Dr. N. Varadharaju Professor and Head Post Harvest Technology Centre TNAU
Short Description
FOOD PRCESING...
Description
Commercial Food Processing Opportunities Dr. N.Varadharaju Professor & Head Post Harvest Technology Centre Agricultural Engineering College & Research Institute Tamil Nadu Agricultural University Coimbatore – 641003
Need for Food processing Food production in India to double in the next ten
years. India will add more than 500 million people in the 40
years. Today the total food market is approximately US$
69,444 million. Consumption of value added processed food to treble Food is one of the highest economic multipliers
among Indian industries
….
Contd
Today value addition to food production is only 7 per
cent India has the potential to become the largest food
factory Value added foods produced from the food
industries would reach Rs. 2,75,000 crores by 2010
Investment Opportunities Diverse agro-climatic condition, it has a wide range and large raw material suitable for food processing sector
Biggest emerging sector to market over 1billion population 50 per cent of population are under 30 years 250 to 300 million are in middle class
Per capita consumption levels of processes foods are low Demand for convenience foods Increased female literacy Increased number of working women
Contd….
Institutional & Tourism sectors
Hotels, Airlines, Hospitals and Defence Services
Government accord high priority Investment reforms
Agriculture In India Contributes 29.1% to GDP 69% of work force depends on Agriculture 22 % of export from agricultural products
Major Achievements Self sufficient in food grain production (210 million tones) Ranks second in fruits (48 million tones) and vegetable production (98 million tones)
Largest producer of milk (72 million tons )
Food Processing Sector White Revolution Green Revolution
Blue Revolutio
Yellow Revolution (Post Harvest Processing)
India- “world’s largest food factory”- over 27,500 units (both large and small)
Post Harvest Losses Food grain sector
: 8–12%
Fruits and vegetable : 20–30 % Pre-harvest Factors
3-5%
Harvest
2-5 %
Packaging
3-6 %
Transport
1-4 %
Storage
4-8 %
Processing
1-5 %
Handling
1-5 %
Urban Distribution
2-8 %
Total Losses
18-48 %
Important Sub sectors
Cereals & pulse processing Fruit & Vegetable Processing Milk Processing Meat & Poultry Packaged & Convenience Food Alcoholic & Non Alcoholic Beverage
Progress of Fruits and Vegetable Industry in India
Particulars Production of processed Foods (Lakh tons)
2000
2005
9.9
12.5
Installed capacity (Lakh tons)
22.0
29.0
No. of Licenses issued under FPO
5293
5856
Reasons for Under Utilization of Processed Foods in India High cost of processed foods Low quality raw material affecting the final quality of processed foods
Prevailing rules and regulation and high tax for processed foods
Contd….
Lack of knowledge about process, equipment & technology
Lack of proper infrastructure like electricity, good quality water, communication facilities, etc.
Inadequate cold storage and refrigerated facility
Market Needs Domestic Market Factors Triggering
Potential for New Products
• Increasing nuclearisation of families
• Convenience Foods, semi cooked
• Increasing number of working women
• Ready to cook / eat foods
• Changing role of Women
• Organic foods, Natural Colours, Flavours, Neutraceuticals,
• Increased health consciousness
• Fortified foods, Energy Foods, Low Fat Foods, Sprouted Foods
• Changing Retailing System
• Packed & Branded Commodities
Export Market Competitiveness for Indian fresh and processed foods Increasing number of Indian population in foreign countries Acceptance of Indian Food in Foreign Markets
APEDA’s SCHEDULED PRODUCTS
Fruits, Vegetables and their products Meat and Meat Products Poultry and Poultry Products Dairy Products Confectionery, Biscuits and Bakery Products Honey, Jaggery and Sugar Products Cocoa Products Alcoholic and Non-Alcoholic Beverages Cereal Products Groundnuts, Peanuts and Walnuts Pickles, Papads and Chutneys Horticulture and Floriculture Products Herbal and Medicinal Plants Rice (non-Basmati)
Methods of Food Preservation with Examples Methods
Examples
Physical Method
Thermal processing, Concentration/drying/Dehydration, Sterilizing, Filtration, Radiation/Irradiation, etc.
Chemical Method
Solidification (salting), Saccharification (sugar addition), Artificial acidification, Gaseous preservation, Ethyl alcohol addition, etc.
Biochemical Method
Lactic fermentation (natural acidification), Alcoholic fermentation
Combined Method
Combination of above methods
Fruit and Vegetables processing 18% of gross agricultural product India’s share in world trade is @1% Major exports: fruit pulps, pickles, chutneys,
canned fruit & vegetables, conc. juices and dehydrated vegetables
Market for Multipurpose Fruits & Vegetables Pastes
Overseas a) Tomato Paste Major Importers
: :
15,00,000 MT Germany, UK, Japan
b) Banana Puree Major Importers
: :
1,20,000 MT USA, Japan, Russia, EU Countries
c) Mango Pulp Major Importers
: :
95,000MT USA, EU, Middle East Countries
d) Guava Puree Major Importers
: :
15000 MT USA, EU Countries
e) Papaya Puree Major Importers
: :
1500 MT EU, Middle East Countries
POST HARVEST HANDLING - BANANA SELECT UNIFORM BUNCHES ( 75 – 80% MATURITY) ↓ CAREFULLY HARVEST ↓ DE-HAND FRUITS (WITHOUT INFLICTING DAMAGE) ↓ DE-FLOWER ↓ CLEAN CUT TO THE CROWN ↓ WASH HANDS ↓ ANTIFUNGAL TREATMENT ↓ AIR-DRY ↓ PACK IN CORRUGATED FIBRE BOARD BOXES
PRE-COOLING (13-14 oC) ↓ TRANSPORT TO AIR PORT OR SEA PORT ↓ LOAD INTO TEMPERATURE CONTROLLED REFER CONTAINERS ↓ STORE IN COLD STORE ↓ RIPENING ↓ RETAIL MARKETING
Vacuum Packaging Product is packed in a vacuum condition
Vacuum packaging offers an extensive barrier
against corrosion, oxidation, moisture, dirt, fungal growth, etc
Best suited for dried fruits & nuts
Vacuum packaging of banana
Increases the shelf life for 30 days
Ripening takes 7 to 10 days after opening the bags.
No residual effect of fungicide
VACUUM PACKED CAULIFLOWER
Mango Processing Raw Mango
pickle, chutney and beverages
Ripe Mango mango pulp , squash, juice, jam, leather Machineries required
Rotary washer, , blanching unit, mixing unit,, steam generator, brine tank, can reformer, can flanger, can seamer, retort, sterilization unit, cooling unit, bottle capper, bottle washer , filling table bottling unit
Area required Capacity Cost
: 1000 sq.m : one tonne per day : Rs. 50, 00, 000
FRESH MANGO PROCESS FLOW CHART
HARVESTING (With Mango Harvestors at 7o – 8o Brix) ↓ DESAPPING ↓ WASHING ↓ HOT WATER TREATMENT (at 48o c / 1 hours) & OTHER POST HARVEST TREATMENTS
↓ FINAL GRADING (Refer standards)
↓
WEIGHING
↓ PACKING (IIP APPROVED PACKING)
↓ PALLETISATION
↓ PRE COOLING (12o C + 0.5o C)
↓ COLD STORAGE (12o C + 0.5o C)
↓ STUFFING INTO CONTAINER
↓ EXPORT BY SEA
Mango Fruit bar Mango fruit ↓
Washing ↓
Cutting ↓
Pulp extraction ↓ Addition of sugar ↓ Heating ↓ Cooling ↓ Drying ↓ Packing
Gherkin processing Gherkin ↓
Washing & Grading ↓
Soaking in 14% brine solution (Barrels) ↓
Maintaining the salt concentration ( 30 days) ↓
Packing ( Bottle /can / barrel )
Mushroom preservation Poor shelf life Cold storage – always not
possible Domestic consumption
Value Addition Drying Canning (2 % Nacl) Pickling
Preservation of sugarcane juice
In aluminum pouch
In glass bottle
Sugarcane juice in PE bags
Sugarcane juice in PP bags
Sugarcane juice preservation Pre heating ( 700C for 15 min)
Cooling Addition of preservative ( sodium benzoate 125 ppm) Filling and sealing Pasteurization (800C for 15 min)
storing
Mr.R.Ramalingam Pondicherry
500Bottles/day
Edible films and coatings Gives the food product a protective superficial layer Made from proteins, starches, waxes, lipids, etc., Also made from food-grade anti-microbial and
antioxidant compounds
e.g., Ethyloleate coating for grapes increases the
drying rate and gives a better quality raisin
Wax Application Paraffin wax, Carnuba wax and bee wax Enhances the shelf life by
- 10 days
Rate of application
- 1 kg/ 1000kg
Guava, Mango, Banana
- Waxol W/12
Lime, Apple, Tomato
- Waxol O/12
Products Prepared from Fruits and Vegetables Name of Crop
Products
Guava
Jelly, cheese, Toffee, Nectar, Canned guava, Squash, Vinegar
Aonla
Pickle, squash,RTS, dried flakes&powder, candy
Papaya
Jam, candy, Nectar, Pickle, Sauce, Canned papaya, Papain
Banana
Pickle, squash,RTS, dried flakes&powder, candy, chips
Grape
Wine, Juice, Raisin
Tomato
Pickle, puree, ketchup,sauce,concentrate, jam, juice
Onion
Dried flakes, pickle, dried powder
Cassava
Starch based materials
Moringa
Dehydrated powder, moringa seed oil
Coconut
Coconut water, coconut milk powder, desiccated coconut
Chillies
Red chilli powder, paste, sauce
Sugarcane
Bottling of sugarcane juice
Machineries for fruits and vegetable processing
Fruit mill, Fruit pulpers, Juice extractors, Packing machines, Filling machines, Steam boilers, Steam jacketed kettles, Sterilizers
Area required Capacity Cost of the machinery
: 1000 sq.m : One tonne per day : Rs. 50,00,000
Market for Potato Products Global Market for Potato Products a) Potato Flour Major Importers
: :
65,000 MT Netherlands, Poland, Germany
b) Potato Flakes Major Importers
: :
130,000 MT Japan, UK, Italy, Spain
c) French Fries Major Importers
: :
10,00,000 MT Price 1500 USD/MT Japan, EU Countries
d) Other Products
:
Granules, Wafers, Fabricated Wafer (Pringle type)
Technology Driven Projects • Aseptic Packaging
• Irradiation - Onions, Potatoes, Fruits, Marine, Meat, Spices
• Cryogenic grinding – Spices, Herbs.
• Retort pouches – prepared curries, pulses etc.
• Modern Cold Storages – C.A., M.A.
ASEPTIC PACKAGING
Sterilized food material is packed in a sterile container in sterile zone
Production of ambient shelf-stable foods
UHT milk and pasteurized fruit juices
Alternative for metal cans and glass jars
Aseptic packaging involves 3 separate sterilization process • • •
Sterilization of product Sterilization of equipment Sterilization of packaging material
Food raw materials preparation
Formulation Blending, Mixing
Sterilization Pasteurization Heating
Holding
Aseptic zone
Cooling
Packaging material
Homogenization
Filling Sealing
Product storage
Distribution & Consumption
Sterilization
Products used for aseptic packaging Mango & Guava pulp Pine apple & apple juice Tomato & banana puree Tomato paste Papaya syrup Flavored milk and ice cream mix Packages used for aseptic packagin Plastic Paper Metal foils
Advantages of aseptic packaging
Minimize degradation of heat sensitive products Retains colour, flavour, texture and reduces the loss of nutrients Post processing cost is less (refrigerated storage not necessary )
Application of Radiation • Shelf life extension – fruits and vegetables • Destruction & inactivation of insects & parasites • Kills pathogenic bacteria, molds and yeasts • Inhibition of sprouting of tubers
Food Irradiator
Irradiated and Non-irradiated Onion and Potato
FOODS APPROVED FOR IRRADIATION Food products
Purpose
Dose (kGy)
White potato
Extend shelf life
0.05-.15
Date of Clearance 1965 Nov
Spices and dry seasoning
Disinfect insect
30
1983 Jul
Fresh fruits
Delay maturation
1
1996 Apr
Poultry (fresh or frozen)
Control illness
3
1990 Dec
Red meat
Decontamination
3
1997 Dec
Potato
Inhibit sprouting
0.15
1960 Nov
Onions
Sprouting inhibition
0.15
1965 Mar
Wheat, flour,wheat flour
Disinfestations
0.75
1969 Mar
Poultry meat
Decontamination
1.5-3
1992 Sep
Red meat(fresh)
Decontamination
4.5
1997 Feb
Cereals
1
Bulbs and tubers
0.2
Herbs Condiments
Decontamination
10 10
1984 Oct
Commercial Applications
Insect disinfestations of stored products
Quarantine treatment for fruits and vegetables
Inhibition of sprouting in tuber and bulb crops
Delay in ripening of fruits
Extended shelf life of seafood, meat and meat products
Improving food safety and decontamination of spices and sterilization of foods
STATUS OF FOOD IRRADIATION More than 40 countries approved the processing
of about 100 products. About 28 countries in commercial scale In India, Vashi and Lasalgaon(Maharastra)
(onion and potato sprout inhibition) BARC, unit - 20 tons/day for treatment of spices
Dairy Industy India ranks first 50 per cent – Buffalo milk Variation in milk consumption Only 40 per cent used for products New dairy products
Milk & Milk Products Fluid milk, cream, butter, ghee, khoa, Cheese, buttermilk, yoghurt, ice cream, flavoured milk, casein, milk powder Machineries required Can washers, Plate chiller, pasteurizer, cream separator, homogeniser, butter churn, ice cream freezers, evaporators, spray driers, form fill & seal machine
Area required : 1000 sq.m Capacity : 10,000 litres per day Cost : Rs. 75,00,000
Snack Foods Overall production 3,50,000 tonnes (Rs. 14 billions) Namkeans salty snacks, chips pappadums & bakery
snacks like biscuits Potato chips Namkeans Chick peas, pulses, edible oil, groundnut and spices
Market Trend of Snack Foods Taste varies across regions Flavour ingredients Pack size- affordable Attractive packaging Baked snacks & roasted snacks are
to be potential areas
Extruded Foods Ragi , Rice & Wheat
Machineries required Kneader, blender , extruder, dryer, packing equipments etc.,
Area required : 1000 sq.m Capacity
: one tonne per
day Cost
: Rs. 60,00,000
Bakery Products Bread, bun, cakes, puffs, biscuits, pastries
Machineries required Kneader, mixer, sheeter, proofer, rotary oven, moulder, slicer, packing machines, moulds, trays etc
Area required : 1000 sq.m Capacity : 50,000 bread per day Cost : Rs. 40,00,000
Retort pouch processing
Advantages of Retort pouch processing Replacement for can Cheaper Simple operation Low initial investment
Frozen Foods Frozen vegetable peas, cauliflower Frozen chicken Frozen dairy dessert paneer kulfi ice cream Frozen meat and sea foods Cold chain
Cold Chain Industrial cold stores in the Production zones Refrigerated vehicles for long distance transport Refrigerated room in wholesale markets Refrigerated distribution vehicles Refrigerated rooms and display cabinet in retail
stores
Cold Storage Industry
First cold storage plant was setup at Calcutta in 1892
Growth of the industry was negligible till 1995
Normally growth of the industry has been pronounced in north India (MP,UP,WB,Bihar ,Harayana)
90% of the cold storage unit used for potato
Remaining 10% used for other fruit and vegetables
Commodity wise distribution of cold storage units in India Commodity
No. of cold storage units (%)
Potato Fruit & Vegetables Milk & Milk Products Meat Fish Meat and Fish Multi-purpose Others
63.0 1.1 6.9 0.8 11.3 2.1 9.7 5.1
Total
100.0
Recommended Storage conditions Fruit / vegetable
Temp.(0C)
Banana Pine apple Apple Grapes Mango Potato Onion Carrot Bhendi Cabbage tomato
14 – 15 8 – 10 0- 2 0- 2 10 - 12 3-4 1- 2 2- 3 8 -10 1-2 8 -10
R.H. 80-85 85-90 85-90 85-90 85-90 85 70-75 95 90 90-95 90-95
Storage period 2 months 2 months 8 months 2 months 1-2 months 8 months 6 months 6 months 1 month 3 months 2 months
Funds for Cold Storage Units National Horticultural Board providing capital subsidy to entrepreneurship for construction,expansion and modernization of cold storage for horticultural produce
Objectives To promote cold storage in the country for reducing post harvest losses
Eligible Organizations
NGO’S Association of growers Corporations Agricultural produce marketing committees Marketing boards/committees Agro industries corporations
Major Considerations for a New Project 1) Market Needs – Domestic as well as Overseas 2) Availability of Competitive Resources 3) New Technologies 4) Other Factors – Socio-Economic Environment, Government Fiscal Policies, Incentives, etc.
Food Industry Laws PFA 1954 Prevents customers against adulterated food Domestic & imported food products Food colour, preservative, pesticide residues, packaging labeling & sales Not upto date with advances in food processing sector Labeling requirement Language, name, address, description of product, Constituents, date of manufacture, expiry date
Contd…
The Standards of Weights & Measures Act 1976 Essential Commodity Act 1955 Fruit Product Order 1955 Milk & Milk Product Order 1992 Pulses, Edible oil seeds and Edible oils Order 1977 MRTP Act 1969 BIS 1952 Agricultural Produce Grading & Markets Act 1987 Environment Protection Act 1986 HACCP
Food Safety & Standards Authority of India (FSSAI)
Thank You
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