PROJECT OPPORTUNITIES FOR SETTING UP OF FOOD PROCESSING

INDUSTRIES

Model Food Chain

Agricultural Production

Processing and Manufacturing

Transport & Distribution

Food Service and Household Food Street Food Vending

Catering establishment Preparations Operations

Consumption2

Advantage India for food processing

Abundant and large variety of farm produce due to diversified

(26 types of ) climatic conditions

Largest Livestock Population

3rd largest food producer in world

Largest producer of pulses

Leading producer consumer of milk and milk based products in world.

5th in poultry production.

Ranks Second in production of wheat, rice & groundnut and fourth in

coarse grains

Second largest producer of fruits & vegetables.

Abundant skilled & unskilled work force at cheaper cost

Leading Producer of coconut, cashewnut, ginger, turmeric & black pepper.

India confronts a situation in which the surplus

and the starvation exist together. Uneven

distribution, wastage and spoilage of food mainly

contribute to such an anomaly.

Prof. M. S. Swaminathan, Chairman, National Commission on Farmers (India) “Having

mountains of grains on one side and hungry

millions on the other, by 2020, the demographic

divide, economic divide and the nutritional divide

will widen unless we address them with our

existing technologies.”

Lack of proper Post-harvest infrastructure & adequate supply chain result in losses of harvested farm produce worth approx. Rs. 30000

crores annually in the country.

To improve farmer’s economy & save nation’s wealth, need of the hour

is to build sustainable supply chains to link the farmer to the

processing & marketing centres and also to develop integrated post-

harvest technology & infrastructure.

FOOD PROCESSING INDUSTRY & SOCIOECONOMIC DEVELOPMENT

Labour intensive (Employs 18 – 20% labour force) ,

offer major employment opportunity

High Priority Area ( Thrust Area)

Optimal utilization of agro resources

Highly decentralized small & Cottage scale industries Dominate,

Predominance of primary processing units

Enhancement of farmer’s economy, improvement in quality of life of

rural

Contributes to food security and price stabilization

Constraints for food industrial

growth Raw material availability (price, suitability, consistency )

Higher logistics cost

Large number of marginal farm holding

Huge gap between farmgate price & price to consumer (80%)

Varietal suitability for processing & price / yield factor.

MOFPI Vision 2015 document

(2005) targets

Increase level of processing of perishables

from 6 to 20% (3 times)

Increase value addition from 20% to 35%

Increase India’s share in global food market

from 1.5% to 3% by 2015

1.1 billion population base with 1.6% annual population growth, who spend over 50% income on food

350 million urban middle class with its growing purchasing power

Changing food habits (preference to convenience, processed food)

Growing need for convenience foods due to urbanization

Favourable market drivers for

packaged processed foods

•Increasing proportion of urban working women, growing organized retails.

•Shift on house hold expenditure on Cereals, Pulses, edible oils, salt, sugar, spices declined. Milk & milk products, meat, egg & fish, fruits, vegetables & beverages increased

•Increased food safety and hygience consciousness. Growing health & wellness consciousness.

•Paradigm shift of joint families to nuclear families .

•Emergence of wide range of innovative, safe and reliable quality branded foods.

Product modification matching to

Consumer demands Products having lesser synthetic ingredients, preferably

no additives

Foods & ingredients healthier for him

Local flavour & taste at modest price

Existing product modified to address lifestyle disorders like obesity, hypertension, diabetes, heart ailments, etc (Health & wellness based products)Lowsugar, low fat, reduced calorie, low sodium foods

Probiotic enriched diary products & baby foods

Products having much needed essential nutrients

Nutritient & nutraceutical enriched food products

Examples Fruit juices/ beverages (Tropicana / Real), Sport

drink (Gatorado), Hifibre biscuits, Flaxseed biscuit (Benne

Vita)

Multigrain biscuits, Low sugar / sugarfree products

(confectionary, beverages, ice-cream)

Nutrichoice Diabetic Friendly Essentrals

XXX Energy drink Cereal bar (Horlick, Nutirbar) Mother

Horlicks, Junior Horlicks, Complan Memory, Amaze Brain

Foods

Ingredients used- Omega-3, Vitamin B1 & B 12,

antioxidants, protein ingredients, vital minerals and

phytochemicals such as Ginko bilola, brahmi extracts,

carotenoids, fibres, probiotics.

Causes of food deterioration

decomposition by microorganisms (bacteria,

yeast and moulds)

self-decomposition of the food (by enzymatic biochemical reactions and chemical reactions

like oxidation)

damage by insects, pests, rodents and other

animals, mechanical causes, etc.

METHODS OF FOOD PRESERVATION

Reduction of water activity a)Drying and Dehydration b)Preservation by adding sugar c) Preservation by salt

High temperature processing

Low temperature preservation (refrigerated/cold storage)

Freezing preservation

Preservation by using chemical preservatives

Adjustment of pH/ Acidity

Oxygen removal

Preservation by hurdle technique

Radiation preservation

Packaging

PROCESSED FOOD PRODUCTS/ TECHNOLOGIES

CEREALS :

PRIMARY PROCESSING OF FOOD GRAINS (CLEANING, GRADING,

DESTONING, POLISHING, PACKAGING),

DRY MAIZE MILLING (GRITS, GERMS)

WET MAIZE MILLING (STARCH & ITS DERIVATIVES)

GRAIN FLOURS (WHEAT, JOWAR, BAJARA)

MINI RICE MILL

SHELF STABLE OPTIMALLY MILLED BROWN RICE

PARBOILED RICE, QUICK COOKING RICE, CURING OF NEW PADDY

CEREAL FLAKES (RICE, JOWAR, WHEAT,MAIZE,RAGI)

RTE LOW FAT FLAKED SPICY MAIZE/CORN SNACKS

FLAKED JOWAR RTE LOW FAT SWEET & SAVOURY

SNACKS

PUFFED CEREALS

MAIZE CHIPS

RAGI DECORTIVATION / ENZYME RICH FLOUR

RAGI BASED MURUKKU / CHKALLI

MULTIGRAIN BASED FORETIFIED SNACK

WHEAT MILLING / BAKERY PRODUCTS

Biscuit formulations: Salt/Sweet, Nutro, Cocoa, High Protein, Whole

wheat flour, Cardamom flavour, Onion flavour, High fiber, Wheat

germ, Sunflower grits, Low sodium, Therapeutic, Sugar free

Bread: production ( Several varieties - Brown, Plain, Sweet, Milk, Whole

Wheat, Fruit, High fiber, Ragi, Bajra, Sugar free ).

Buns : Plain, Sweet, Fruit, High Protein

Honey based Bakery Products : Biscuit, Bread, Bun, Cake

Bar cake, Sugar free cup cake, Eggless cake, Sugar free layer cake

Whole wheat flour, Paustik atta , fortified atta

Composite vermicelli based on millet flour

Composite Ragi rusk, Sugar free rusk, High Protein rusk, Cake rusk,

Sugar free cake rusk

High protein Upma Mix

South Indian Parotta

High protein ready to eat burfi

Shelf stable Chapati

PULSES

MINI DAL MILL

IMPROVED DAL MILL

VERSATILE DAL MILL

MODERN DAL MILL

GOTA SEPARATOR

PROCESSED BESAN FOR SEV / BOONDI

PAPAD (PULSES / RAGI)

LEGUME BASED READY-TO-FRY SNACKS

QUICK COOKING, GERMINATED AND DEHYDRATED PULSES

DETOXIFICATION OF KESARI DAL

OILSEEDS / PROTEIN BASED :

OIL (EXPELLING/ GHANI/SOLVENT EXTRATION) & DEOILED CAKE,

DEHULLING OF SUNFLOWER / SESAME

HEAT RESISTANT WHITE SESAME SEEDS

NUTRI OIL BLENDS

LOW FAT HIGH PROTEIN SNACK FOODS

AFLATOXIN DECONTAMINATION OF OILS

•EDIBLE GRADE OILSEED FLOURS (GROUNDNUT,

SOYABEAN)

•PROTEIN ISOLATES/HYDROLYSATES

•SOY DAL, SOYMILK, SOY CURD, SOY PANEER, SOY

NUGGETS,SOY LECITHIN, BLAND SOY PROTEIN

CONCENTRATE

•NUTRO CRISPO (SWEET AND SAVOURY )

•PEANUT BUTTER

CEREALS, PULSES, OILSEEDS

ENERGY FOOD

INFANT FOODS (HIGH PROTEIN, OPTIMISED 12% PROTEIN, LACTOSE FREE

LOW COST MALTED WEANING FOOD

INSTANT READY MIXES (GULAMJAMUN, UPMA, HIGH PROTEIN UPMA, IDLI, VADA, DOSA, CAKE, EGGLESS CAKE, CHAKLI, JILEBI, MADDUR VADA, PAKODA, PAYASAM, DOUGHNUT, MUSHROOM SOUP, MULTIGRAIN SWEET, PUJABI HALWA, BOMBAY HALWA, SOYA BASED SAMBAR, FERMENTED AND DEHYDRATED READYMIX FOR IDLI AND DOSA

•IDLI, DOSA, CHAPATI, VADA (MACHINE MADE) •FRIED TRADITIONAL SNACK FOODS (SWEET, SAVOURY) •INSTANT TRADITIONAL FOODS (RASAM, SAMBAR, PONGAL, PULIOGURE, EMLI POHA,

•PUFFED CEREALS/PULSES (FLUIDISED ROASTER)

•EXTRUDED SNACKS (READY TO EAT, READY TO COOK, READY TO FRY, LOW FAT / LOW CALORIE) • RTE LOW FAT SNACK LIKE CHAKLI • LOW FAT EXPANDED SNACKS • CEREAL BAR • CHIKI : PLAIN, FORTIFIED• FOOD FOR DIABITIC

FRUITS AND VEGETABLES PROCESSING

• India Second largest producer of fruits &

vegetables in the world with low levels of

current yields

• Mostly consumed fresh

• Less than 2% is processed with appropriate

raw material availability as constraint

• Farmer, the base of economy, gets much lower

returns due to too many intermediataries

between farmer and consumer

•Need to Establish farmer<-> processor

linkages

Fruit & Vegetable Processing in

India

Fresh consumption 96% Processed – 4%

Processing, Cottage scale -70% medium & large

scales -30%.

TECHNOLOGY FOR FRESH FRUITS AND VEGETABLES

• Pre and Post Harvest Technology Protocols for Export of Fruits by

Sea

Mango – Alphonso, Banganapalli, Kesar, Neelum

Banana – Dwarf Cavendish

Pomegranate – Ganesh Variety

• Mango Ripening – Accelerated Process

• Minimally Processed Vegetables

• Antifungal Paste for Banana

• Wax Emulsion – Formulation and Use

MINIMALLY PROCESSED VEGETABLES UNDER MAP

Ash gourd Coriander leaves Mint leaves

Beet root Curry leaves Okra

Beans Cucumber Onion

Bitter gourd Drumsticks Plantain

Carrot Field Beans Ridge gourd

Cabbage Fenugreek leaves Snake gourd

Cauliflower Green peas Spinach leaves

Cluster beans Green chillies Tomato

Coccinia Knol-khol Turnip

FRESH VEGETABLES

Sorting, Washing

Preparation (Removal of inedible portions)

Cutting (Manually or using a cutting machine)

Treatments (Minimal treatments with safe chemicals)

Surface drying (Preferably in a mechanical drier near ambient temperature)

Weighing, filling into pouches and sealing

Filling the pouches into secondary package

Cold storage

MINIMALLY PROCESSED VEGETABLES

FLOW DIAGRAM FOR THE PRODUCTION OF

MINIMALLY PROCESSED VEGETABLES

FRUITS POST- HARVEST PROTOCOL (MANGO, BANANA, POMEGRNATE)

FRUIT PULPS/JUICES AND CONCENTRATES (CHEMICALLY

PRESERVED, BOTTLED, CANNED, ASEPTICALLY BULK PACKED,

FROZEN)

RTS FRUIT BEVERAGES (BOTTLES, TETRAPACK) : MANGO, PINEAPPLE, GUAVA, LITCHE, CARROT, SUGARCANE, GINGER TEA, HONEY BASED, NUTRI BEVERAGE / MIX FRUIT AND VEGETABLE, JUICE BASED

CLARIFIED FRUIT JUICES

SQUASHES, SYRUPS, CORDIALS, NECTARS, CRUSHES

FRUIT CEREAL FLAKES

FRUIT JUICE POWDERS (MANGO, BANANA, ORANGE, LIME, AMLA, TOMATO)

DEHYDRATED PRODUCTS (SUN DRIED, OVEN DRIED, VACUUM

DRIED, ACCELERATED FREEZE DRIED, OSMO-DEHYDRATED) – RAW MANGO , GRAPES , AMLA, BER, JACK FRUIT, WHOLE LIME, CITRUS PEELS, ONION POTATO, GREEN CHILLIES, DRUM STICK, BITTER GOURD, CAULIFLOWER, CABBAGE, CARROT, BEANS

•JAMS, JELLIES, MARMALADES

•CANDIES & PRESERVES (AMLA, PAPAYA, GINGER, SWALLOW ROOT CASHEW APPLE )

•PICKLES & CHUTNEYS.

•SAUCES & PASTES•BRINE PRESERVED FRUIT PIECES (MANGO, LIME)

•FRUIT BARS & TOFFEES •PECTIN•PAPAIN

•POMEGRANATE / CUSTARD APPLE/ FIG/ JAMUN/AMLA PRODUCTS

•DIPPING OIL FORMULATION FOR GRAPE DEHYDRATION•WAX EMULSION / ANTIFUNGAL PASTE

•AMLA PASTE •DATE SYRUP CONCENTRATE •HONEY BASED FRUIT SPREDS

VEGETABLES:

INSTANT PICKELS, STRAINED BABY FOOD,

DEHYDRATED VEGETABLE (SLICES, FLAKES,

CUBES, POWDER)

CANNED/ BOTTLED VEGETABLES (IN BRINE,

CURRIES)

GRAVY PASTES FOR INDIAN CUISINES

SOUP POWDERS

CARROT JUICE BEVERAGES

MINIMALLY PROCESSD VEGETABLES PACKED UNDER MAP.

READY TO EAT FOODS (MEALS) IN RETORT

POUCHES

MUSHROOM CULTIVATION AND PROCESSING

TOMATO PRODUCTS (PUREE, PASTE, KETCHUP, CHUTNEY, )

POTATO PRODUCTS (CHIPS, POWDER, FRIED WAFERS)

FRESH JUICE

Heating to 900c

pH adjustment

Filling into clean, sterilized hot bottles

Crown corking

Pasteurization at 850 C for 25 to 30 minutes

Air cooling, packing & storage

BOTTLED FRUIT JUICES

Sterilized crown corks

FLOW DIAGRAM FOR THE PRODUCTION OF FRUIT JUICES

FRUIT JUICE

Homogenization

Heating to 87 C, filling into

sterilized hot bottles (200 ml)

Crown corking

Mixing with sugar syrup, citric acid, essence &

colour

Filling into 750 ml

bottles

R. O. Sealing

SQUASHES, SYRUP &

CORDIALS

Pasteurization at 85 C for 25-30

min

RTS BEVERAGES

Cooling

Mixing with sugar syrup, citric acid, essence

colour and preservative

FLOW DIAGRAM FOR THE PRODUCTION OF

RTS BEVERAGE, SQUASHES, SYRUPS AND CORDIALS

READY –TO-SERVE BANANA BEVERAGE

CLARIFIED BANANA JUICE/ JUICE CONCENTRAE

SUGAR SYRUP ADDITION

COLOUR + FLAVOUR ADDITION

MIXING / BLENDING

HOMOGENIZATION

FILLING IN CLEAN BOTTLES AND CAPPING

PROCESSING IN BOILING WATER

COOLING AND STORAGE

CAPACITY OF SUGGESTED UNIT : 5000 BOTTLES(200ML) /DAY

TOTAL PROJECT COST : Rs. 25 LAKHS

LIQUID FRUITS (CLARIFIED FRUIT JUICE)

Substitute fro synthetic soft drinks.

Pulpy fruits like Banana, Guava etc. can be processed

Banana

Washing & Peeling

Cutting & Pulping

Heating

Partial cooling

Enzyme treatment

Filtering

Hot filling into bottles

Pasteurization

* Optional – Concentration to 70oBrix

CAPACITY OF SUGGESTED UNIT : 300 KG/DAY

TOTAL PROJECT COST : Rs.15.75 LAKHS

ASEPTICALLY PACKED BANANA PULP

RIPENING BANANA FRUIT

RIPE AND SOUND BANANA

WASHING & PEELING

PULPING

HOMOGENIZATION

DESEEDING

DEAERATION

PASTEURIZATION

COOLING

ASEPTIC FILLING

STORAGE

CAPACITY OF SUGGESTED UNIT : 3 MT BANANA / HOUR

TOTAL PROJECT COST : Rs.1011 LAKHS

FROZEN BANANA PULP / CLARIFIED JUICE / CONCENTRATE

RIPE BANANA FRUITS

WASHING & PEELING

PULP / JUICE EXTRACTION

STANDARDIZATION AND HEATING (PASTEURIZATION)

FILLING IN PE BAGS IN VERTICAL POCKETS

MULTI-PLATE CONTACT FREEZING AT -32o C

FROZEN STORE (-28o C)

CONTAINER PACKAGING

TRANSPORTATION IN REFRIGERATED CONTAINER

DISTRIBUTION IN COLD CHAIN

CAPACITY OF SUGGESTED UNIT : 30 MT BANANA / DAY

TOTAL PROJECT COST : Rs.633 LAKHS

INDIVIDUALLY QUICK FROZEN OF IQF BANANA

SLICESRIPE BANANA

WASHING & PEELING

SLICING

IQF FREEZING AT -32o C

FROZEN STORAGE

CONTAINER PACKING

TRANSPORTATION IN REFRIGERATED CONTAINER

DISTRIBUTION IN COLD CHAIN

FRESH FRUIT /VEGETABLE

Sorting & Washing (manual / mechanical)

Preparation(manual or mechanical)

Blanching (for vegetables)

Treatments

Dehydration

Packing

DEHYDRATED PRODUCT

Dehydration of Fruits & Vegetables

SPRAY-DRIED / DRUM –DRIED / VACUUM SHELF –

DRIED BANNANA POWDERBANANA PULP

MIXING WITH FUNCTIONAL ADDITIVES

HOMOGENIZATION

SPRAY DRYING / DRUM DRYING / VACUUM SHELF DRYING

SIZE REDUCTION AND SCREENING

DEHYDRATED BANANA POWDER

PACKAGING AND STORAGE

CAPACITY OF SUGGESTED UNIT : 1 MT PRODUCT /DAY

TOTAL PROJECT COST : Rs.389 LAKHS

FRUIT BARS Nutritious and ready to eat product with good shelf life

Marketed as confectionery items

Banana

Washing & Peeling

Cutting & Pulping

Mixing with other ingredients

Heating pulp

Partial cooling and addition of preservative

Spreading in trays

Drying & Cutting

Packing & storage

CAPACITY OF SUGGESTED UNIT : 250 KG/DAY

TOTAL PROJECT COST : Rs.25 LAKHS

DEHYDRATED WHOLE LIME

Lime Fruit

Washing

Pre-treatment

Dehydration

Dehydrated whole lime

Packaging & Storage

Capacity : 10 MT lime/day

Project Cost : Rs. 45 lakh

SPICES & PALANTATION CROPS

SPICE POWDERS (CHILLI, TURMERIC, CORIANDER)

SPICE OILS(PEPPER, GINGER, CARDOMOM)

SPICE OLEORESINS (PEPPER, GINGER, TURMERIC, CHILLIES)

GRAVY PASTE FOR DIFFERENT INDIAN CUISINE

CASHEW APPLE CANDY

TAMARIND PRODUCTS (PULP, PASTE, JUICE CONCENTRATE, POWDER, KERNEL POWDER, CANDY, GREEN TAMARIND SPICE MIX )

•GINGER PRODUCT (DRIED GINGER, CANDY & PRESERVE)

•SUGARCANE –BOTTLED JUICE / SPREAD BIO-PRESERVATION OF RTE SUGARCANE CHUNKS

•NEERA BOTTLING

•COMPOUNDED ASAFOETIDA

•ENCAPSULATED FLAVOURS

•NATURAL FOOD COLOURS (BEET ROOT, SAFFLOWER, KOKUM, GRAPES, ANNATO, CHILLI, TURMERIC)

•SPICE MIX FORMULATIONS (SAMBAR, RASAM, PULAO)

•INSTANT GRAVY MIXES – DEHYDRATED/PASTES

•SPICE PASTES (GINGER, GARLIC)

•GARLIC- FLAKES, POWDER, PICKLE, OIL.

•CORIANDER DAL

•DESICCATED COCONUT

• COCONUT SPREAD AND COCONUT DIETARY FIBER

• VIRGIN COCONUT OIL

• VALUE ADDED COCONUT PRODUCTS : INSTANT ADJUNCT MIX, INSTANT FILLING MIX, COCONUT RICE MIX, COCONUT BITES

•CASHEW PROCESSING- FRIED & FLAVOURED NUTS / SPREAD

TECHNOLOGIES FOR MEAT, FISH AND POULTRY

Pork - Ham, Becan, sausage, pickle, dehydrated, canned

Sheep / Goat - Sausages, kabab, pickle, frozen curry, canned, sap

cube, sausage casing , Meat Burger, Meat wafers,

Beef - Sausage, corned beef

Fish - Wafer, sausage, frozen curry, marinated paste, pickle

Poultry - Dressed chicken, curried, kabab, pickle, chicken wafer,

shelf stable biriyani, kabab mix & titbits, marinated

tandoori sausage, sandwich spread, soup mix, frozen

curry, soup cube, egg loaf,

Instant Gravy Mixes ( Dehydrated) - Multi purpose gravy, Biriyani,

Tandoori, Kabab, Meat preparations fish preparations

FOOD BIOTECHNOLOGY EMERGING AREAS

• Production of Natural colourants from plant sources

• Spirulina production for health foods & pharmaceuticals.

• Production of Phycocyanin from Spirulina Spp.

• Production of Xanthan gum

• Clarification of fruit juices through microbial enzymes

• Low lactose infant food

• Detection kits- Pesticides, Aflatoxins

• Biogas generation using fruit and vegetable wastes

• Biosensors- Glucose, Sucrose, Lactic acid, Pesticides, Tea

• Alcohol (banana, cashew apple, mahua, grapes, tapioca )

• Enzymes – pectinase,amylase,amyloglucosidase,phytase

• Vinegar generation

• Production of Fructooligosacharides (syrup & powder)

• Cultivation Botryococcus Braunii, Dunaliella (β carotene rich algae)

FOOD MACHINENARY DESIGNS

Indigenous machinery for traditional foods : Idli, Dosa, Vada,

Chapati, Papad, Jilebi

Forming and frying machine for foods

Roaster : vibro fluidised bed, hot air

Combined IR and hot air heating system for food processing

Devise for pneumatic dough extrusion & cutting of dough into Geometric shape

Leaf cup and plate making machine

Laddu molding machine (Besan, Rawa & Similar )

Sheeting and cutting device for chikki and similar products

Hand operated lemon cutting device

Dry maize milling plant

Infrared heating of Cashew kernels for testa removal

Hot air popping machine

Sugarcane deskinng machine

Shitting and cutting device for chikki and similar products

Sugarcane juice extractor

CONTINUOUS CHAPATI MAKING MACHINE - DESIGN

FROM CFTRI

• Chapati or Roti is a popular traditional food in the Indian diet.

• The developed machine which can cater to the large requirement

of chapatis in a short span of time.

Capacity : 600 - 800 Chapathi’s/hr

LPG Consumption : 3Kg/Hr

Power : 7.5 HP

Size of Chapati : 160mmdia/1.5 thickness

Machine dimension : 6Mx1Mx2M

AUTOMATIC IDLI MAKING MACHINE - DESIGN FROM

CFTRI

• CFTRI, Mysore has developed an

automatic continuous idli making machine

with a capacity to produce 1200 idlis per

our. The machine is the first of its kind. It

can continuously produce ready to eat /

serve idlis, untouched by hand

CONTINUOUS DOSA MAKING MACHINE - DESIGN

FROM CFTRI

All operations in the Dosa making -

from batter dispersion, depositing and

spreading on the hot plate to toasting /

roasting & oil application are

organized in a systematic way. At the

end of the pre-determined residence

time, the hot Dosas are rolled and

discharged.

Capacity : 400 Dosas per hour

INTEGRATED

HOT AIR

ROASTING

MACHINE

Combustion chamber

LPG Flue + Fresh air

Food

Material

Outlet

Food

Material

Inlet

Hot air

recirculation 70%

Fresh air

30%

LPG

Cylinders

Wheat, soji,

greengram and jowar

as well as Snack foods

( vermicelli, corn

flakes and fryams)

roasted with

satisfactory results.

Automatic Continuous Urd Vada Making Machine

Feeding

Conveyor

Control

Panel

Hopper

Blower

Hopper

Conveyor

Blower

Chaff Separator

SPOUTED BED ROASTER

Roasting

Chamber

Receiver

COMBINED INFRARED AND HOT AIR HEATING SYSTEM

Product/Process:

Machine for dehydration of fruits

And vegetables.

The conventional drying systems are either batch type or energy

intensive systems. The combined infrared and hot air heating system

utilizes the synergistic effect of electromagnetic radiation and hot air

for the dehydration of vegetables. The conveyorized system could be

used for continuous operation. The versatile system could be used for

the other thermal processes such as blanching and roasting with

suitable minor modifications in the system. The prototype has a

capacity of 15 kg/h of raw vegetables.

Approximate price per machine: Rs. 15 lakh (400 kg/h of raw material)

Process/Technology:

Product/Process:

Machine for cutting of lemons

in to four pieces.

Process/Technology:

Washed lemons are transferred into the tray of the lemon cutting machine. The

lemons flow into the pockets of the centralizing disc due to the gradient of the inlet

chute. The centralizing disc carry/move the lemon against the cutter. The whole

lemon is cut into four pieces when the centralizing disc carrying the whole lemon

moves against the cutter. The lemons cut to four pieces are dropped on to the outlet

chute, when the centralizing disc moves away from the cutter. The outlet chute will

discharge the cut lemon into the tray/vessel. A geared motor drives the centralizing

disc.

Approximate price per machine: Rs 25,000/-

CIRCULAR LEMON CUTTING MACHINE

Other process control toolsPest control programme is one of the important activities in the entire

production and process as pests pose a threat to the entire system, right

from incoming raw material to storage of finished goods.

Installation of fire-control and alarm systems & periodic inspection and

maintenance thereof.

Aircurtains maintain the constant interior temp of cold room chambers /

icecream chambers These high-velocity airflow air curtain block entry of hot

air, insects, dust, dirt, fumes by creating invisible curtain of high pressure air

when the doors are open.

Metal detection and seperation systems

CIP (Clean-in Process) systems

ORGANIC FOODS

Organic foods (Product of farming system avoids

use of man made fertilizer, pesticides, growth

promotor) it relies. After 3 yrs such treatment, first

produce is ‘Organic’.

‘Organic’ product – Min 95% organic agri

ingredients. e.g. Corn flake

Made with organic ingredients –Min. 70% Organic

agri. Ingredients e.g. ketchup, grape wine

Selection criteria for food packaging system :

Packing requirements of food product

Barrier, strength and product

compatibility properties of packaging

system

Intended shelf-life

Cost

Package forms

Flexible

Semi-rigid

Rigid

Primary

Secondary

Tertiary

Metal

Glass

Plastic

Wood

PaperAl-Foils

Composites

Laminates

Coextruded films

Coatings

Different

forms

Retailer’s margin 15% in India against 2% in US

Wholesaler’s margin 15% in India against 4% in US

10% processed F&V consumed by 70% of population (rural/small towns); 60% by 4 metropolitan cities and 30% in state capitals and other big cities.

Good scope for processing units both for local markets and export

Marketing Pattern of

Processed Fruit &

Vegetable Products in

IndiaSector Market Share

(Value based)

Institutional 40%

House holds &

housewives 40%

Export 20%

66

Quality

Safety Nutrition

Sensory,

Physical,

Kinesthetic

and Other

dimensions

Macro-

&

micro- nutrients

Microbiology,

Additives,

Contaminants,

Toxins,

Environmental pollutants,

Adulterants

Food Issues

FOOD SAFETY is an important issue

globally. Food manufacture needs to

assure safe & quality food at

affordable & competitive price to the

consumer. Food safety & quality

encompasses the entire food chain

starting from farm products on to

processing transportation &

distribution, till consumption.

68

FOOD STANDARDS

A. Safety Standards B. Quality Standards

A - Gives protection to health of consumers

Minimum quality requirements as laid down under

“Prevention of Food Adulteration Act, 1954 and Rules

thereof, 1955”.- This will be replaced by Food Safety &

Standards Act shortly.

* Mandatory

B - To improve the quality at the manufactures level

and encourage the food industry BIS, Agmark, FPO

etc.,

* Voluntary

Nutrition Information Panel

Total calories

Calories from fat

Total fat

Saturated fat

Transfat

Cholesterol

Sodium

Potassium

Nutrition Facts:

Mandatory components (underlined) and

voluntary components – to be declared in the

following order:

Conti…69

Carbohydrates

Dietary fibre

Sugars

Protein

Vitamin A

Percent of Vitamin A as Beta-carotene

Vitamin C

Calcium

Iron

Other vitamins and minerals

70

Contd…

Govt. Support through various

promotional agencies.

- Capital Investment subsidy

- R&D Support

- Quality Control Support

- Market development assistant

- Export incentives

- Establishment of Food Parks, Food Clusters, Agri Export Zone

- Cold Chain Incentive Schemes

- Storage infrastructure

TECHNOLOGY TRANSFER FROM CFTRI

Identification of the CFTRI technology by the entrepreneurs

Payment of premium to CFTRI by the entrepreneurs

(remittance by DD favouring Director, CFTRI, Mysore.

Signing of License Agreement

Technical dossier to the Licensee

Demonstration of process know-how, at CFTRI, Mysore

Participation of two authorized representatives in the

demonstration-cum- training

One to one discussion with the concerned faculty and

quality control procedure

USER ORIENTED SERVICES OF CFTRI

Analytical and Quality Control for Food Industries

Industrial Consultancy to Industries

Contract Research for Product Development and Trouble-

Shooting in Food Processing Sectors

Sensory Assessment and Consumer Acceptance Studies

Packaging Materials Testing & Food Packaging Assistance

Need Based Bibliography in Food Science and Technology

D P R for Establishing Food Industry/Food clustres

HRD & Training

Analytical Capabilities Physico-chemical and microbiological analysis of

processed and primary foods as per FPO,PFA, BIS, AGMARK, FDA-USA and Codex specification/ guidelines

Nutrition facts (FDA, Codex, EEU, ICMR/DGHS)

Additives (Preservatives,colours, sweetners, antioxidants)

Food Contaminants (Toxic metals, Pesticide residues, Mycotoxins)

Vitamins and Minerals

Sensory Analysis (quantitative descriptive analysis, product positioning) odour porfile, texture profile)

Microbiological analysis

Packaging materials(incl. migration tests for food grade nature)

Shelf-life studies