam roasting process, commonly known as “cooking process” • Baby boiler followed by a steam cooker where the cashew nuts are

cooked with steam• Adopted widely in India

Page 34: Module I - Plantation Crops

Baby boiler

• Hand stoked fire tube boiler, which produces steam at 4.5-5 kg cm−2

• 2-3 kg fuel once in 15-20 min• Cashew shell or de-oiled cake• Discharge – stack height – 13-15 cm

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Cashew nut cooker

• Maximum – 360 kg cashew can be processed• Steam pressure – 4.5 – 5 kg cm−2

• process time - 10-20 min • total batch time is about 40- 45 min• cooking operation - 2-4 h in a day• 5-10 batches of nuts (depending on capacity)• Cooling

Page 36: Module I - Plantation Crops

Cutting

• nut-shaped knives• nuts placed between the knifes and pushed towards kernel to cut the

shell leaving the kernel intact• 40 to 50 kg raw nut/person/8 hr• 90 % whole kernel• Nuts smaller than 18 mm cannot be cut using cutting machines

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FULLY AUTOMATIC METHOD OF PROCESSING• OLTERMARE

1. Cleaning and calibration2. Washing and conditioning3. Roasting, centrifugation and cooling4. Drying5. Shelling and pneumatic separation of the shells6. Peeling, grading / sorting7. Packing

Page 38: Module I - Plantation Crops

Cleaning and calibration

• size grading and pre-cleaning• dried raw cashew nut (RCN) – dust, debris etc.,• calibrator/grader machine is used, the machine will have cylinder

shaped sieves having whole of various dimensions/size • RCN passed through different wholes will be segregated and collected

separately• 3-5 grades (India only 3)

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Roasting and centrifuging

• CNSL roasting followed by centrifuging to remove the remaining oil• conveyed through the cooling tunnel• next section (shelling)

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Shelling

• shelling machines - shell is split into two halves• kernels and shells - vibrating screen• Aspirator – suck out empty shells• If not separated – centrifugal separator • super calibrator - whole, broken and rotten kernels are separated.

Page 41: Module I - Plantation Crops

Peeling

• Mechanical and pneumatic actions – remove testa• Rocket peeler• Air peeling (pneumatic) machine

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Raw nuts

Conditioning

Drum roasting

Hand shelling

Borma drying

Hand Peeling

Grading

Packing

Shells

Testa

Cashew Processing – Quilon (Kerala)

Page 43: Module I - Plantation Crops

Raw nuts

Conditioning

Mild roasting

Shelling in leg & Hand operated machine Shells

Borma drying

Hand peeling

Grading

Rehumidification

Packaging

Expeller

CNSL Residue Testa

Cashew processing - Mangalore

Page 44: Module I - Plantation Crops

Cashew processing - Panruti

Raw nuts

Sun Drying

Hand Shelling Shells

Borma drying

Hand peeling

Grading

Packaging

Kilns

CNSL ResidueTesta

Page 45: Module I - Plantation Crops

Raw nuts

Conditioning

Single action cutting m/c

Improved Through Flow Drier

Abrasive peeler

Hand Peeling

Grading

Rehumidification

Packaging

Expeller

CNSL Residue

Shells

Peels

Extraction

Residue

Improved Cashew Nut Processing

Tannin

Page 46: Module I - Plantation Crops

Storage

• Resistant to insects

• Do not suffer from infection or deterioration in quality up to six months after harvesting

• Optimum moisture contents is 8.9% for good keeping quality and for yielding good quality kernels

Page 47: Module I - Plantation Crops

Mechanical sheller• Designed by Post Harvest Technology Centre, Indian Institute of

Technology,Kharagpur.

• Sheller uses principles of compression and shear, taking into account the physical and mechanical properties of cashew nuts.

• Consists of four compartments power supply transmission, feeding, shelling and discharging

• Feeding section consists of a hopper and horizontal screw conveyor for positive feed of the roasted nuts to the shelling section.

• Design criteria for the hopper and screw conveyor use size, bulk density, coefficient of friction and angle of repose of roasted cashew nuts.

• A flat plate sliding gate is used to control the feed rate of cashews into the sheller.

Page 48: Module I - Plantation Crops

Contd..• Shelling of roasted nuts takes place between two wooden discs, one of which is

stationary (fixed to the machine casing) while the other is mounted on to a shaft.

• The rotating disc is spring loaded in order to compress and shear the roasted cashew nut against the stationary disc.

• Sufficient pressure is exerted by the spring in order to compress the nuts between the two discs.

• The compression and differential speed of the discs causes the shells to be broken and removed.

• At the bottom is a square opening for discharging the kernels and shells.

• A conduit is provided to prevent the kernels from being damaged by falling on to the collecting tray.

• Performance of the Sheller is optimal at 320 rpm. • Capacity :18 kg/h• Shelling efficiency :70 %• Whole kernel yield :50 %• Half split yield :22 %• Broken yield :28 %

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Cashew shelling machine

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Cashew products

• Three main cashew products are traded on the international market: raw nuts, cashew kernels and cashew nut shell liquid (CNSL)

• A fourth product, the cashew apple is generally processed and consumed locally.

• The raw cashew nut is the main commercial product of the cashew tree, though yields of the cashew apple are eight to ten times the weight of the raw nuts.

• Raw nuts are either exported or processed prior to export.

• Processing of the raw nuts releases the by-product CNSL that has industrial and medicinal applications.

• The skin of the nut is high in tannins and can be recovered and used in the tanning of hides.

Page 51: Module I - Plantation Crops

Cashew nut shell liquid• Cashew nut processing allows for the development of an important by-product,

which can increase its added value.

• The liquid inside the shell (CNSL) represents 15 percent of the gross weight and has some attractive possible medicinal and industrial uses.

• CNSL is one of the few natural resins that is highly heat resistant and is used in braking systems and in paint manufacture.

• It contains a compound known as anacardium, which is used to treat dermatological disorders.

• The main markets for CNSL are the United States, the European Union (mainly the United Kingdom), Japan and the Republic of Korea.

• Together these account for over ninety percent of world trade, most of which is supplied by India and Brazil.

Page 52: Module I - Plantation Crops

Cashew apple

Plucking and removing nuts

Washing and weighing

Fruit mill

Juice extractor

Sulphitation

Inoculation

Fermentation

Distillation

Adjusting strength to 60%

Aging in Wooden vats

Dilution to 43%

Bottling

Preparation of Feni

Page 53: Module I - Plantation Crops

Cashew kernels• 60 percent of cashew kernels are consumed in the form of snacks

while the remaining 40 percent are included in confectionery.

• Cashew competes in the same market as other edible nuts including almonds, hazels, walnuts, pecans, macadamias, pistachios and peanuts.

• There has recently been a considerable rise in demand for edible nuts by consumers interested in quality and health aspects of food.

• The breakfast cereal, health food, salads and baked goods markets are all expanding markets for cashew nuts.