cereals & millet processing

Processing of Cereals

A.Poshadri M.Tech (Food Tech.)

Assistant ProfessorDepartment of Food Technology

Prof. Jayashankar Telangana State Agriculture UniversityEmail: poshadri_fst@yahoo.co.in

Cell No: +919492828965

IntroductionCereals are staple foods, and are important sources of nutrients in both developed and developing countriesWheat, rice, and corn are the major important grains in the human diet. The minor grains include oats, barley, rye, triticale, sorghum and milletsCereals grains are rich sources of fibre, vitamins, minerals, and photochemicals

• After harvest, correct storage of the grain is important to prevent mould spoilage, pest infestation and grain germination

• Dehusking (Dehulling) and Milling are the main processing techniques associated with cereals

Cereals and Millets– Sorghum– Maize– Foxtail Millet – Pearl Millet– Finger Millet– Kodo Millet– Little Millet– Proso Millet– Barnyard Millet

Production status

Crop Production (Million Tonnes) (2012-2013)

Rice 101.8Wheat 92.2Sorghum 5.2Maize 21.0 Pearl Millet 8.1 Finger Millet 1.7 Small Millets 0.4Ref: Ministry of Agriculture, GOI

Nutritional compositionCrop Protein

(g)Fat (g)

Fiber (g)

CHO (g)

Minerals (g)

Iron (mg) Calcium (mg)

Rice raw milled

6.8 0.5 0.2 78.2 0.6 0.7 10

Wheat 11.8 1.5 1.2 71.2 1.5 5.3 41

Sorghum 10.4 1.9 1.6 72.6 1.6 4.1 25

Maize 11.1 3.6 2.7 66.2 1.5 2.3 10

Foxtail Millet 12.3 4.3 8.0 60.9 3.3 2.8 31

Pearl Millet 11.6 5.0 1.2 67.5 2.3 8.0 42

Finger Millet 7.3 1.3 3.6 72.0 2.7 3.9 344

Kodo Millet 11.0 3.6 10.0 66.6 1.9 0.5 27

Little Millet 7.7 7.6 1.5 9.3 27

Proso Millet 12.5 4.2 2.2 73.0 1.9 0.8 14

Barnyard Millet

12.2 3.85 10.1 55.8 3.2 1.4 24

Maize• It is a cheap form of starch and is

a major energy source for animal feed

• Commercial important varieties of maize are

1.dent maize (identified by the dent in the crown of the kernel);

2.flint maize (hard, round kernels);3.sweet corn (a dent-type maize);4.popcorn (flint-type maize which

expands when heated).

Sorghum

•It is an important food crop in sub-Saharan Africa on account of its drought tolerance

•Low glycemic index and increase satiety

•Gluten Free foods

Foxtail Millet

• Foxtail millet (Setaria italica) is one of the important food crops in parts of the Indian subcontinent, African countries and China. Telugu : Korra

• Foxtail millet ranks second in the total world production of millets.

• Foxtail Millet contains 9–14% protein, 70–80% carbohydrates and is a rich source of dietary fiber.

• It contains maximum amount of chromium among all the millets with an account of 0.030mg per 100g.

• Foxtail Millet is a starchy food with a 25:75 amylose to amylopectin ratio. Lipids are 3-6%having about 50% of the lipids in the form of polyunsaturated fatty acids

Pearl Millet

• India is the largest` producer of pearl millet in Asia, both in terms of area about 9 million ha and production 8.3 million tons. Telugu : Sajja

• A pearl millet grain comprises about 8% pericarp, 17% germ and 75% endosperm .

• Pearl Millet Protein 7.3, Fiber 3.6,Minerals 2.7, Iron 3.9, Calcium 344 .

• Pearl millet for increasing its acceptability as ready to serve break-fast food and improving rural economy and health of rural people .

Finger Millet

• Finger millet(Eleusine coracana (L.) Gaertn.) is originally native to the Ethiopian highlands and introduced into India approximately 4000 years ago. Telugu : Ragi

• The major producers are Uganda, India, Nepal, and China.

• Finger millet has high yield potential and grain stores very well.

• In Indiais cultivated on 1.8 million ha, with average yields of 1.3 t/ha. The major finger millet growing states are Karnataka, Andhra Pradesh and Tamil Nadu.

Kodo Millet

• Kodo millet (Paspalum scrobiculatum) was domesticated in India almost 3000 years ago.

• Telugu : Arikelu, Arika• Kodo millets also contain high amounts of polyphenols, an

antioxidant compound• The fiber content of the whole grain is very high. It contains 11%

protein and 10% fiber.• Kodo millet is a nutritious grain and a good substitute to rice or

wheat

Little Millet

• Little millet (Panicum sumatrense) was domesticated in India.• Telugu : Samalu • Little millet is another reliable catch crop in view of its

earliness and resistance to adverse agro-climatic conditions.• The stover is a good fodder for cattle.

Proso Millet

• Proso millet (Panicum miliaceum L) was domesticated in Manchuria and introduced to Europe about 3000 years ago.

• Telugu : Variga• Proso millet is well adapted to many soil and climatic

conditions.

Barnyard Millet

• Barnyard millet (Echinochloa colona) is the fastest growing of all millets and produces a crop in six weeks.

• Telugu : Udalu, Kodisama• It is grown in India, Japan and China as a substitute for rice

when the paddy crop fails.• plant has attracted some attention as a fodder in the United

States and Japan.

Sector-wise Number of Registered Food Processing Units

• Gluten free

• High fibre

• Diabetic foods

• Mineral rich foods

• Multi benefit foods

• Food for life style diseases

Coarseness , colour and overall appearance

Considered as staple of food of poor

Difficulty in processing at domestic level

Non-prestigious

Non availability of ready to use or easy to

cook foods from millets in the market

Govt. subsidy to fine cereals

Growing NCD population

Growing health –conscious population

Surge in consumption

Stagnant production

Likely shortages

Likely higher prices

Possibility of importing

• .

Over the past few years, output has remained stagnant and there is an urgent need to

promote cultivation of these crops

( annual economic survey, prepared by the finance

ministry, India)

• Dehulling technology is available for various

capacity dehulling fabrication of machine is

possible

• Whole grain flour

• Dehulled grain flour

• Coarse rawa

• Semolina

• Fermented flour and rawa

• Germinated rawa and flour

• Autoclaved rawa and flour for RS3 enhancement

• Composite flours

Value-Added Supply Chain

• Excellent food products can be and are made from millets.The value-added supply chain includes• Seed supplier (seed production) - quality and purity• Grain producer• Harvesting• Storage• Handling and transportation• Processing into products• Marketing

Milling

• The millet was decorticated in pilot-scale rice milling machinery with suitable adaptations.

• Husking was done in a centrifugal sheller. • The husked material was debranned in a horizontal emery

cone according. • The husk and the bran fractions together (seed coat material)

formed 26% of the millet

The process involves grain hydration followed by steaming and

pressing of the grains. The grain is soaked to its equilibrium moisture content and is

steamed or roasted to gelatinize the starch and dried to 18%

moisture , conditioned decorticated and then flaked by passing

through an edge runner. Thick flakes can be deep fried or dry roasted and this can be used for

uppitu after boiling and seasoning. These can be coated with any desired additives for value addition Since wet cooking slows down the digestion this feature can be

exploited for preparation diabetic foods at industrial scale

Flakes

Ref: Dept of food science technology, Kasetsart University, Thailand

Mechanical popping can be done by equilibrating the grain to 16% moisture and then exposing to 230 ºC for a fraction of a minute.

Special millet varieties are required for popping.

The varieties with hard endosperm with medium thick peri carp are suitable.

Some states in India, popped sorghum and millets are being marketed.

Can be used for further value added products like break fast bars, snack bars by combining with protein rich foods

• Popped grain• Chudwa• Payasam• Punugulu• Teepithalikalu• Laddu• Barfi• Muruku• Pappu Chekkalu• Namakpara

Extrusion process

Different grain flours

Blending (composite flour, 70: 30)

Conditioning (moisture adjustment)

Extrusion cooking

Extrudates

Drying Cooling

Packing in HDPE bags

Cereal and Millets based products

• Crispies • Cookies• Cake• Idly mix• Dosa mix

Sorghum/Pearl millet crispies Raw materials

(Sorghum/Pearl millete flour and Optional ingredients)

Composite flour preparation

Pre conditioning(moisture adjustment) Extrusion cooking

Drying of Crispies

cooling

Oil spraying and spicing

PackagingStorage

Common bakery products such as biscuits , cakes and bread were prepared and tested using. Dehulled sorghum or millet grain and milled flour of finer particle size is most amenable for production of these products.

Incorporation of 20-30% refined wheat flour produces a product acceptable on par with wheat biscuits .

Many tastes can be created Coconut

Bakery Products

Preparation of Cookies

Preparation of Cake

Preparation of idly mix:

Instant Dosa mix

Noodles

PastaMixing of Wheat flour and Millets

Dough Preparation

Extrusion

Drying

Packaging

Vermicelli

Mixing of Wheat flour and Millets

Dough Preparation

Extrusion

Drying

Packaging

Flavorings

Milk Protein Enriched SnacksMilk Protein Enriched Snacks

Extrusion Cooking process reduced the level of phytate as well.

Manufacturing process for Composite milk-Manufacturing process for Composite milk-Millet RTE BreakfastMillet RTE Breakfast

Ground millet Sweeteners Salt

Cooking

Water

Drying (22-250C)

Flaked cereal

Toasting 150oC, 25 min

Lump breaking (1-2 cm)

Flaking

Drying (22-250C)

Dried Powder

Milk

Milk-Millet Slurry

Gelatinization

Drying of Slurry

RTE Composite Breakfast

Process for Manufacture of Process for Manufacture of Bajra LassiBajra Lassi

Water

Heating

Addition of Stabilizer

Addition of Salt & Spices

Heating

Cooling

Milk

Pasteurization

Addition of Bajra Flour

Heating

Cooling

Incubation

CurdMixing

Filling Bajra Lassi Storage

Pearl Millet based Raabadi-like Beverage (Bajra Lassi)

Total Solids FatProteinCarbohydratesAsh Moisture Acidity (% LA)

8.740.652.404.571.2891.26 0.60

Chemical Composition

Suitable bacterial starter have been developed that can ferment milk as well as cereal solids

Process of fermentation reduced the level of phytate and improved the bioavailability of minerals

Conclusion • World over increasing number of NCD is leading

to Commercialization of millet products is the need of the hour

• Ready-to- eat food industry should come forward to provide a healthy food to the mankind keeping in view the changing demography

• Public private partnership helps for better commercialization

• Farmer encouragement

Better Millet Thank you for Your Kind Attention