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Agro Food Processing and Packaging Technology

AGRO FOOD PROCESSING AND PACKAGING TECHNOLOGY FOOD LAWS Introduction Food safety and standard act The ABCD of FSSA Salient features of FSSA Responsibilities of the food business operator Improvement notices Offences and penalties Licensing and registration Nutrition labelling Requirements Content on label Hazard analysis and critical control point (HACCP) IS 15000) Principles of HACCP Features Some salient points are Benefits of HACCP License process Food safety management systems certification scheme (IS/ISO 22000) Features Benefits Licence procedure ISI Mark: Bureau of Indian Standards (BIS, 1986) Features License procedure Weight and Measure Act Regulations Package Commodity Act Regulations READY-TO-EAT SNACKS EXTRUSION TECHNOLOGY Introduction Materials and methods Raw materials Dehulling and milling Formulations used Extrusion conditions for lab scale extruder Spicing of samples Sensory evaluation Physical characteristics Proximate composition Consumer acceptability of extruded snacks Results Sensory evaluation Physical parameters of the extrudates Proximate composition of the extrudates Consumer evaluation of products POTATO CHIPS Introduction Materials and methods Procurement of raw material Preparation of potato chips Fat analysis Sensory Evaluation Statistical analysis Results and discussion READY TO EAT PROTEIN RICH FOOD BARS Introduction Formulation and preparation of protein rich food bars Results Organoleptic evaluation of protein rich rood bars Proximate chemical composition, mineral content and IVPD of most acceptable protein in rich food bars GRADING AND SORTING FOOD PRODUCTS USING COMPUTER Introduction Digital image processing Fundamental steps in image processing Image acquisition Image preprocessing Image segmentation Image representation and descriptioner Image recognition and interpretation Elements of digital image processing system Automatic grading and sorting of food products using computer vision systems Bakery products Fruits Vegetables Grains Limitations of the system IQF FREEZING AND APPLICATION IQF Spiral Freezers Applications Benefits Low operation cost Impingement Polybelt Tunnel Freezer Applications Modular IQF fluidized tunnelfreezer Multipass belt tunnel freezer Applications Tray IQF fluidized tunnel freezer Applications Drag-thru-dolly tunnel freezer Application FOOD CANNING Plant site Factory building Water supply and drainage Workers Machinery and equipment Canning method Key processes Sorting and grading Washing Peeling, coring and pitting Hand peeling Peeling, coring and pitting by machine Peeling by heat Lye peeling Blanchng Can filling Syruping or brining Lidding or clinching Exhausting Sealing Processing/Manufacturing Heat penetration in cans Manufacturing processes Non-acid Vegetables Effect of altitude on processing time Effect of altitude on processing pressure and temperature Effect of acidity on sterilization Effect of processing on strain in can Cooling Testing Labelling, storing and packing FRUITS CANNING TECHNOLOGY Canning of fruits Apples Storage Washing Grading Peeling and coring Blanching Canning Filling Exhausting Sterilizing Cooling Mangoes Oranges Papaya Pineapple Harvesting The Ginaca machine Trimming Slicing Grading and packing Prevacuumizing Syruping Double seaming Processing Cooling Crushed pineapple By products Peaches Grading Cutting and pitting Cutting and pitting by hand Cutting and pitting by machine Peeling and washing of clingstone of peaches Slicing Cans Filling Syruping Peeling and washing, freestone peaches Steaming Scalding in water Combination of steam and lye Sorting Grading Exhausting Closing Processing Cooling Storage Pears Grading Peeling and coring Grading and filling Syrupping Exhausting Closing Process Cooling PREPARATION OF FRU

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Agro Food Processing and Packaging Technology

AGRO FOOD PROCESSING AND PACKAGING TECHNOLOGY FOOD LAWS Introduction Food safety and standard act The ABCD of FSSA Salient features of FSSA Responsibilities of the food business operator Improvement notices Offences and penalties Licensing and registration Nutrition labelling Requirements Content on label Hazard analysis and critical control point (HACCP) IS 15000) Principles of HACCP Features Some salient points are Benefits of HACCP License process Food safety management systems certification scheme (IS/ISO 22000) Features Benefits Licence procedure ISI Mark: Bureau of Indian Standards (BIS, 1986) Features License procedure Weight and Measure Act Regulations Package Commodity Act Regulations READY-TO-EAT SNACKS EXTRUSION TECHNOLOGY Introduction Materials and methods Raw materials Dehulling and milling Formulations used Extrusion conditions for lab scale extruder Spicing of samples Sensory evaluation Physical characteristics Proximate composition Consumer acceptability of extruded snacks Results Sensory evaluation Physical parameters of the extrudates Proximate composition of the extrudates Consumer evaluation of products POTATO CHIPS Introduction Materials and methods Procurement of raw material Preparation of potato chips Fat analysis Sensory Evaluation Statistical analysis Results and discussion READY TO EAT PROTEIN RICH FOOD BARS Introduction Formulation and preparation of protein rich food bars Results Organoleptic evaluation of protein rich rood bars Proximate chemical composition, mineral content and IVPD of most acceptable protein in rich food bars GRADING AND SORTING FOOD PRODUCTS USING COMPUTER Introduction Digital image processing Fundamental steps in image processing Image acquisition Image preprocessing Image segmentation Image representation and descriptioner Image recognition and interpretation Elements of digital image processing system Automatic grading and sorting of food products using computer vision systems Bakery products Fruits Vegetables Grains Limitations of the system IQF FREEZING AND APPLICATION IQF Spiral Freezers Applications Benefits Low operation cost Impingement Polybelt Tunnel Freezer Applications Modular IQF fluidized tunnelfreezer Multipass belt tunnel freezer Applications Tray IQF fluidized tunnel freezer Applications Drag-thru-dolly tunnel freezer Application FOOD CANNING Plant site Factory building Water supply and drainage Workers Machinery and equipment Canning method Key processes Sorting and grading Washing Peeling, coring and pitting Hand peeling Peeling, coring and pitting by machine Peeling by heat Lye peeling Blanchng Can filling Syruping or brining Lidding or clinching Exhausting Sealing Processing/Manufacturing Heat penetration in cans Manufacturing processes Non-acid Vegetables Effect of altitude on processing time Effect of altitude on processing pressure and temperature Effect of acidity on sterilization Effect of processing on strain in can Cooling Testing Labelling, storing and packing FRUITS CANNING TECHNOLOGY Canning of fruits Apples Storage Washing Grading Peeling and coring Blanching Canning Filling Exhausting Sterilizing Cooling Mangoes Oranges Papaya Pineapple Harvesting The Ginaca machine Trimming Slicing Grading and packing Prevacuumizing Syruping Double seaming Processing Cooling Crushed pineapple By products Peaches Grading Cutting and pitting Cutting and pitting by hand Cutting and pitting by machine Peeling and washing of clingstone of peaches Slicing Cans Filling Syruping Peeling and washing, freestone peaches Steaming Scalding in water Combination of steam and lye Sorting Grading Exhausting Closing Processing Cooling Storage Pears Grading Peeling and coring Grading and filling Syrupping Exhausting Closing Process Cooling PREPARATION OF FRU

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AGRO FOOD PROCESSING AND PACKAGING TECHNOLOGY

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AGRO FOOD PROCESSING AND PACKAGING TECHNOLOGY

Written By

EIRI Board of Consultants & Engineers

* E-Mail: [email protected] & [email protected] *Website: www.eiriindia.org & www.industrialprojectreports.com

4449, Nai Sarak, Main Road, Delhi - 110006 (India) Ph: +91-11-23918117, 23916431, 45120361, 23947058, 64727385 * E-Mail: [email protected] & [email protected] *Website: www.eiriindia.org & www.industrialprojectreports.com

PRINTED & PUBLISHED BY


4449, Nai Sarak, Main Road, Delhi - 110006 (India)
Ph: +91-11-23918117, 23916431, 45120361, 23947058, 64727385

* E-Mail: [email protected] & [email protected] *Website: www.eiriindia.org & www.industrialprojectreports.com


Sole Distributor: EIRI PROJECT CONSULTANTS AND PUBLISHERS 4/54 Roop Nagar, Delhi-110007

Preface
Agro-food processing industries have been chosen as one of the Technology Mission Areas for more reasons than one. This structural change in output has not been accompanied by corresponding change in the occupational structure of the countrys labour force. Nearly 74 per cent of the countrys population live in rural areas. A little over 60 per cent of the total labour force is still engaged in the agricultural sector. The rural economy has so far been unable to absorb the increasing rural labour force in production activities and this has been a big constraint for reducing the incidence of rural poverty. Agro-food processing industries have the potential to generate directly significant employment in production activities and also indirect employment through its forward and backward linkages. The term agro-food processing covers a wide range of activities utilizing farm, animal and forestry based products as raw materials. There are certain traditional agro-based industries such as rice and flourmills, sugar, khandsari and gur manufacture, edible oils and the processing of plantation crops like tea, coffee and cashew nuts. There are also some relatively modern food processing industries such as dairy products, confectionery, marine products, horticultural and vegetable products as well as meat and poultry products. In addition, there is also a limited extent of processing of agro-wastes and by-products of main agro-based industries. Due to this wide range of activities, there is a lot of diversity in the nature of problems and issues relating to different agrofood processing industries. It is, therefore, difficult to envisage an overall technology policy framework covering the various agro-

Copyrights Reserved by Sudhir Gupta, Delhi

ISBN: 9789380772264
Printed in New Delhi (INDIA) The book is sold subject to the condition that it shall not, by way or trade or otherwise, be lent, resold, hired out, or otherwise circulated without the publishers prior written consent, in any form of binding or cover other than in which it is published/compiled and without a similar consent including this condition being imposed on the subsequent purchaser and without limiting the rights under copyrights reserved above, no part of this publication may be reproduced, stored in or introduced into a retrieval system, or transmitted in any form or by any means (electronic, mechanical, photocopying or otherwise), without the written prior permission of both the copyright owner and above-mentioned publisher of this book. While the book has been prepared carefully, yet the publisher, printer and compiler do not hold any responsibility on the subject of the book. All disputes regarding this book are Subject to Delhi Jurisdiction only.

` 1100/Printed & Published by Sudhir Gupta for Engineers India Research Institute , 4449 Nai Sarak, Main Road, New Delhi -110006

food processing industries. This book has chosen to concentrate on a few sectors wherein the introduction of modern technologies has the potential of creating a substantial impact on the rural economy and improving the income of the rural population. Any technology policy relating to agro-food processing activities apply differently in the case of different activities depending on the purpose of processing. Some processing refer to necessary processing that must be done before consumption. Although most of the technology is readily available in the country, it is not being extensively adopted because economic incentives are often mission, or institutional arrangements for collection, processing and marketing of he byproducts may be lacking. Since the processing of byproducts in the cereals sector constitutes introduction of new manufacturing activities, or the expansion of existing ones, such activities would generate additional employment. The next category of food processing concerns processing and packaging in order to provide easy transportability and marketability of some food products. The processing of milk and milk products falls in this category. This would increase the income of farmers, especially small farmers and landless agricultural labourers in the rural areas. It would also promote consumer welfare. However, processing in the organized sector helps in achieving higher efficiency in the use of raw materials and by products. Processing in the organized sector generates additional employment in trade and transport activities which may be quite substantial as compared to direct employment created in processing activities. At the same time, consumer welfare is enhanced by modern processing technoloy which ensures better quality and clean packaging in an uncontaminated environment. Export potential also improves. The book contains following chapter on various aspects of agro food processing and packaking:

Food Laws, Ready-to-Eat Snacks Extrusion Technology, Potato Chips, Ready-to-Eat Protein Rich Food Bars, Grading and Sorting Food Products Using Computer, IQF Freezing and Application, Food Canning, Fruits Canning Technology, Preparation of Fruit Juices, Squashes And Cordials, Technology of Vegetables Canning, Poultry Processing, Aqua Farm, Pulse Production, Production Process of Large Cardamom, Rice-Fish-Poultry Farming, Organized Dairy Farms, Polyhouse Technology for Production of Vegetables, Productivity of Goats, Continuous Processing of RTD Tea and Coffee Beverages, Cold Chain Supply, Processing and Preservation of Fish, UHT Plant For Milk in Aseptic Pouches, Plant Economics of Aquaculture Shrimp Farming, Plant Economics of Canning and Preservation of Vegetables, Plant Economics of Canning of Fruits and Vegetables, Plant Economics of Cold Supply Chain, Plant Economics of Dairy Farming (Buffaloes Kundi), Plant Economics of Dairy Farming (Jersey Cows) & Milk Processing, Plant Economics of Frozen Food by IQF Technology, Plant Economics of Fruit Juice in Tetrapack, Plant Economics of Gram Dall/Pulse Mill, Plant Economics of Green House/Poly House, Plant Economics of Mango Pulp, Plant Economics of Namkeens (Kurkure Type Snack Food), Plant Economics of Pineapple, Tomato, Fruit Juice and Other Products Bottling Plant, Plant Economics Of Potato Chips With Nitrogen Packing (On Imported M/C), Plant Economics of Poultry and Hatchery Farming, Plant Economics of Protein From Soyabean, Plant Economics of Ready to Eat Foods in Tetra Packs, Plant Economics of Rice Sorting/Grading Plant, Plant Economics of Seeds Grading and Processing, Plant Economics of Snack Food (Crax Size) (Roll and Ball Type), Suppliers of Plant and Equipments for Food Processing and Allied Industry. EIRI Board of Consultants & Engineers

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