basic operations for fruits and vegetable...
TRANSCRIPT
Basic Operations for Fruits and Vegetable Processing
Dr. Rakesh K. Singh Professor and Head
Department of Food Science &Technology The University of Georgia
India’s Fruits & Vegetable Industry
Export (average 20% but 50% for mangoes):
Processed Fruit and Vegetable export increased to US$ Million 555.07 in 2006-07.
Mango Pulp (Rs. 505.83 Crores) (US$ Million 112.21),
Dried and Preserved Vegetable (Rs. 424.06 Crores) (US$ Million 94.07),
Pickles and Chutneys (Rs. 293.59 Crores) (US$ Million 65.03),
Other Processed Fruits and Vegetables (Rs. 508.15 Crores) (US$ Million 112.72),
Pulses (Rs. 770.65 Crores) (US$ Million 170.95)
• World production around 370 MT
• India is #1 producer with annual output of 32 MT (growth rate 3.9%)
• Major Indian fruits consist of:
mango, banana, citrus fruits, apple, guava, papaya, pineapple and grapes.
• The fruits are processed into various products such as fruit juices & concentrates,
canned fruit, dehydrated fruit, jams & jellies etc
Increase in processing of fruits/vegetables:
Frozen 121%
Dehydrated 24%
Source: Government of India – Department of Commerce
Source: Government of India – Department of Commerce
Vegetable Production
Use furrow or ditch irrigation
Courtesy of Trevor Suslow
Use clean well water to wash fresh produce
Potable water is drinking water that is wholesome and
clean and does not cause illness. It is free from any
micro-organisms and parasites and from any substances,
that in numbers and concentrations, constitute a
potential danger to human health.
Harvesting
Clean Harvest Containers and Tools Daily
Evaporative Field Cooler
• A squirrel-cage fan pulls dry air through a water-saturated pad to cool the air, which is forced through vented produce cartons to remove field heat
• See UGA Extension bulletin for instructions to build a simple cooler system
ORGANIZED CHAOS: Fresh produce mixes with rotting
vegetables in Bangalore's Krishnarajendra Market
Different levels of acidity in fruits
Fruits are more acidic than vegetables which affects pathogen growth
Very acidic fruits pH<3.7
Moderately Acidic fruits pH3.7-4.5
Less acidic fruits pH >4.5
Grapefruit Lemon Lime Orange Tamarind Tangerine
Guava Mango Passion fruit Pineapple Strawberry Tomato
Banana Breadfruit Melon Papaya Squash
Assuming all fruits are fully ripe, from ‘The Composition of Foods’, Paul, A.A. and Southgate, D.A.T., Elsevier, 1985
Time before spoilage starts in selected fruits and
vegetables
A few days A few weeks 1-2 months
Fruits Banana (dessert) Cantaloupe melon Guava Mango Papaya Passion fruit Pineapple Strawberry Watermelon
Vegetables Cauliflower Cucumber Green bean Leek Lettuce Okra Peppers Spinach Spring onion Tomato
Fruits Avocado Banana (cooking) Breadfruit Grapefruit Jackfruit Vegetables Cabbage Capsicum Chickpea Cowpea Lima bean/Navy bean Pigeon pea Pumpkin Soybean Squash
Fruits Gourd (bottle) Lemon Lime Orange Tamarind Tangerine Vegetables None
Time available between harvest and processing before spoilage begins
Ideal Location for Processing Facility
• Near production area and main road
• Good roads
• Reliable electricity
• Adequate supply of potable water
• Access for workers & staff
• Availability of other supplies
• Other facilities, e.g., schools, shops, etc
Fruit & Vegetable Processing Building
Should be hygienically designed and easily cleaned to prevent contamination
• Movement of food should not cross paths
• Should have enough space to separate raw, processed, packages
& ingredients
Food movement
Processing
area
Office/
Lab Packaging
Washing
Product
Raw
Basic rules for hygiene and sanitation in fruit
and vegetable processing
Facilities required in the processing room
• A changing room where clothing and shoes that are not worn for
work can be stored.
• Separate hand-washing facilities for staff, with soap, clean water,
nail brushes and clean towels.
•Toilets, which should be separated from the processing room by
two doors or located in a nearby building.
• First aid materials.
• Protective aprons or coats washed regularly, hats/hairnets and if
necessary, gloves and shoes.
• Cleaning chemicals, stored away from the processing room.
Pulped
FRUITS & VEGETABLE PRODUCTS
Fruits Vegetables
Whole fruit Pulped Extract Whole vegetables Fresh-cut
Pectin Papain Dried Packed Chutneys/
Pickles
Fruit peels Dried
(Adapted from: Fellows, 1997)
Bottled Salted/
Pickles/
Chutneys
Sauces Juices
Extracted Juice Whole pulp
Fermented Juices Squashes/
Syrups Jellies/
Marmalades
Jams Nectars Pastes/
Purees/
Fruit
‘cheese’
Fruit
‘leathers’
Sauces
Wine
Second
Fermentation
Vinegar
Distilled
Spirits
Fruit and vegetable of desired quality
Receiving roller conveyor
Washing machine
De-stoning/De-podding
Peeler remover
Inspection / sorting conveyor
Elevator
Cutting machine/cubing machine
Vibro distributor Transporting conveyor
Blanching
Hydraulic conveyor
Pre cooling
Process flow diagram for mango cubes, fruits and vegetables
cubes, sweet corn and baby corn etc.
Selection table
Shredding and Slicing: Vegetables: Spinach,
Cabbage, Gourd
Fruits: mangoes, pineapples
Grating Vegetables: Most hard vegetables, e.g. potatoes, carrots, turnips, sweet potatoes Fruits: Apples,
Manual Graters - stainless steel graters . Mechanized graters - food processors
Weighting Shredded veg are then weighted
to a standardized measurement and packed
in either plastic bags.
Packaging The packaging is then sealed using a bar sealer
Manual Operation for Small Scale Fresh-cut Process
Fresh-Cut
Optimal gaseous environment (for
respiration control)
Temperature control
Sanitizing treatment
Package design
Sensory and consumer testing
Marketing Fresh Blueberries
Calculate Raw Materials & Ingredients
• Decide the amount of product to make
• Calculate from a recipe
Recipe Calculation Amount needed to make 50kg
Mango 500 g (500/803.5) x 50 31.1 kg
Sugar 300 g (300/803.5) x 50 18.7 kg
Ginger 0.5 g (0.5/803.5) x 50 31.1 g
Mustard 0.5g (0.5/803.5) x 50 31.1 g
Chillie 1.0 g (1.0/803.5) x 50 62.2 g
Garlic 0.5 g (0.5/803.5) x 50 31.1 g
Salt 1.0 g (1.0/803.5) x 50 62.2 g
Total 803.5 g 50.0 kg
Example: Mango chutney 50 kg/day
Note: Losses are not included
Typical Losses During Processing of Fruits and
Vegetables
Stages in a Process Typical Losses (%)
Washing fruits/vegetables
Sorting
Peeling
Slicing/dicing
Batch preparation/weighing
Boiling
Drying
Packaging
Machine washing
Accidental spillage
Rejected packs
(does not include evaporation
losses)
0-10 5-50 5-60 5-10 2-5 5-10 10-20 5-10 5-20 5-10 2-5
(Source: Fellows, P., Midway Technology Ltd, Bonsall, UK), 1997
Example: Calculating the weight of fruit after drying
Taking 15.5 kg of fresh fruit, initially the fruit contains 75% water and 25% solids.
Therefore 15.5 kg of fruit contain 11.6 kg of water and 3.9 kg solids
After drying the weight of solids has not changed (only water is removed) and the moisture
content is reduced to 8%.
Therefore the solids content is (100 - 8) = 92%
If 3.9 kg solids is 92%, then the total weight of product = (100 /92) x 3.9 = 4.2 kg
Therefore (15.5 - 4.2) = 11.3 kg water is removed
There were also losses of 200g due to rejected dried fruit. Therefore 4 kg of product is
available for sale.
It is in the interests of the processor to reduce product losses as much as possible
Example: Calculation of boiling losses:
The solids content in the mix of ingredients before boiling is found as follows:
Ingredient Weight Solids content Weight of solids
(kg) (%) (kg)
_____________________________________________________________
Mangoes 31.1 15 4.67
Sugar 18.7 100 18.7
_____________________________________________________________
Total 49.8 23.37
Total after 10%
wastage 44.8 kg 21 kg
% solids in batch before boiling = (21/44.8) x 100 = 46.9%
So 21 kg equals 46.9% of the batch before boiling. After boiling there is no loss of solids
(only water is removed) but the solids content has been increased to 70%.
Therefore 21kg equals 70%.
Therefore the total weight of the batch after boiling = (100/70) x 21 = 30 kg
And boiling losses are (44.8 – 30) = 14.8 kg
Packaging When selecting packaging materials, the processor should consider:
• technical requirements of the product (for protection against light, crushing, air,
moisture etc.)
• the design (for promotional and marketing requirements) and
• the relative cost and availability of different types of packaging.
The daily production rate is used to calculate the numbers of packages required.
Example: Calculation of number of packs required and time to fill and seal them
If 25 kg of dried fruit is produced per day and packed into 100 g bags and there are 50
bags in each cardboard distribution box:
the number of bags required = 25 x 1000/100 = 250 bags
and the number of boxes = 250/50 = 5 boxes
If on average it takes a worker 45 seconds to fill and seal a bag,
the time required = 250 x (45/60) min = 188 min (3 hours, 8 min)
or if 4 people are working together, the time required is just over ¾ hour.
Record Keeping
1. Financial records 2. Production records
Recipes
Raw materials and ingredients received and
suppliers
Wastage % at different stages of the process
Stock levels for each ingredient
Production volumes and measurements
Maintenance programs and schedules
Income from sales
Costs of all process inputs
Staff records
Cash flow
Profit/loss
Tax records
Bank statements
3. Quality assurance records 4. Sales records
Target amounts of ingredients and
any changes made to recipe
Measurements made at process
control points
Batch numbers and product code
numbers
Cleaning procedures and schedules
Names of customers and amounts sold to each
Weekly and monthly sales volumes
(Source: Fellows, P., Midway Technology Ltd,
Bonsall, UK), 1997
Dried Products Dried fruits, vegetables, herbs and spices are low-volume, high-value foods
Blanching: Hot water blanching for vegetables. Steaming can protect nutrients.
1% Sodium bicarbonate in blanch water protects green color
2% Calcium chloride solution firms soft vegetables
Blanching times for vegetables
Food Blanching time (min)
Steam Boiling water
Leafy vegetables Sliced beans Squashes Cabbage Peas Carrots Cauliflower Potatoes
2 - 2.5 2 - 2.5 2.5 2.5 3 3 - 3.5 4 - 5 6 - 8
1.5 1.5 - 2 1.5 - 2 2 3.5 3 - 4 5 - 6 8 - 12
(Source: Fellows, P., Midway Technology Ltd, Bonsall, UK, 1997)
Sulphuring and sulphiting
• Sulphur dioxide protects the natural color of some fruits (banana, pineapple
etc)
[Caution: Do not use on red fruits, it bleaches color]
1. Burning sulphur
Place cut fruits on trays, and 350-400g sulphur are burned per 100 kg
fruit for 1-3 hours
2. Solution of sodium sulphite, sodium metabisulphite or potassium
metabisulphite (1 g/L solution)
Fruits are dipped for 5-10 minutes, or add in the blanch water for
vegetables
• Other treatments: Salting for limes to used in pickles
Process for Dried Fruits and Vegetables
Essential step Optional Notes
Fruit Harvest carefully to reduce bruising and other damage.
Inspect
Wash
Remove mouldy, rotten, and damaged fruit. Also remove all
foreign material: leaves, stems, stalks, sticks and stones. Use
wash tanks or washers with clean, potable water to remove
contaminants, e.g., pesticide residues, insects, soil or dirt, etc
Sort/grade
Uniform size and maturity are important to get uniform drying
times for all pieces. Over-ripe fruits are easily damaged and
difficult to dry. Under-ripe fruits have poorer flavor, color and
appearance.
Peel
Core
Cut/slice
Blanch
Allows faster blanching, sulphur dioxide treatment and drying.
Peel by hand using knives or peelers, or peeling machines.
Check that all traces of peel are removed. Depending on the type
of fruit/vegetable, cut by hand using sharp stainless steel knives,
corers etc. or using choppers, cutters, slicing or dicing machines.
Check for uniform sized pieces.
For vegetables, using a boiling pan, heater, wire basket or
steamer. Check water temperature, time of heating.
Acid dip
Can be used to prevent browning of light coloured fruits and
vegetables. It involves dipping fruit in 2% citric acid, lemon or
lime juice for 5-10 minutes. Equipment required includes
weighing scales or scoops and food-grade plastic tank.
Process for Dried Fruits and Vegetables [continued]
Essential step Optional Notes
Treatment with sulphur
dioxide
Sulphuring cabinet or a food-grade plastic tank for
a sulphite dip. Other equipment includes weighing
scales or scoops. Check weight of sulphur or
concentration of sulphite and time of exposure.
Dry
Pack
Time needed for drying depends on the
temperature, humidity and speed of the air, the type
of dryer and the size of the food pieces. Check for
mould growth, insect contamination and the
temperature and time of drying.
Using an electric heat sealer to produce moisture-
proof, airtight plastic bags. Check fill-weight and
seal.
Label
Store
Check that label is correct for type of product.
Store in a cool dry place away from sunlight.
Protect fragile foods from crushing.
Flour can be made by grinding the dried fruit in a hammer mill before packaging.
Process for chutney
Stage in Process Notes
Fruits/Vegetables
Inspect
Fruits should be picked carefully to reduce bruising and checked for full maturity but not over-
ripe. Vegetables should be fully mature.
Remove mouldy, rotten, and badly damaged fruits and vegetables.
Also remove all foreign material.
Wash Use clean, potable water in a wash tank to remove contaminants, e.g., pesticide residues, insects,
dirt and soil, etc.
Sort/grade
Peel
Sort by hand on a sorting table to get similar colour or maturity
Most fruits and vegetables require peeling, but some chutneys include un-peeled fruits. Peel by
hand using sharp knives or peeling machines that are made for some types of fruits. Check that
all traces of peel are removed.
Cut/slice/core Cut into thin strips or small cubes by hand using knives, or slicing or dicing
machines. Pieces should be similar in size to produce uniform mixtures and allow faster
penetration of sugar syrup into the pieces. Check for uniform sized pieces.
Mix ingredients Weigh ingredients and mix in a stainless steel or food grade plastic mixing bowl.
Heat
Boil the mixture in a stainless steel boiling pan with constant stirring, until it is thick and
concentrated. Check the time and temperature of boiling. An optional check can be made of
sugar content (68-70%) using a refractometer.
Fill & Seal Hot fill using a filler into pre-sterilised jars (boiled in water or in an oven at 100C for 10-15
min). Seal lids and check fill-weight and properly sealed lid. An optional bottle rinser can be
used to save time If jars are not obtainable, plastic pots or bags can be used,.
Cool
Label
Store
To room temperature, either by lying jars on their side on a table or using a bottle cooler .
Label and check that the correct label is used and that label quality is satisfactory.
Store in cool dry place away from sunlight
Equipment
Size of equipment
• One large, several small or
multiple batches?
• Jam making 36 kg/day
• Time available to boil the 36 kg
fruit/sugar batch = 3 h
• Boiling throughput = 36
3 = 12
kg/h
• A batch should be boiled in 20
min to maintain quality, 2
batches/h?
• Either one pan with 12 kg size, or
a pan with 6 kg capacity but use
two batches
Type of equipment
• Mixing of ingredients
• Heating burners
• Boiling pan
• Filling & Packaging
• Labeling
• Cleaning
Hot air drying
Blueberries
Carrots
Vacuum belt drying of blueberries
Capsule sealer
Bottle cooler
Boiling pan/pasteuriser
Hygiene and Sanitation
• Raw material should be suitable for its intended
purpose
• Processing facility should be in sanitary condition
• Equipment (must be cleanable and kept clean)
• Persons handling food and their responsibilities to
protect it from contamination
• Building design and construction including water
supplies, drainage, toilet facilities, wash-hand basins,
provision of first aid facilities, places to store clothing,
facilities for washing food and equipment, lighting,
ventilation, protection against infestation by rats and
insects and removal of wastes.
Display of fruits and vegetables