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
3
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
12/18/2014 4
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
12/18/2014 5
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
6
SS
Facilities
at CFTRI
Pilot plant
Automated
Wheat mill
Maize mill Sensory booth
Instrumentation facility
Analytical Lab
12/18/2014 7
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
12/18/2014 8
12/18/2014 9
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
15
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
17
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
17
18
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
21
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
22
Dill greens
Basil leaves
23
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.
24
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
30
Membrane Processes
Low temperature and low pressure process
Low energy consumption
Advantages
31
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
5
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
38
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
52
Preparation of Crude Extract
Fully grown spirulina biomass
Washed with distilled water
Homogenization
Spirulina cells releasing phycocyanin during homogenization Centrifugation
Crude Extract
53
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
54
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
55
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
57
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
12/18/2014 63
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
70
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
Top Related