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PROJECT OPPORTUNITIES FOR SETTING UP OF FOOD PROCESSING INDUSTRIES – TECHNOLOGIES FROM CFTRI By P.M.Badgujar Head CFTRI Resource Centre MUMBAI Central.

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Presentation on theme: "PROJECT OPPORTUNITIES FOR SETTING UP OF FOOD PROCESSING INDUSTRIES – TECHNOLOGIES FROM CFTRI By P.M.Badgujar Head CFTRI Resource Centre MUMBAI Central."— Presentation transcript:

1 PROJECT OPPORTUNITIES FOR SETTING UP OF FOOD PROCESSING INDUSTRIES – TECHNOLOGIES FROM CFTRI By P.M.Badgujar Head CFTRI Resource Centre MUMBAI Central Food Technological Research Institute, Mysore –

2 Model Food Chain Agricultural Production Processing and Manufacturing Transport & Distribution Food Service and Household Food Street Food Vending Catering establishment Preparations Operations Consumption 2

3 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.

4 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.”

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

6 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

7 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.

8 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

9 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

10 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.

11 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

12 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.

13 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.

14 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

15 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

16 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

17 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

18 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

19 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

20 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

21 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

22 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

23 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

24 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

25 Fruit & Vegetable Processing in India Fresh consumption 96% Processed – 4% Processing, Cottage scale -70% medium & large scales -30%.

26 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

27 MINIMALLY PROCESSED VEGETABLES UNDER MAP Ash gourdCoriander leavesMint leaves Beet rootCurry leavesOkra BeansCucumberOnion Bitter gourdDrumsticksPlantain CarrotField BeansRidge gourd CabbageFenugreek leavesSnake gourd CauliflowerGreen peasSpinach leaves Cluster beansGreen chilliesTomato CocciniaKnol-kholTurnip

28 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

29 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

30 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

31 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)

32 FRESH JUICE Heating to 90 0 c pH adjustment Filling into clean, sterilized hot bottles Crown corking Pasteurization at 85 0 C for 25 to 30 minutes Air cooling, packing & storage BOTTLED FRUIT JUICES Sterilized crown corks FLOW DIAGRAM FOR THE PRODUCTION OF FRUIT JUICES

33 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 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

34 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

35 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 70 o Brix CAPACITY OF SUGGESTED UNIT : 300 KG/DAY TOTAL PROJECT COST : Rs LAKHS

36 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

37 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 -32 o C FROZEN STORE (-28 o 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

38 INDIVIDUALLY QUICK FROZEN OF IQF BANANA SLICES RIPE BANANA WASHING & PEELING SLICING IQF FREEZING AT -32 o C FROZEN STORAGE CONTAINER PACKING TRANSPORTATION IN REFRIGERATED CONTAINER DISTRIBUTION IN COLD CHAIN

39 FRESH FRUIT /VEGETABLE Sorting & Washing (manual / mechanical) Preparation(manual or mechanical) Blanching (for vegetables) Treatments Dehydration Packing DEHYDRATED PRODUCT Dehydration of Fruits & Vegetables

40 SPRAY-DRIED / DRUM –DRIED / VACUUM SHELF –DRIED BANNANA POWDER BANANA 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

41 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

42 DEHYDRATED WHOLE LIME Lime Fruit Washing Pre-treatment Dehydration Dehydrated whole lime Packaging & Storage Capacity : 10 MT lime/day Project Cost : Rs. 45 lakh

43 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 )

44 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)

45 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

46 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

47 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)

48 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

49 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

50 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.

51 Capacity : Chapathi’s/hr LPG Consumption :3Kg/Hr Power : 7.5 HP Size of Chapati : 160mmdia/1.5 thickness Machine dimension :6Mx1Mx2M

52 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

53 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

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55 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.

56 Automatic Continuous Urd Vada Making Machine

57 Feeding Conveyor Control Panel Hopper Blower Receiver Hopper Conveyor Blower Chaff Separator SPOUTED BED ROASTER Roasting Chamber Receiver

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59 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:

60 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

61 Other process control tools Pest 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

62 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

63 Selection criteria for food packaging system :  Packing requirements of food product  Barrier, strength and product  compatibility properties of packaging  system  Intended shelf-life  Cost

64 Package forms Flexible Semi-rigid Rigid Primary Secondary Tertiary Metal Glass Plastic Wood Paper Al-Foils Composites Laminates Coextruded films Coatings Different forms

65 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

66 Marketing Pattern of Processed Fruit & Vegetable Products in India Sector Market Share (Value based)  Institutional 40%  House holds & housewives 40%  Export 20%

67 67 Quality Safety Nutrition Sensory, Physical, Kinesthetic and Other dimensions Macro- & micro- nutrients Microbiology, Additives, Contaminants, Toxins, Environmental pollutants, Adulterants Food Issues

68 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.

69 69 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

70 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… 70

71  Carbohydrates  Dietary fibre  Sugars  Protein  Vitamin A Percent of Vitamin A as Beta-carotene  Vitamin C  Calcium  Iron  Other vitamins and minerals 71 Contd…

72 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

73 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

74 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

75 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

76 Mail :Head CFTRI Resource Centre Bhavan’s College Campus, Andheri (W) Mumbai – Telephone : Fax:022 – Web Site:www.CFTRI.com Head Quarter:CFTRI, Mysore – Director Telephone: / Fax:

77 P. M. BADGUJAR CFTRI Resource Centre Bhavan’s College Campus, Andheri (West), Mumbai Mobile No:


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