INNOVATIVE PROCESSES AND MACHINERY

FOR FOOD PROCESSING

August 19-20, 2013
Two day training programme
Kolkata

Dr. H Umesh Hebbar, M.Tech., Ph.D.

Principal Scientist, Department of Food Engineering
CSIR- CFTRI, Mysore, India

About CFTRI
..Processes
.Products
..Machinery

About CFTRI
One Stop Centre for Food Science
and Technology
Premier Food Research Institute established in 1950.
One of the constituent laboratories of CSIR, Govt. of India
Mandate to develop cost-effective, bio-friendly food processing
technologies, with total concern for food safety, health, nutrition
and environment.
17 R&D departments, 14 supporting departments and 3 Resource
Centers
Around 500 scientific/supporting staff , 150 Research Fellows
Certifications and Accreditations
ISO 9001 Quality Management System
ISO 14001 Environmental management System
12/18/2014
ISO 17025 NABL Accreditation

CFTRI Portfolio.
Pre/Post-harvest protocols for extension of shelf-life
Disinfestation, handling, packaging of Fruits
Technologies for shelf-life extension
Minimal processing, Fumigation, Thermal/non-thermal
processing, Biotechnological approach, Packaging
Development of products
Convenience foods RTE, RTC, Easy to prepare,
Designer foods Low GI, Low Fat, Low Calorie, Geriatric
Functional/Speciality Foods Pro-biotic/pre-biotic
Equipment development
Traditional Indian Foods, Improved efficiency, nonconventional energy source s
Basic research
Biochemistry, Nutrition, Cell culture, Biotechnology,
Nanotechnology
12/18/2014

Other Activities
Consultancy assignments
Industry sponsored projects

Imphal

Technology/Know-how transfer
BR Hills

Turn-key projects

HRD activities
Lucknow
M.Sc. Food Technology (2 years)
Certificate Course on Milling Technology (1 year)
Entrepreneur Development Programmes
Short-term Courses for Entrepreneurs (1-2 weeks)
Ph.D. Programme for Research Fellows
Project work for Under Graduate/Post-graduate students
12/18/2014

Pilot plant

Automated
Wheat mill

Analytical Lab

Facilities
at CFTRI

Maize mill

12/18/2014

Sensory booth

Instrumentation facility

SS
6

Agricultural Production Scenario in

Eastern/N-E India

Fruits & Vegetables (Potato, Onion, Pea, Mushroom)

Cereals (Rice, Maize, Wheat, Millets)
Spices (Ginger, Chilli and Turmeric)
Milk & Poultry products
Sugarcane

Mostly in small and medium scale industries

Scope for Value addition is high.
Value addition to these agri-materials is one of the potential
areas of Industrial and Research importance

12/18/2014

12/18/2014

PRE/POST HARVEST PROTOCOLS

Post harvest technology protocols for
Air cargo space and
export of Mango variety Alphonso in
uneconomical and exorbitant
Reefer Container by ship.
air freight charges (3 times).
Technology protocol for export of
Banana variety dwarf Cavandish by ship.
Orchard management pre harvest care with spray treatments to control fungal
and insect damages to the fruit, optimum stage of maturity for harvest,
desapping, handling, packing-house operations such as grading, washing,
post harvest dip treatments, packing in specially designed CFB boxes, precooling, stacking in reefer containers, optimum storage temperature and
humidity management inside the reefer container and post transportation
ripening conditions.

12/18/2014

Shelf-life extension by 35
days for Mango and 42
days for banana

Minimal Processing (MP) of Vegetables

Preparation
procedure
generally includes processes
such as washing, peeling,
cutting, trimming, slicing,
shredding, dicing and coring .

Simple and Cost effective

Generates gainful employment

Maintains freshness and quality

Render vegetables in convenient
and "Ready-to-cook form".
Bulk reduction for better storage,
easy transportation and packaging

Extends shelf-life by 3-5 folds

At rural and urban level

Ash gourd
Beetroot
Beans
Bittergourd
Carrot
Cabbage
Cauliflower
Cluster beans
Coccinia

Boosts export of vegetables

Renders 60% value addition

Low cost technology

Coriander
leaves
Curry leaves
Cucumber
Drumsticks
Field beans
Fenugreek
leaves
Green peas
Green
chillies
Knol-khol

Mint leaves
Okra
Onion
Plantain
Ridge gourd
Snake gourd
Spinach
leaves
Tomato
Turnip

Controlled/Modified atmosphere storage

Pretreated fruits

Concentrations of Oxygen, Carbon di-oxide, Nitrogen

Temperature
Humidity

Dehydration of fruits and vegetables

Removal of moisture leads to reduction in
Water activity
Microbial activity
Enzyme activity

Slices, Shredding,
Powder

Ultimately results in shelf-life extension

Reduction in density, storage space and transportation cost

Osmotic-hot air dehydration

Osmotic dehydration
followed by hot air
drying at lower
temperatures

Jack fruit slices

Amla segments (sweet and salted)

Pineapple slices
Mango slices
Vegetables

Electromagnetic radiation assisted drying

Conventional Heating
H
M

EMR Heating
W
M H

Case hardening

H = Heat, M = Mass, W = Waves

Rate of Heat and Mass transfer is more

Reduces drying time
Improves product quality

Near Infrared (NIR) heater

Air vent
NIR heat
sources
Material
bed

Wavelength: 1.1-1.3 m (max.)

Power: 6 kW
Max. temperature: 220C
Operation: Continuous/batch
Heating: Top & Bottom

15

INFRARED PROCESSING OF CASHEW KERNELS

FOR TESTA REMOVAL AN ALTERNATIVE TO BOURMA DRYING
RAW NUTS
ROASTING
SHELLING

24 h

BOURMA

DRYING
PEELING
~1 h

GRADING
PACKING

IR
INTERMITTENT HEATING

16

ADVANTAGES
Reduced processing time (80% over Bourma)
Higher yield of White Wholes (5-6%)
No Scorched kernels(2% in Bourma)
Elimination of High Cooling step

Lower processing cost (20%)

Easy to scale up
Continuous process with minimum labor requirement

17
17

COMBINED IR AND HOT AIR DRYING

18

Air Vent
90.2C

IR Heat Sources

Control Panel

Temperature Sensor
Conveyor
Air Heater
Air Duct

Blower

SYNERGISTIC EFFECT OF HOT AIR AND INFRARED

1911

Infrared Drying
Reduced drying time (43%)
Higher rehydration moisture (6-7%)

Higher carotenoid retention (88%)

Better cell structure

COMBINED RF AND HOT AIR DRYING

Energy efficient dryer

27.12 MHz

Higher product thickness

VEGETABLES

Self regulating system

SPICES
HERBS

Ideal for finish drying

21

Basil leaves

Dill greens

22

MW-Convective drying

BATCH

Reduction in drying time by ~40%

Retention in volatile oil by ~20%

Improved color values

CONVEYORIZED
23

Solar Drying
The indirect drier has three main components:
external air heater
drying room (or cabinet) with its trays
air circulation and evacuation device with
eventual recycling.

Cardamom dryers
Natural Convection dryers
on the filed itself
Solar dryers for increased
energy conservation
24

Vibro Fluidized Bed Dryer/Roaster

Food
Material
Inlet

Hot air
recirculation 70%

Food
Material
Outlet

Fresh air
30%

Combustion chamber
LPG Flue + Fresh air

LPG
Cylinders

INTEGRATED HOT AIR

ROASTING MACHINE

Comparison of HSD and LPG fired ovens

Description

Type of oven

Diesel

LPG

Indirect

Direct

10,300 Kcal / kg

11,642 Kcal / kg

Fuel quantity

49.5 Kgs / per ton of

Food

42 Kgs/ per ton of

Food

Cost of Fuel

Rs 24.50 / Kg

Rs 22.50 / Kg

Rs 1213 / per ton of

Food

945 / per ton of Food

Type of Heating
Gross Calorific Value

Total Fuel Cost

Saving of Fuel (cost) by
converting diesel-fired oven to
LPG fired oven.

15.15% (22.09 %)

Endurance test conducted with wheat, soji, greengram and jowar.

Snack foods - vermicelli, corn flakes and fryams also roasted with
satisfactory results.

INFRARED ROASTING OF GROUNDNUT SEEDS

Overall
Liking

80
70
60
50
L 40
30
20
10
0

Texture

Flavor

12
8

TI(Min)

Appearance/
Color

4
150

160

170

180

190

200

TE(C)

Method of
roasting

Product quality
Compressive
Oil yield
strength
(%)
(N)

Temp.

duration

(C)

(min)

4.43

68.90

47.03

Drum

180

20

1.60

57.23

Sand

180

12

1.30

IR

180

8.0

0.87

Control

Moisture

Hedonic scale

(%)

Peroxide
Value
(meqO2/kg)

70.45

0.34

4.90

49.98

57.45

0.67

5.88

64.13

49.57

68.00

0.46

5.15

67.50

51.68

36.50

0.38

4.98

Lightness

(% w.b)

FFA

27

Spouted Bed Roasting

Hopper

Chaff Separator

Control
Panel

Receiver

Spouted Bed Roaster

mixing
Effective Gas-Particle
contact facilitating HTST
process.
Enhanced aroma and flavor
On line chaff separation
and dust removal
Visual display
arrangements helps in
roasting bean color control

Membrane Processes
Classification
MF, UF, NF and RO depending on pore size
& trans-membrane pressure
Plate & Frame, Tubular, Spiral wound and
Hollow fiber modules.
Scale-up is easy as they are modular.
Becoming more cost effective as material is
imported now.
Polymeric and ceramic membranes
30

Membrane Processes
Advantages
Low temperature and low pressure process
Low energy consumption

Disadvantages
Maximum achievable concentration
Membrane fouling
Concentration polarization
31

Keishing Foundation,
Management of Tribal Areas (MATA),
Litan, Manipur

View of the Buildings on the site

Orange & Pineapple juice concentrates

MATA plant first in India in membrane area
by CSIR-DSIR-MFPI.
MF for clarification and concentration by
evaporation.
Hot filling or HTST bag-in-barrel.
RTS (Ready-to-Serve) beverages are through
tetrapack.

View of the process plant

Membrane system

Vaccum Evoparator

Pineapple and Orange products

Membrane processing of black tea extracts

Black tea extract

Diafiltration
(150%)

50 fold extract (45 min, 90C)

TSS - 0.61%; PP- 0.348%
Conc. extracts 2, 5 & 10%

Retentate
MF/UF

Clarified
black tea
extract

Undesirable cream
components

Protein
Pectin
Minerals - Ca

Primary quality
criteria
Low turbidity
Low tea cream
Original color

Desirable - Higher
Soluble solids
recovery
Polyphenols
recovery
TF/TR
Catechins

MF
UF
VCR

Membranes
- 450, 200 nm
- 25, 50, 100 & 500kDa
-5

Membrane processing of Honey

Membrane processing
Feed

Micro-filtration (MF)

- (3 Membranes)

Retentate

MF

Permeate

Ultra-filtration (UF)
(5 Membranes)

Retentate

UF

Permeate

Commercially

sterile honey
without
cloudiness
or
sedimentation

Vacuum
Concentration

Vacuum
Concentration

- Beverages

Enzyme enriched honey

- Nutritional

Filtered Enzyme Enriched Honey

Ultrafiltered Honey

Scheme for Membrane Processing

OMD Plate & Frame Membrane Unit

1

5
5

1. Ball Valve
2. OMD Plate and Frame Module
3

3. Feed Reservoir

4. Osmotic Agent Reservoir

5. Peristaltic Pump

Concentration up
to 65Bx
38

Hurdle Technology for Extending the shelf life

Hurdle Technology for extending the
shelf life for a minimum of 6 - 8
weeks using Hurdle technology

Prepared idlies/dosa/paddu
Placing them in pouches

Steam flushing

Hurdle Technology used here rely on

a mild heat treatment (65-95C)
followed by storage at chilled
temperature (<10C) for safety and
preservation.

Heat sealing
Racking
pasteurization
Refrigerated storage (3-4 C)

Value added products from Ginger

Bleached ginger
Unbleached ginger
Salted ginger
Ginger preserve
Ginger candy
Ginger paste
Ginger powder
Ginger oil
Ginger oleoresin
O

OH

CH3 O

HO

(CH3)

GINGEROL

C17H26O4

n = 6
n = 8
n = 10

Preparation of Ginger Oleoresin

Fresh ginger
Drying
Powdering
Steam distillation

Spent

Drying

Ginger oil

Solvent Extraction
Desolventization

waste

Oleoresin

Traditional processing of turmeric

Harvested lot
Fresh Rhizomes

Pre-cleaning

TURMERIC COOKING

Separation of fingers & bulbs

Cooking in water (40-60 min)

Heaping
Polishing

Spreading for sun drying

Polishing & Bagging

Production of Turmeric Powder

Fresh turmeric rhizomes
Grading/separation
Slicer/dicer
Down stream processing time for
Turmeric slices
Drying

production of hygienic Turmeric

powder
starting from freshly
harvested turmeric rhizomes is
very low (with in 24 h) compared
to traditional
methods, which
takes minimum of 25-30 days.

Dried turmeric slices

curcumin and volatile oil
Powdering Higher
content in the finished product1

Turmeric Powder

Patent A process for

production of turmeric
powder
from
fresh
turmeric
rhizomes
250/del/2013 filed

Primary processing of chilli

Value added products from chilli

Harvesting at near ripe red stage

Indoor heaping for full colour
development
Solar/ shade drying- 8-15 days
Improvements in drying
Processing of paprika

Chilli powder
Chilli oleoresin
Chilli seed oil
Chilli paste
Chilli colour
High pungency chilli oleoresin
Capsaicin

Production and Processing of

Oyster Mushrooms
a) A technology for the Large scale production and processing of Oyster (Pleurotus
species) Mushrooms has been developed and transferred to entrepreneurs, which
involves
Culture & Spawn
Large scale production
(Urban & Rural Models)
Mushroom dehydration
Pickle & Sweet Chutney
Canning
Instant mushroom soup mix.
b) Plantation crop wastes like fresh coffee pulp and coir fibre waste are also used
substrate and yields are at par with that on rice straw (more than 100% BCE).
c) Mushroom produced without any fungicide/pesticide and hence, can be regarded as
Organic Food

VALUE ADDED PRODUCTS FROM COCONUT

Virgin
coconut oil

Desiccated Coconut Powder

Coconut Protein Powder

Spray Dried Coconut Milk Powder

Coconut Dietary Fiber

Tender Coconut Beverage

Coconut Spread

VCO Technology
transferred to more than
30 entrepreneurs

Processing of Sugarcane Juice Beverage

Sugarcanes
Pretreatment

Crushing

Filtration
Hygienic Crusher

Bottling / canning

Aseptic filling

Pasteurization

Cooling
Storage

Commercial sterility upto

120 days at RT

Commercial sterility upto 150

days at RT

Sugarcane Juice Spread

Sugarcanes
Pretreatment
Crushing
Filtration
Processing
Filling
Cooling

Stability 120 days

Storage

Sugarcane Juice Concentrate & Powder

Sugarcane

Crushing

Filtration

Sugarcane Juice

Concentrate (Vacuum)
with additives

Sugarcane juice
Concentrate (120 days)

Dehydration with
additives
Sugarcane juice Powder

Kakambi & Jaggery

Sugarcane

Crushing

Filtration

Sugarcane Juice

Evaporation under
vacuum

Kakambi

(20 days)

Two stage evaporation

Jaggery

(160 days)

Phycocyanin
Phycocyanin
Is a blue colored phycobiliprotein obtained from
Spirulina platensis and has high commercial value

Purity =

A620
A280

Applications

Purity

Grade

Cost per mg
(in US $)

0.7

Food grade

0.13

1 3.9

Reactive grade

15

> 4.0

Analytical grade

15

as fluorescent markers
food colorants (Lina blue)
in cosmetics
pharmaceuticals
immunological aspects

52

Preparation of Crude Extract

Fully grown spirulina

biomass

Washed with
distilled water

Homogenization

Crude
Extract

Centrifugation

Spirulina cells releasing phycocyanin

during homogenization
53

Betalains-Current Practice
Fermentation to remove the sugar

Wet grinding of whole beat and spray drying

Drawbacks
Large quantity needed to get hue
Tedious process

Differential Partitioning of Betalains and Sugars

using Aqueous two Phase Extraction

54

Flowchart of the downstream processing of Betalains

Fresh beet
root

Wash, peel, slice and grind

with acidified water

Centrifuge at 12000 rpm to

remove polyphenols

PEG
Recovery

Betalains

Product
(concentrated)

Sugar and other

components

Fresh juice
subjected to
ATPE

Betalains
powder
Lyophilization
55

Value addition to food waste

Apple pomace contains 18%starch,10% pectin,
25% insoluble and 7% soluble fibre, 1400mg
phenolics & 392 mg flavonoids/100g dry wt.
Development of cereal flakes & bakery products
like cookies, bun and muffin.
Watermelon (Citrullus lanatus) rind: Citrulline of the
rind is known for its ability to remove ammonia in
the human body and is essential for excretion of
oxidative waste processes.
Development of Watermelon rind tit bits employing
osmo-dehydration technique

Bromelain from pineapple wastes

Meat tenderization
Pharmaceutical
applications

57

Low calorie RTS fruit beverages, low glycemic RTS blended

vegetable beverages, value added products

Karaunda
Pumpkin

Shelf life of 45-90 days

Mulberry

Value added products from

custard apple

Bio-functional beverage and jelly from debittered sweet orange (Citrus sinensis)

Sweet orange juice turns bitter, even at

room temperature and on heating for
pasteurization it further intensifies
besides development of off-flavor
Bitter principles:

Naringin
Limonin

Beverage and jelly from

Mangosteen
(Garcinia mangostana) fruit rind

- mangostin

Retention of xanthones in processed

products.

SPRAY DRIED PRODUCTS

Honey powder
Application: Dry mixes
Advantages:
Free flowing with honey flavor and color
Long shelf life (PET/FOIL/LAMINATE)
Higher honey content
Patent:

Spray dried honey powder (DEL/419/01)

Mango powder
Bael Powder
Encapsulated bioactive compounds

PRODUCTS FOR CHILDREN

Energy Food Multigrain Product
- High Calorie
- Fortified with nutrients
- Dry mix for consumption
- Preparation Products
High Energy Biscuits High Calorie

Fortified Products Minerals, Vitamins

12/18/2014

63

Traditional Indian Foods

Non homogenous nature and their variations in
recipes & shapes add to problems.

Food material
processing

properties

change

during

Many of them derive standard conditions of

serving.
To be operated on small batch capacities and
hence scope for mechanization is limited.

Technology and machine

should go hand in hand

development

AUTOMATIC CONTINUOUS DOSA MACHINE

Designed and
Developed at
CFTRI
400 Dosa/h
LPG based system

More than 800 units

across India

AUTOMATIC CONTINUOUS IDLI MAKING MACHINE

Capacity : 1200 Idlis/ h

Sensor Based Automatic Deposition
Synchronized Mechanical Scooping system

Cleaning-In-Place (CIP) System

Electronic Counter
Hygienic and untouched by human element
Final Product of Uniform Quality

CONTINUOUS CHAPTHI MAKING MACHINE

Designed and
Developed at CFTRI

1000 Chapatis/h
LPG based system
Forming, Baking and
Puffing section

CONTINUOUS VADA MAKING MACHINE

Poory Machine
(600 nos/h)

Automation for Safe

Food
Garlic Peeling
Machine (100 kg/hr)

Laddu machine
(2000 nos/h)

Wet /Dry Grinder

( 50 kg/h)

Pneumatic lemon cutting machine

(2500 nos/hr)

70

Jilebi Making System

Leaf Cup Making System

Murukku Making
Machine

ACKNOWLEDGEMENTS
Dr . KSMS Raghavarao

Dr. MN Shashirekha

Dr. M Madhava Naidu

Dr. K Ramalakshmi

Dr. K Vankatesh Murthy

Research Students

Prof. Samir Brahmachary, DG CSIR

Prof. Ram Rajasekharan, Director, CSIR-CFTRI

Thank you