Innovative Food Processing Technologies

INNOVATIVE TECHNIQUES AND MACHINERY
FOR FOOD PROCESSING
April 16, 2015
3 Day Workshop,
SPIPA, Ahmedabad
Dr. H Umesh Hebbar, M.Tech., Ph.D.
Principal Scientist, Department of Food Engineering
CSIR- CFTRI, Mysuru, India
About CFTRI &
Facilities
..Processes
….Products
…..Machinery
About CFTRI……
 One of the constituent laboratories of CSIR, Govt. of India
 Premier Food Research Institute established in 1950
 Mandate
to develop cost-effective, bio-friendly food
processing technologies, focusing on food safety, health,
nutrition and environment
 Catering to the needs of farmers, MSMEs & global players
 18 R&D departments, 14 supporting departments and 3 RCs
 ~ 450 scientific/supporting staff & 300 Research Fellows &
Students
Certifications and Accreditations
• ISO 9001 Quality Management System
• ISO 14001 Environmental management System
4/19/2015• 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/value addition
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 sources
 Basic research
Biochemistry, Nutrition, Cell culture, Biotechnology,
Nanotechnology
4/19/2015
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Other Activities…………
Consultancy assignments
Industry sponsored projects
Imphal
Technology/Know-how transfer
Turn-key projects
BR Hills
Food Analysis (FSL)
Lucknow
HRD activities
• M.Sc. Food Technology (2 years)
• Certificate Course on Milling Technology (1 year)
• Short-term Courses for Entrepreneurs (1-2 weeks)
• Entrepreneur Development Programmes
• Ph.D. Programme for Research Fellows (AcSIR & Univ.)
• Project work for Under Graduate/Post-graduate students
4/19/2015
• Programme for school children
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FREE TECHNOLOGIES FROM CFTRI
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Amla candy
Composite ragi bread
Fruit spreads
Green chilli sauce
Protein enriched buns
Ready-to-use dosa batter
Ginger dehydration and bleaching
Ready-to-use idli batter
Turmeric curing and polishing
Contact: [email protected];
Ph: +91-821-2514534
CSIR 800 Programme
Disaster Relief Work
CPYLS for Students
OPEN DAY
Pilot plant
Automated
Wheat mill
Analytical Lab
Facilities
at CFTRI
Maize mill
4/19/2015
Sensory booth
Instrumentation facility
SS
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FOOD PROCESSING SCENARIO IN INDIA
Provides opportunities and challenges…………
 Top positions in Rice, wheat, fruits, vegetable and milk production
 Abysmally low level of value addition - 20-30% for grains and 2-5% for
fruits and vegetables
 High level of post harvest handling losses - 30-40% of fruits and vegetable
amounting to ~ Rs. 60,000 crores
 Growing population - need to double the production by 2020
 Increasing demand for processed foods and products with higher nutritive
value - especially in the urban areas
 Highly unpredictable weather conditions – effecting
extensively damaging crops
sowing and
 Rapid& indiscriminate urbanization – leading to shrinking of arable land
4/19/2015
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Majority of the industries (70%) are in unorganized sector
The need of the hour for food processing sector is
i) infrastructure for storage and transportation, particularly for
perishable foods and processing units at strategic locations
Cold rooms, cold chain, food processing parks etc.,
i) technologies that are simple, cost effective and can be employed
at the farm level to convert perishable foods into intermediate
product, if not the end product.
Manually operated, solar radiation based systems etc.,
i) technologies that are energy efficient, hygienically processed,
environmental friendly and can be used by large-scale
processing industries
Hygienic processing,
technologies
4/19/2015
very
high
quality
and
green
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Food processing
Technologies
Farm/Rural
scale
Small/Medium
scale
Large scale
Simple, low cost,
and mostly manual
Semi-auto units,
higher investment
and production
Automated plant, very
high investment and
rate of production
Local market
4/19/2015
Domestic
market
Domestic/
Export
market
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4/19/2015
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PRE/POST HARVEST PROTOCOLS
 Post harvest technology protocols for
export of Mango variety Alphonso in
Reefer Container by ship.
Air cargo: Space and
uneconomical (3 times)
 Technology protocol for export of
Banana variety dwarf Cavandish by ship.
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.
4/19/2015
Shelf-life extension by 35
days for Mango and 42
days for banana
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Minimal Processing (MP) of Vegetables
Preparation
procedure
generally includes processes
such as washing, peeling,
cutting, trimming, slicing,
shredding, dicing and coring .
Simple and Cost effective
 Generates 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
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Ash gourd
Beetroot
Beans
Bittergourd
Carrot
Cabbage
Cauliflower
Cluster beans
Coccinia
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 Boosts export of vegetables
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 Renders 60% value addition
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 Low cost technology
Coriander
leaves
Curry leaves
Cucumber
Drumsticks
Field beans
Fenugreek
leaves
Green peas
Green
chillies
Knol-khol
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Mint leaves
Okra
Onion
Plantain
Ridge gourd
Snake gourd
Spinach
leaves
Tomato
Turnip
Controlled/Modified atmosphere storage
Pretreated fruits
• Concentrations of Oxygen, Carbon di-oxide, Nitrogen
• Temperature
• Humidity
Dehydration of fruits and vegetables
Removal of moisture leads to reduction in
Water activity
Microbial activity
Enzyme activity
Slices, Shredding,
Powder
• Ultimately results in shelf-life extension
Reduction in density, storage space and transportation cost
Osmotic-hot air dehydration
Osmotic dehydration
followed by hot air
drying at lower
temperatures
Jack fruit slices
Amla segments (sweet and salted)
Pineapple slices
Mango slices
Vegetables
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.
Cardamom dryers
Natural Convection dryers
on the filed itself
Solar dryers for increased
energy conservation
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Electromagnetic radiation assisted drying
Conventional Heating
H
M
EMR Heating
W
M H
M
M
Conventional heating
H
Case hardening
W
H = Heat, M = Mass, W = Waves
• Longer processing time
• Lower thermal efficiency
• Poor product quality
Rate of Heat and Mass transfer is more
Reduces drying time
Improves product quality
Near Infrared (NIR) heater
Air vent
NIR heat
sources
Material
bed
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INFRARED PROCESSING OF CASHEW KERNELS
FOR TESTA REMOVAL – AN ALTERNATIVE TO ‘BOURMA’ DRYING
RAW NUTS
ROASTING
SHELLING
24 h
BOURMA
DRYING
PEELING
~1 h
GRADING
PACKING
IR
80% Reduction in time, higher yield of whole kernels, continuous process
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COMBINED IR AND HOT AIR DRYING
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Air Vent
90.2°C
IR Heat Sources
Control Panel
Temperature Sensor
Conveyor
Air Heater
Air Duct
Blower
SYNERGISTIC EFFECT OF HOT AIR AND INFRARED
2311
Infrared Drying
Reduced drying time (43%)
Higher rehydration moisture (6-7%)
Higher carotenoid retention (88%)
Better cell structure
COMBINED RF AND HOT AIR DRYING
Energy efficient dryer
27.12 MHz
Higher product thickness
Self regulating system
Ideal for finish drying
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MW-Convective drying
BATCH
 Reduction in drying time by ~40%
 Retention in volatile oil by ~20%
 Improved color values
CONVEYORIZED
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MEMBRANE PROCESSING
 Micro-filtration
 Ultra -filtration
Retentate
 Nano-filtration
 Reverse Osmosis
Fruit Juices, Water, Honey, Protein
concentrates, tea
• Non-thermal
• Better product quality
• Energy efficient
Reishing Keishing Foundation, Management of Tribal Areas
(MATA), Litan, Manipur
Membrane system
Vaccum Evoparator
Osmotic Membrane Distillation
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5
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•Fruit juices
•Tender coconut water
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1. Ball Valve
2. OMD Plate and Frame Module
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3. Feed Reservoir
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4. Osmotic Agent Reservoir
5. Peristaltic Pump
Concentration up
to 65°Bx
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Microbial load reduction/sterilization
GAMMA IRRADIATION
INFRARED IRRADIATION
 Sterilization
 Prevent sprouting
4/19/2015
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HIGH PRESSURE PROCESSING
PULSED ELECTRIC FIELD
www.tjskl.org.cn
4/19/2015
Microbial load reduction
Enzyme inactivation
Pretreatment before drying
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OHMIC HEATING
4/19/2015
PULSED LIGHT PROCESSING
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Hurdle technology for extending the shelf life
 Hurdle Technology for extending the
shelf life for a minimum of 6 - 8
weeks using Hurdle technology
RTE Foods
Prepared idlies/dosa/paddu
Heat processing in pouches
Heat sealing
Refrigerated storage (3-4° C)
TOMATO PRODUCTS
 Tomato is one of the most versatile fruit
 The surplus production during seasons
could be suitably processed and
preserved in bottles and cans in the form
of tomato juice, paste or puree,
ketchup/sauce, tomato chutney and
tomato pickles - popular ready-to-serve
products relished very much in local as
well as export markets
 With fast food sector expanding, the
demand for tomato ketchup and sauces
is estimated to have expanded as
indicated by the trend
TAMARIND POWDER
 Tamarind
pulp
is
cleaned
manually, de-seeded and fibers
removed
 The pulp is processed under
standardized
conditions
of
temperature, humidity and mill
settings to get a hygienic product
in powder form
 The final product has good
reconstitution characteristics and
is packed in HDPE pouches
Value added products from Ginger
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Salted ginger
Ginger preserve
Ginger candy
Ginger paste
Ginger powder
Ginger oil
Ginger oleoresin
O
OH
CH3 O
HO
(CH3)
n
GINGEROL
C17H26O4
n = 6
n = 8
n = 10
Traditional processing of turmeric
Harvested lot
Fresh Rhizomes
Pre-cleaning
TURMERIC COOKING
Separation of fingers & bulbs
Cooking in water (40-60 min)
Heaping
Polishing
Spreading for sun drying
Polishing & Bagging
Production of Turmeric Powder
Fresh turmeric rhizomes
Grading/separation
Slicer/dicer
Down stream processing time for
Turmeric slices
Drying
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.
Dried turmeric slices
curcumin and volatile oil
Powdering Higher
content in the finished product1
Turmeric Powder
Patent “A process for
production of turmeric
powder
from
fresh
turmeric
rhizomes
250/del/2013” filed
Primary processing of chilli
Value added products from 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
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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”
VALUE ADDED PRODUCTS FROM COCONUT
Virgin
coconut oil
Desiccated Coconut Powder
Coconut Protein Powder
Spray Dried Coconut Milk Powder
Coconut Dietary Fiber
Tender Coconut Beverage
Coconut Spread
VCO Technology
transferred to more than
30 entrepreneurs
Processing of Sugarcane Juice Beverage
Sugarcanes
Pretreatment
Crushing
Filtration
Bottling / canning
Aseptic filling
Pasteurization
Cooling
Storage
Commercial sterility upto
120 days at RT
Commercial sterility upto 150
days at RT
Sugarcane Juice Spread
Sugarcanes
Pretreatment
Crushing
Filtration
Processing
Filling
Cooling
Stability 120 days
Storage
Sugarcane Juice Concentrate & Powder
Sugarcane
Crushing
Filtration
Sugarcane Juice
Concentrate (Vacuum)
with additives
Sugarcane juice
Concentrate (120 days)
Dehydration with
additives
Sugarcane juice Powder
Kakambi & Jaggery
Sugarcane
Crushing
Filtration
Sugarcane Juice
Evaporation under
vacuum
Kakambi
(120 days)
Two stage evaporation
Jaggery
(160 days)
Preparation of Crude Extract
Food Colorant
Fully grown spirulina
biomass
Homogenization
Crude
Extract
Centrifugation
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Flowchart of the downstream processing of Betalains
Fresh beet
root
PEG
Recovery
Betalains
Product
(concentrated)
Sugar and other
components

Betalains
powder
Lyophilization
Fresh juice
subjected to
ATPE
Differential Partitioning of
Betalains and Sugars using
Aqueous two Phase
Extraction
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Value addition to food waste
Apple pomace mainly contains insoluble and
soluble fibre, phenolics & flavonoids
•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
Bromelain from pineapple wastes
 Meat tenderization
 Pharmaceutical
applications
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Low calorie RTS fruit beverages, low glycemic RTS blended
vegetable beverages, value added products
Karaunda
Pumpkin
Shelf life of 45-90 days
Mulberry
Value added products from
custard apple
Bio-functional beverage and jelly from debittered sweet orange (Citrus sinensis)
Sweet orange juice turns bitter, even at
room temperature and on heating for
pasteurization it further intensifies
besides development of off-flavor
Bitter principles:
Naringin
Limonin
Beverage and jelly from
Mangosteen
(Garcinia mangostana) fruit rind
- mangostin
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
 Mango powder
 Bael Powder
 Encapsulated bioactive compounds
PRODUCTS FOR CHILDREN
Energy Food – Multigrain Product
- High Calorie
- Fortified with nutrients
- Dry mix for consumption
- Preparation Products
High Energy Biscuits – High Calorie
Fortified Products – Minerals, Vitamins
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Vibro Fluidized Bed Dryer/Roaster
Food
Material
Inlet
Hot air
recirculation 70%
Food
Material
Outlet
Fresh air
30%
Combustion chamber
LPG Flue + Fresh air
LPG
Cylinders
INTEGRATED HOT AIR
ROASTING MACHINE
Comparison of HSD and LPG fired ovens
Description
Type of oven
Diesel
LPG
Indirect
Direct
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
Rs 1213 / per ton of
Food
945 / per ton of Food
Type of Heating
Gross Calorific Value
Total Fuel Cost
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.
Spouted Bed Roaster
Hopper
 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
GRAIN PROCESSING EQUIPMENT
MINI VERSATILE DHAL MILL
• Dhal milling is probably the third largest of
food processing industry in India, after rice
and wheat.
• The Mini Versatile Dhal Mill , developed at this
institute, has been designed to process all
types of pulses including minor ones.
• The Mini Versatile Dhal Mill consist of three
principal
system,
assemblies
Aspiration
namely
system
and
Dehulling
Grading
system.
• These assemblies are mounted on a sturdy
frame for trouble free operation.
• Destoner
• Parboiling plants
ABOUT THE MILL
MINI DHAL MILL
• Mini dhal mill is a small scale integrated
pulse milling system suitable to dehull
pulses efficiently and could be easily be
used under rural conditions.
• The mill consist of a dehulling unit, an
aspirator and a dhal separator, all run by a 1
HP single phase motor.
• The dehusking unit is based on the principle
of abrasion and consist of an emery-coated
cone, which rotates inside a wire mesh cage.
• Preconditioned pulses are first dehulled and
split and cleaned dhal is finally obtained
after aspiration of husk and separation of
broken from the millstream.
• This mini dhal mill is suitable for efficient
dehulling of bolder pulses like pigeon pea,
chick pea, pea, soybean etc.
More than 100 units distributed
Traditional Indian Foods
AUTOMATIC CONTINUOUS DOSA MACHINE
• Designed and
Developed at
CFTRI
• 400 Dosa/h
• LPG based system
• More than 800 units
across India
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
Poory Machine
(600 nos/h)
Automation for Safe
Food
Garlic Peeling
Machine (100 kg/hr)
Laddu machine
(2000 nos/h)
Wet /Dry Grinder
( 50 kg/h)
Pneumatic lemon cutting machine
(2500 nos/hr)
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Jilebi Making System
Leaf Cup Making System
Murukku Making
Machine
ACKNOWLEDGEMENTS
Prof. Ram Rajasekharan, Director, CSIR-CFTRI
Staff of CSIR-CFTRI
Research students
Thank you
CONTACT:
DIRECTOR
CSIR-CFTRI,
Mysuru – 570 020
www.cftri.com
[email protected]