Food Processing

Definition, Principles of Food Processing, Effect of processing on Nutrients.

FOOD PROCESSING is defined as the practices used by food and beverages. Bakery and
confectionery, meat processing industry, dairy industry to transform raw (plants and animals)
materials such as grains, produce meat and dairy, into desired products into the market.
Nearly all our food is processed in some way. Examples include freezing vegetables, milling
wheat into flour and frying potato chips. Slaughtering animals for meat is also sometimes
considering a form of food processing. From dairy industry so many milk products are
producing for consumers.

The main AIM of food processing is to preserve the food with in the safe environment
and to distribute the processed foods to consumers with optimum quality with reasonable
price.

“PROCESS” may be defined as combination or sequence of operation which take place

in one or more pieces of equipment’s leads to physical, chemical or biological changes in the
feed material resulting in a desirable product. Food process engineering is about the operation
of number of processes in which food is manufactured modified, standardized, filled, sealed
and packed.

The main purpose of food processing is to design the process and standardize the
process, validation of the process and to operate the process which results in safe food
products with specific, desired properties and structure. Before going to design a process it is
more important to understand the physical, chemical and biological properties of food.

WHY ARE FOODS PROCESSED?

Food manufactures process the foods to increase the availability thought out year and to
increase the shelf life and to add value to food products, by adding dietary nutrients like
vitamins, minerals and to improve the appearance, taste and with different new technologies.
Food products are prepared by different food industries to attract the people, to meet the
consumer demands, and their requirement with production of different food products like
ready to eat, ready to cook, ready to use, functional foods also known as designer foods,
medical foods and fortified food, nutritional foods, nutraceutical foods, therapeutic foods and
healthy foods, extruded products. Nutraceuticals can be Intake as in the form of fortification;
supplements are consumed directly as genetically enriched foods. Functional foods play
important role in promoting health and reducing healthy risks. Functional foods may be
defined as those with a traditional counter past, while nutraceuticals or those derived from
different edible source but consumed in medical form like tablets or capsules or pills.
Nutraceuticals can be prepared from chemical synthesis, fermentation and genetic
engineering. They include a range of agro food ingredients or photochemical extracted from
the edible plants or animals products.

Food processing technologies like evaporation, concentration, mixing, homogenization,

dehydration, pasteurization, sterilization, irradiation, pulsed electric field processing,
extrusion technology, ultra sonication, ozonation, omhic heating, aseptic processing, pulsed
light, size reduction place a major role in processing of different foods.

Processed foods are CATEGORIZED INTO THREE mainly - Minimally processed foods,
Ingredient and Highly processed foods. Even though there is no universally accepted method
of categorizing processed foods, it is helpful to make the distinction between foods like
toaster pastries, which are highly processed; flour, which is processed food ingredient; and
milk, which is generally consider minimally processed. Most of ours food has been processed
to same degree, sometimes using techniques that have been practiced for centuries.

Some sounds of food packaging also pose health concerns. Biphenyl - A (BPA) is a chemical
commonly used in linings of metal cans and in the manufacture of heard plastics, such as
some bottles and food storage containers. Studies have found links between BPA exposure
and cardiovascular disease diabetes, male sexual dysfunction, certain cancers and changes
into immune functions. A recent study of products package in metal cans and plastic wart,
including soups, vegetables and infant formula, detected low levels of BPA in those foods.
As a precautionary measure, some manufactures have stopped using BPA in bottles and
packages.

In India food processing industry plays important role in Indian economy. APEDA
(Agricultural and Processed food products Export Development Authority), MOFPI (Ministry
of Food Processing Industries), CFTRI (Central Food Technological Research Institute),
ICRISAT (International Crops Research Institute for Semi – Arid Tropics) - nutriplus
knowledge center, directorate of sorghum research and so many government and non -
government organizations and NIN are working for new products development, in the
manner of research and development and their analysis for their nutrient content.

PRINCIPLES OF FOOD PROCESSING

1. To increases the availability of food products throughout the year with optimum
quality.
2. To maintain the quality of product during storage and distribution until it reach the
consumer.
3. To increase the shelf life of the products.
4. To increase the nutritive value of the products as by fortification enrichment.
5. To increase the production of food products with number of varieties which are
suitable for customer with different shape, size and utilization of different food
processing technologies.
6. To increases the Indian economy with food processing application in food processing
industry.
 7. To reduces the microbial load by using different food processing and preservation
methods.
8. To prevent the self-decomposition of foods.
9. To prevent the physical and mechanical damage of the food products.
10. To avoid the wastage of surplus food crops.

EFFECT OF PROCESSING ON NUTRITIVE VALUE OF FOODS

Almost all foods consumed by man are subject to cooking, the exception being fruits and
some greens and vegetables, which are used raw for salads and chutneys. When one talks of
nutritional content of foods, it should be related to cooked foods that reach the table.
However, cooking practices vary from one region to another in the country and even from
one household to another. Hence, cooked food cannot be standardized and information on the
effect of wide range of cooking particles on nutritive value of foods is not available. Cooking
has both adverse and beneficial effects. The effects of some typical methods of cooking on
nutritive value are discussed.

The following processes are involved in cooking as practiced in India. Wet method of
cooking by boiling, steaming or pressure cooking; dry method of cooking at high temperature
like frying, roasting and baking. The loss of nutrients on cooking depends on the temperature,
duration of cooking and the nutrient.

The loss of nutrients during the ordinary cooking is not as much as it is generally
believed. Ordinary cooking causes little loss of protein, fat, carbohydrate in cereals, pulses
and meat. Some protein may be lost if vegetables are cooked in water containing salt and the
cooking water is discarded. If the cooking water is thrown away, there is considerable loss of
minerals, especially Na, K and Ca due to leach. It is therefore advisable either to cook in a
minimum amount of water or to use the cooking water in soups and gravies. Root vegetables
do not suffer much loss of nutrients by either wet or dry method of cooking since outer skin
prevents leaching out of nutrients. It is therefore recommended that the root vegetables are
cooked with their skin and peel them before using them in other preparations. Cutting
vegetables into small pieces and exposing them to air before cooking may result in loss of
vitamins, particularly vitamin C. It is advisable to cut larger size pieces and put into boiling
water immediately and cook for a short period. Steaming, however, prevents losses due to
leaching.

Thus, cooking as practiced has several advantages in improving the quality, digestibility
and palatability. At the same time, cooking also can reduce the vitamin and mineral content,
but taking certain precautionary measures like cooking in limited water and in presence of
acids, it can help preserve vitamins to a greater extent.

Questions:

1. Define food processing and its principles (5m)

2. Write a note on effect of processing on nutritive value in foods(5M)
 Rice Processing
Rice refers to two species (Oryza sativa and Oryza glaberrima) of grass, native to tropical
and subtropical southeastern Asia and to Africa, which together provide more than one fifth
of the calories consumed by humans. Rice is an annual plant, growing to 1-1.8 m tall,
occasionally more, with long slender leaves 50-100 cm long and 2-2.5 cm broad. The small
wind-pollinated flowers are produced in a branched arching to pendulous inflorescence 30-50
cm long. The seed is a grain (caryopsis) 5-12 mm long and 2-3 mm thick. The word
rice derives from the Tamil word arisi.

The common cereals and millets consumed in India are rice, wheat, maize, sorghum. Cereals
are the foods consumed in large and at greater frequency by a vast majority of population in
the world. In about 75% of the countries of the world, cereals and millets from the staple food
of diets.

It is the most extensively grown in India and its forms the staple article of diet of a majority
of people in the country, carbohydrates in the forms of starch, which provides energy to the
body, constitute the bulk of the rice grains. Rice provides about 350 calories per 100gms dry
weight. The protein content of rice is only around 7% which is an appreciable amount,
though the proteins content in rice low, as compared to wheat, the quantity of rice protein is
superior to wheat proteins. Rice protein however is deficient in lysine and threonine, as
compared with a protein of high-quality like egg protein. However, when rice is eaten with
pulses, as is the common practice in India, its protein quality improves due to the mutual
supplementary effect between cereals and pulses proteins, as a latter contains adequate
quantities of these 2 amino acids.

Rice is poor source of fat and minerals, especially calcium and iron. Therefore, rice eaters
must depend on order sources such as green leafy vegetables for minerals supplementation.
Rice is a poor source of carotene or pro-vitamin A, but is an important source of B-vitamin.
Since most of these vitamins present in outer layer, polishing (removal of the bran) to
produce the white rice for sale, reduces the B-vitamin content of different degrees depending
on the extent of polishing. Highly polished rice has therefore very low level of B-vitamin. It
is better to consume rice which is not polished too much.

Processing: The rice kernel is composed of four primary components, viz. hull or husk, seed
coat or bran, embryo or germ and endosperm. The primary objective of milling rice is to
remove the indigestible hull or husk and additional portions of bran to yield whole unbroken
endosperm. Milling is a series of mechanical operations which remove the hull, embryo and
outer layer of the rice kernel.

The mature rice grain is harvested as paddy, in which the caryopsis is enclosed in a tough
siliceous hull [husk].The rice caryopsis is enveloped by the hull, composed of 2 leaves lamma
& palea. Hulls are about 20% [range 16-28%] of rough rice weight. Endosperm of matured
rice is protected or covered by three layers.
  Pericarp
 Seed coat [tegman] and
 Nucellus [forms caryopsis coat]

COMMERCIAL MILLING

Commercial milling systems mill the paddy in stages, and hence are called multi-stage or
multi-pass rice mills. The objective of commercial rice milling is to reduce mechanical
stresses and heat buildup in the grain, thereby minimizing grain breakage and producing
uniformly polished grain. Compared to village-level systems, the commercial milling system
is a more sophisticated system configured to maximize the process of producing well-milled,
whole grains.

The rice milling facility comes in various configurations, and the milling components vary in
design and performance. “Configuration” refers to how the components are sequenced. The
flow diagram below shows a modern commercial mill catering to the higher end market. It
has three basic stages,

 The husking stage,

 The whitening-polishing stage, and
 The grading, blending, and packaging stage.

Objective of commercial milling:

A commercial rice miller will have following objectives:

 Produce edible rice that appeals to the customer - i.e. rice that is sufficiently milled
and free of husks, stones, and other non-grain materials
 Maximize the total milled rice recovery out of paddy and minimize grain breakage.

MODERN RICE MILLING

In Modern rice mills, many adjustments (e.g. rubber roll clearance, separator bed inclination,
feed rates) are automated for maximum efficiency and ease of operation. The whitener-
polishers are provided with gauges that sense the current load on the motor drives which
gives an indication of the operating pressure on the grain. This provides a more objective
means of setting milling pressures on the grain.

Modern rice milling processes consist of:

Stage Function

Pre-cleaning Removing all impurities and unfilled grains from the paddy

Husking Removing the husk from the paddy

Husk aspiration Separating the husk from the brown rice/unhusked paddy

Paddy Separating the unhusked paddy from the brown rice

 separation

De-stoning Separating small stones from the brown rice

Whitening Removing all or part of the bran layer and germ from the brown rice

Polishing Improving the appearance of milled rice by removing remaining bran

particles and by polishing the exterior of the milled kernel

Sifting Separating small impurities or chips from the milled rice

Length grading Separating small and large brokens from the head rice

Blending Mix head rice with predetermined amount of brokens, as required by the
customer

Weighing & Preparing milled rice for transport to the customer

bagging

Flow diagram of a modern rice milling

The flow diagram below represents the configuration and flow in a typical modern rice mill.
Description of flow of materials and processes:

1 – paddy is dumped in the intake pit feeding the pre-cleaner

A – straw, chaff and empty grains are removed
2 – pre-cleaned paddy moves to the rubber roll husker:
B – husk removed by the aspirator
3 – mixture of brown rice and unhusked paddy moves to the separator
4 – unhusked paddy is separated and returned to the rubber roll husker
5 – brown rice moves to the destoner
C – small stones, mud balls etc. removed by de-stoner
6 – de-stoned, brown rice moves to the 1st stage (abrasive) whitener
7 – partially milled rice moves to the 2nd stage (friction) whitener
D – Coarse (from 1st whitener) and fine (from 2nd whitener) bran removed from the rice
grain during the whitening process
8 – milled rice moves to the sifter
E – Small broken/brewer’s rice removed by the sifter
9a – (for simple rice mill) ungraded, milled rice moves to bagging station
9b – (for more sophisticated mill) milled rice moves to the polisher1
10 – Polished rice, will move to length grader
11 – Head rice moves to head rice bin
12 – Broken moves to broken bin
13 – Pre-selected amount of head rice and broken move to blending station
14 – Custom-made blend of head rice and broken moves to bagging station
15 – Bagged Rice moves to the market
 AGEING

Freshly harvested rice cooks to a sticky lumpy mass, swells but a little and yield a thick gruel;
these drawbacks tend to disappear as the rice is stored for a few months.

Aging is a post-harvest storage process to improve rice quality and functional properties.
Stored rice is preferable to freshly harvested rice because stored rice has a favoured taste and
aroma and increases milling quality. Aging is important in the post-harvest process because it
can extend shelf life and increase the commercial value. Rice's commercial value consists of
sensory and physicochemical properties. Aging has different sensory properties from fresh
rice. It affects rice, especially flavour, color, and aroma. Rice color change is influenced by
enzymatic or non-enzymatic reactions and fungal presence. In addition to sensory properties,
the aging process may affect physicochemical characteristics such as elongation ratio,
whiteness, volume increase, water requirement, solid quantity loss, and pasting properties.
Other factors, such as aging temperature, also affect physicochemical properties that
contribute to various micro and macromolecular reactions such as amylose and amylopectin
in rice.

Aging effects on chemical characteristics:

 In the aging process, there are several changes in the chemical composition of rice.
There is a relationship between the duration of the aging process and changes in
chemical composition. The chemical components of rice that change include the
amount of amylopectin. Rice was stored for 9 months, with decreased starch
gelatinization due to decreased amylopectin. Also, the aging process affects protein
and fatty acid content.
 Amylopectin degradation during the storage process affects the endogenous amylose
content in the starch structure. The decrease in short-chain amylopectin caused by
degradation during storage will affect rice's pasting properties. The aging process can
also increase the interaction of amylose - amylose, amylose-amylopectin, and starch-
protein, which can increase water absorption and gelatinization time.
 The components of macromolecules that are affected by the aging process are
carbohydrates, proteins, and lipids. There is a change in carbohydrates; the
endogenous enzyme α-amylase in rice will hydrolyse the starch during the aging
process and cause a high amount of short-chain starch compared to medium and long
chains. Besides, the number of monosaccharides at the beginning of aging is less and
increases after aging. It is indicated because glucose still binds to other
macromolecules.
 The aging process also affects protein. Proteins consist of albumin, globulin,
prolamin, and gluten. The protein content in rice affects adhesiveness. Also, during
the aging process, protein oxidation can occur, which causes a change in the
sulfhydryl group's disulphide bond structure, which causes an increase in micelle
bonds in rice starch, which can inhibit swelling in rice.
  The main lipid content in rice is oleic acid and linoleic acid. During the aging process,
lipase can hydrolyse lipids in rice, reducing rice quality. The lipid hydrolysis process
can be regulated by providing suitable humidity conditions and a higher temperature.

Aging effects on physical characteristics:

 Physical characteristics may change during storage. It can affect cooking and eating
quality, such as absorbing water, hydration ability, swelling, increased volume,
hardness, and pasting properties.
 If there is an increase in the hardness value and a decrease in the adhesiveness value,
it will affect the pasting properties because rice starch will experience difficulty in
hydrating.
 The viscosity and breakdown viscosity values showed the ability of starch granules to
swell and fragile.
 The lower the swelling ability of the starch gel formed, the stiffer and denser it will
be. Rice, with Postharvest Yellowing (PHY), which has been treated with aging,
shows a change in physical properties.
 This rice has a higher breakdown viscosity than normal rice. The aging process affects
the pasting properties where the stored rice has a higher peak viscosity and a lower
pasting temperature than fresh rice.
 The decrease in viscosity is influenced by the amylase content, which causes a high
percentage of increase in short chains and a decrease in long chains during storage
contributes to increasing the starch's swelling ability during the gelatinization process.
 The pasting properties change in rice during storage is due to the interaction between
starch and non-starch components. At high-temperature storage (40 ᵒC), there will be
an increase in the α-amylase enzyme activity and a decrease in amylose water content,
causing changes in pasting properties viscosity and viscosity breakdown.

PARBOILING OF RICE

Introduction

The technique for parboiling of rice was developed in India to prevent losses occurring due to
breakage during hand pounding, especially the long grained varieties. In this technique paddy
is soaked in excess water and later on cooked in its husk, the objective being pre -
gelatinizing the starch. Any hairline cracks are sealed due to homogeneous mass of
gelatinized starch and thus prevent breakage during milling. The paddy is then drained and
dried. Parboiling is pre-treatment or optional milling step in paddy milling. It is also known
as precooking, half boiled or hydrothermal treatment.

Objectives:

 To minimize the breakage during milling and increase the milling efficiency
 To retain the maximum nutrients.

Parboiling process:
Parboiling can be accomplished in variety of ways. The general scheme is to hydrate
(steeping) paddy to 32 – 38% moisture and partially gelatinize the starch by steam heating at
15 lb. pressure for 10 – 20 min. Parboiling causes certain physico-chemical changes such as
improved milling yields (66 – 70%), increased resistance to insects and firmer cooked rice
texture accompanied by a darker and more yellow endosperm. Parboiling has further
advantages like: during soaking and cooking the water soluble vitamins (niacin, riboflavin,
and thiamine) which are present in germ and pericarp gets migrated into endosperm and thus
improves the nutritional value of parboiled rice. Even proteins present on the grain surface
are denatured, become insoluble, and therefore are not removed during washing and cooking.

Parboiling can be done in two ways

1. Single boiling: Generally clod water soaking overnight followed by steaming and
drying to desired moisture level is known as single boiling process.
2. Double boiling process: Generally CFTRI hot water soaking method is best example
of double boiling process.

Single boiling process

 Weigh 1-5kg of paddy and soaked in cold or normal water in soaking bins/vessels for
overnight (24hrs).
 Remove impurities which are floating on the top of soaking bins.
 Drain water after 24 hours soaking.
 Soaked paddy is steamed in autoclave for 10-15 minutes 5. Steamed paddy is subject
to drying either sun drying or keeps in cabinet dryer at 100 ºC for 4 hours.

Double boiling process

 Weigh 1-5kg of paddy and soaked in hot water in soaking bins/vessels having water
temperature 70ºC and allow it for 3-3.5hr.
 Remove impurities which are floating on the top of soaking bins.
 Drain water after 24 hours soaking.
 Soaked paddy is steamed in autoclave for 10-15 minutes.
 Steamed paddy is subject to drying either sun drying or keeps in cabinet dryer at 100
ºC for 4 hours.

CFTRI parboiling process (Central Food Technology Research Institute, Mysore):

 This was developed to avoid bad smell. The paddy is soaked in hot water (65-70°C).
Germ action does not occur in hot water, thus the smell is avoided.
 Soaking time is reduced to 3-4 hrs.
 The CFTRI also developed the pressure parboiling method. Soaking time is only 30-
60 minutes and steam is passed through the grain to raise the pressure slowly from an
initial 0.28-0.70 kg/cm2 to 1.41-2.11 kg/cm2 and this is maintained for 20-30 min. In
this method, the processing time is reduced.
 Draining of water and steaming of soaked paddy in the same vessel for 5-10 minutes,
and
  Drying of the paddy in the sun or in mechanical driers.

Methodology

1. In this method water is first taken into the heating steam to 85-90 0C, or hot water from
a separate storage tank is used. Rough rice previously lifted in an overhead cabin is
then discharged in to the water; the floating chaff is removed, in the rice is allowed to
soak for 3-3.5 hr. at around 70 0c, with occasional recirculation of water within the
tank to equalize the temperature.
2. Some millers prefer to put water and rough rice together in to the tank to avoid
floating chaff, which, they feel, traps and waste some good grain. Still others ,of
“doubling boiling” vintage, let rough rice in to the tank, steam it , and then pump in
cold water; the resulting temperature after circulation is around 60-65 0c,which
requires about 6hr for soaking .
3. After soaking, the rice is drained and steam is incorporated, while the outlet is kept
open to drain out the condensate. Steaming is stopped after excess steam starts
coming out from the bottom and the top.
4. If the drying is done mechanically, rice is discharged into a belt or screw conveyor
and fed to the dryer through an elevator.
5. This is a batch process but it can be made semi- continuous by using a number of
tanks. The process has been adopted fairly widely in India.

Advantages of parboiling:

1. DE - husking of parboiled rice is easy.

2. Grain becomes tougher resulting in reduced losses during milling. This benefit is due
to healing of all kernel defects like cracks and chalkiness by parboiling.
3. Milled parboiled rice has greater resistance to insects and fungus.
4. Loss of nutrients due to the removal of husk and bran in milling are decreased. During
harvesting the vitamins and minerals present in hull (outer covering of the paddy) and
bran coat dissolved and spread into the endosperm.
5. Loss of the water soluble nutrients due to washing of rice is less in parboiling rice
compared with the raw rice.\
6. Parboiling improves the digestibility and protein efficiency ratio is higher compared
to raw rice.

Disadvantages:

 Sometimes it has unpleasant smell and changes in colour and hence not preferred.
 It requires prolonged cooking time and more fuel
 Since the oil content is high the polishers may get choked
 The heat treatment may destroy antioxidants. Due to high moisture content,
mycotoxins may be found.
Popping: Popping is a type of starch cookery, where grains are exposed to high temperature
for short time. Popping is a process in which kernels are heated until internal moisture
expands and pops out through the outer shell of the kernel whereas puffing is a process
where, sudden release of water vapor and expansion of pre-gelatinized kernel. During the
popping of popcorn the pericarp acts as a pressure vessel and popping occurs at about 177°C,
which is equivalent to a pressure of 135psi inside the kernel.

Puffing: Puffing is a thermal process in which rapid heat transfer takes place in order to
phase shift the water to a vapor. Two things are important for grain to puff – the grain must
be steeped or cooked, and a large, sudden pressure drop must occur in atmosphere
surrounding the grain. Rice and wheat are most widely used cereals for puffing. They are
puffed as whole kernel grains. In gun puffing, high temperatures are attained (600 – 800°F)
followed by a pressure drop of 100 – 200 psi. A rotating gun is heated by means of gas
burners with very hot flames; the moisture in the grain is converted into steam. When the lid
is opened to fire the gun, the internal pressure is released, and the puffed grain is caught in a
continuously vented bin.

Methods of Popping and Puffing:

1. Sand roasting: In sand roasting method, pre-gelatinized cereals are exposed to hot
sand, while temperature of sand is about 250°C.Due to sudden thermal gradient, the
moisture inside the grains vaporizes and tries to escape through the micropores,
expanding the starchy endosperm in size in this process.

2. Gun puffing: is a process in which the milled grains are introduced in to the gun or
high pressure chamber after preheating, and then a superheated steam is introduced to
the closed rotating chamber. The steam pressure is critical to the final texture of the
puffed product, as too low pressure would result in product lacking crispiness and too
high pressure would shatter the rice. Sufficient time is allowed for the superheated
steam to cook the grain in semi-plastic state and in the end, the pressure is suddenly
released for obtaining the crispy puffed grain. Keesenberg (1978) developed a puffing
gun, which was composed of a rotating horizontal cylinder having the length of 1.2 m
and the inner diameter of 200 mm. The cylinder was closed on one side and the steam
inlet is placed at this point. On the opposite side a heavy cast iron lid was placed

3. HTST Fluidized Bed Puffing and Popping: A fluidized bed is formed when a
quantity of a solid particulate substance (usually present in a holding vessel) is placed
under appropriate conditions to cause the solid/fluid mixture to behave as a fluid.
Fluidization is known to increase the heat and mass transfer as product surface area is
uniformly exposed to the heating medium, therefore, fluidized bed high temperature
short time (HTST) puffing is more efficient than hot air or conduction roasting or
puffing process.
 4. Microwave Popping and Puffing: During microwave expansion of cereal grains, the
microwave energy heats the product through the vibrational energy imparted on
moisture. Upon heating, moisture generates the superheated steam necessary for
expansion, which accumulates at the nuclei in the glassy matrix, creating a locally
high pressure. As cereal matrix undergoes a phase transition from glassy to rubbery
state, it starts to yield under high superheated steam pressure and expansion takes
place.

Popped and Puffed Cereal Products: Puffed rice is very popular in many countries as a
breakfast cereal or as a light food. It is a whole grain puffed product from parboiled milled
rice. It is prepared from hydrothermally treated or pre-gelatinized milled rice by heating in
high temperature air, oil and sand or by gun puffing method. Puffed rice is ready for
consumption and easily digestible. It is commonly used in snacks, cereals drinks, Ready- to-
Eat (RTE) breakfast cereals and infant foods.

Flaking: Flaked rice is another important value added product prepared from paddy.
Traditionally, it is prepared from soaked paddy, after heat treatment and immediate flattening
using a flaking machine (an edge runner).

Flaked products are produced by passing tempered grits or pellets through two large counter
rotating metal rolls, one of which is adjustable so that the distance between them or roll gap
can be set to produce a flake of the desired thickness. These rolls are hollow and are
internally cooled by passing water through the interior of the roll. A scraper knife on each roll
removes the flakes, which are then conveyed to toasting oven.
Flaked rice is made from parboiled rice. Paddy is soaked in water for 2 -3 days to soften the
kernel followed by boiling water for a few minutes and the water is drained off. The paddy is
heated in a shallow earthen vessel or sand in iron pan till the husks break open. It is pounded
by a wooden pestle which flattens the kernel and removes the husk. The husk is separated by
winnowing. Flaked rice is thin and papery and of white colour.

Quick cooking rice is made by steeping polished rice in water to a moisture content of 35
per cent, cooking under pressure and drying. Alternatively the rice may be subjected to
freezing, thawing and dehydration.

Derived products: Polished rice may be precooked and canned as rice pudding and also used
to make dry breakfast cereals.

NOODLES

A noodle is a thin strip of pasta, usually cut or extruded from some kind of dough. It is the
basic unit in dishes like spaghetti, linguine and soba. The term often refers to moist,
cooked pasta, since it has connotations of curviness and slipperiness, but also to dried
noodles that must be reconstituted by boiling or soaking in water. The word noodle derives
from Latinnodus (knot), via German Nudel (noodle, pasta).

The big difference between noodle varieties is in the fat and water content. The instant or
fried noodles contain only 3 to 6 g of water, compared to non-fried dried noodles, which
have a water content of 12 to 14 g. The proportions are reversed for fat content - instant
fried noodles have around 20 g, while non-fried dried noodles have as little as 3 to 5 g.
Instant or fried noodles are subjected to an additional process step compared to dried
noodles, they are deep fried in oil, hence part of the water is replaced by fat.

Raw material composition

 Noodles nutritional quality depends on wheat quality, basic flour specifications,

ingredient functions, and production variables according to the type of noodles
process. Flour color, protein content, ash content, yellow pigment and polyphenol
oxidase activity are important factors.

 Starch characteristics, protein content and quality are important as well, the relative
importance of starch and proteins varies considerably with noodle type.

 Oil type is important for instant noodles nutritional quality.

 Other factors, such as ingredients added (e.g. minerals and vitamins) in the noodle
formula and processing variables used during noodle preparation, also affect the
cooked noodle nutritional quality.
Question:

1 Write about the Processing of Rice (10M)

2 Write a note on Parboiling of rice (5M)

3 Write a note on By-products of Rice (5M)