Food processing Industry

Group 2
Food Processing Definition

Food processing is the set of methods and

techniques used to transform raw
ingredients into food or to transform food into
other forms for consumption by humans or
animals either in the home or by the food
processing industry.

It involves of all intermediary processes

between Farm to fork that a product undergoes.
Understanding Food
Technology

Food technology is a collection of various

standard applications as required for a
product. Technology is just embedded into the
processes that make sure food is
uncontaminated, and production is looked
after as in normal industries.
Benefits of food processing

Toin removal

!onger shelf"life

#asing marketing and distribution tasks

Increase in off"season availability of foods

#ase in transportation of delicate

perishable foods across long distances

de"activation of spoilage and pathogenic

micro"organisms
Generically used Principles

High pressure processing (HPP)- Involves the

application of very high pressures (up to 6 000
times atmospheric pressure) to pre-packaged or
bulk liquid or solid foods$ in a hydrostatic press
" Finds application in jam$ jellys$ fruit juices$ processed
meat products

Pulsed electric fields processing- %sed mainly for

cleaning and separation
"Finds application in juice$ dairy and beverages
&ontd''

Osotic dehydration- (elps in

reducing moisture content, thereby
increasing shelf life of foods
"Finds application in almost every)here

Processing !y radio fre"uency

electric fields- %sedwhere thermal
application is unfeasible owing to loss
of food quality or nutrition
"Involves radio frequency to sterili*e and
also separation at times
#urrent scenario -
Production
+2, cultivable land
compared to --,
)orld average
.ll -+ major
climates in the
)orld eist in India
/0 out of 01 soil
types eist in India
21 agri"climatic
regions
!argest livestock
population
!argest producer of
milk
!argest producer
cereals
2econd"largest fruit
and vegetable
producer
.mong the top five producers )orld)ide
of rice$ )heat$ groundnuts$ tea$ coffee$
tobacco$ spices$ sugar and oilseeds.
2unshine hours
and day length are
ideally suited for
round the year
cultivation
!ignificant "pportunity
#ndia as a global sourcing
hub
#urrent $cenario -
Processing

#ategory
% of processed of
total production
fruits and vegetales 2.2 ,
3oultry 0,
4arine products 5,
4ilk products 6+,
#urrent scenario -
#onsuption
Food Consumption in India
$ource& B'() * + #$O 11111
, 1111
, 1111
, 11 1 1
, 11 1 1
, 11 1 1
, 11 1 1
111
, 1111
, 1111
1
11
111
111
111
111
1111 1 1 1 1 1 1 1 1 e 1 1 1 1 f 1111 f 1111 f 1111 f 1111 f 1 1 11
CAGR: . % 111
2egments of food processing

Fruits and vegetable processing

7airy

Grain processing

4eat and 3oultry processing

&onfectionery
89#:9I#;

Industry si*e < =1 >illion %27

&ontributes 0.6, to India?s G73

@, share in India?s total industrial production

!arge gro)th potential < out of total agricultural produce$

currently only 2, is processed
2ource A 48F3I )ebsite
2tructure of Indian Food
3rocessing Industry
Fruits and vegetables
2ector Insights

Installed capacity of fruits B vegetables

processing industry has increased from -.-
million tonnes in Canuary -@@6 to 2.- million
tonnes in 2110

The processing of fruits and vegetables is

estimated to be around 2.2, of the total
production in the country

4ajority of processing firms are cottage$

household and small"scale sector$ having
small capacities of up to 2+1 tonnes per
annum
Improvements required'

&onsumption of value added fruits B vegetables are lo)

compared to primary processed foods$ fresh fruits B
vegetables.

The inclination to)ards processed foods is mostly visible in

urban centres due to a high purchasing po)er
. remarkable push can be given to this sector by
strengthening linkages bet)een farmers and food processors

The poor and )eak linkage bet)een farmers and markets$ as

)ell as$ farmers and processing companies has brought about
inefficiencies in the supply chain and encouraged the
involvement of middlemen leading price rise to the products
Government 3olicies for Fruits B
9egetables

Do industrial license required for setting up Fruits B

9egetables 3rocessing Industries Eecept if it?s a
-11, eport oriented unitF

+-, F7I allo)ed for processing of tomatoes$

mushrooms B other fro*en vegetables$ fruits$ nuts$
fruit"peel$ fruit jellies$ marmalades$ juices etc.

2ector is regulated by Fruit 3roducts 8rder$ -@++

EF38F$ issued under essential commodities act

3roducts like pickles B chutneys$ tapioca sago and

tapioca flour are reserved for eclusive manufacture
in small scale sector

#port is freely allo)ed

$%!#& '("&)!!#*+
,)&-*#./)! F"( F(/#,! %*0
1)+),%$2)!

&leaning

3eeling

>lanching

3ickling

7ehydration
9alue .dded 3roducts From Fruits
and 9egetables

Fruit pulps and juices

Fruit based ready"to"serve beverages

canned fruits and vegetables

Cams

2quashes

3ickles

&hutneys

7ehydrated 9egetables

processed mushrooms

curried vegetables
Fruit beverages
/nfermented beverages

Fruit juices )hich do not

undergo alcoholic
fermentation

Include natural and

s)eetened juices$ :T2$
nectar$ cordial$ squash$
crush$ syrup$ fruit juice
concentrate and fruit juice
po)der.
Fermented beverages

Fruit Cuices )hich

undergo alcoholic
fermentation by yeast

#.g. )ine$ champaigne$

port$ sherry$ tokay$
muscat$
nira and cider
G#asily digestible$ highly refreshing$ thirst quenching$ appeti*ing and
nutritionally far superior to many synthetic and aerated drinks.H
2quash
Fruit beverage containing at least 2+,
fruit juice or pulp B /1"+1, total soluble
solids

.lso contains about -, acid B 6+1 ppm

sulphur dioide or 011 ppm sodium
ben*oate
It is diluted before serving.
&ommercial usage " 4ango$ orange
and pineapple

It can also be prepared from lemon$

bael$ papaya$ etc. using potassium
meta bisulphite EI42F as preservative
or from jamun$ passion"fruit$ peach$
plum$ raspberry$ stra)berry$ grapefruit$
etc. )ith sodium ben*oate as
preservative.
F!8;&(.:T F8: 3:8&#22IDG 8F
2J%.2(
()%03-,"-!)(1) ((,!)

&ontains at least -1
per cent fruit juice
and -1, total soluble
solids besides about
1.6, acid.

It is not diluted before

serving$ hence it is
kno)n as ready"to"
serve E:T2F.
Flow-sheet for processing of
(,! beverages
&ordial

It is a sparkling$ clear$ s)eetened fruit juice

from )hich pulp and other insoluble
substances have been completely removed.

It contains at least 2+, juice and 61, T22$

-.+, acid and 6+1 ppm of sulphur dioide.

2uitable for blending )ith )ines.

!ime and lemon are suitable for making

cordial.
F2"4&-%(, F"( '("&)!!#*+
"F &"(0#%2
Dectar
!r *o Fruits 5uice6'ulp 7 .uantity of water
required (litre)
- 4ango 21 Juantity of finished
product ElitreF < Juantity
of Ejuice ElitreF K sugar EkgF
K acid EkgF used
2 3apaya 21
6 Guava 21
/ >ael 21
+ Camun 21
0 .mla .mla pulp 21
!ime juice 2
Ginger juice -
&ontains at least 21 per cent fruit
juice L pulp and -+ per cent total
soluble solids and also about 1.6 per
cent acid.
It is not diluted before serving.
Fermented >everage" ;ine

>everage resulting
from fermentation by
yeasts of grape fruits
)ith proper
processing

.lcohol content < = to

21 ,
F2"4&-%(, F"( '("&)!!#*+
"F 4#*)
5%8

4ade by boiling fruit pulp with

sufficient amount of sugar to a
reasonably thick consistency

.pple$ pear$ sapotaEchikkuF$

peach$ papaya$ carrot$ plum$
stra)berry$ raspberry$ mango$
tomato$ grapes and muskmelon

It can be prepared from one kind

of fruit or from t)o or more kinds.
F2"4&-%(, F"( '("&)!!#*+
"F 5%8
5)223

2emi"solid product prepared

by boiling a clear strained
solution$free from pulp$ after
the addition of sugar and
acid.

Fruits used for preparation

of jelly " Guava$ sourapple$
plum$ papaya$
gooseberry$ .pricot$
pineapple$ stra)berry$
raspberry.
F2"4&-%(, F"( '("&)!!#*+
"F 5)223
8%(8%2%0)
Fruit jelly in )hich slices of the fruit or its peel are
suspended.
Generally used for products made from citrus fruits like
oranges and lemons in )hich shredded peel is used as
the suspended material.
&itrus marmalades are classified into"
9 5elly marmalade
The follo)ing combinations give good quality of jelly
marmaladeA
i. 2)eet orange E4altaF and khatta or sour orange
E&itrus aurantiumF in the ratio of 2A- by )eight. 2hreds of
4alta orange peel are used.
ii. 4andarin orange and khatta in the ratio of 2A- by
)eight. 2hreds of 4alta orange peel are used.
Iii. 2)eet orange E4altaF and galgal ECitrus limoniaF
in the ratio of 2A- by )eight. 2hreds of 4alta orange peel
are used.
: 5am marmalade
The method of preparation is practically the same as that
for jelly marmalade. In this case the pectin etract of fruit is
not clarified and the )hole pulp is used. 2ugar is added
according to the )eight of fruit$ generally in the proportion
of -A-. The pulp"sugar miture is cooked till the T22
content reaches 0+ per cent.
&%*03
. )hole fruit L vegetable or its pieces impregnated with cane sugar or glucose
syrup, and subsequently drained free of syrup and dried, is known as candied
fruit 6 vegetable
The most suitable fruits " amla, karonda, pineapple, cherry, papaya, apple, peach,
and peels of orange, lemon, grapefruit and citron, ginger
Fruit is impregnated with syrup having a higher percentage of sugar or glucose.
. certain amount (:;-<0 per cent) of invert sugar or glucose, vi=, confectioners
glucose (corn syrup, crystal syrup or commercial glucose), de>trose or invert
sugar is substituted for cane sugar
The total sugar content of the impregnated fruit is kept at about =+ per cent to
prevent fermentation.
The syrup left over from the candying process can be used for candying
another batch of the same kind of fruit after suitable dilution for s)eetening
chutneys$ sauces and pickles and in vinegar making.
+la=ed candy
&overing of candied fruits 6 vegetables with a thin transparent
coating of sugar, which imparts them a glossy appearance

'rocess
< &ane sugar and )ater E2A- by )eightF are boiled in a steam pan at --6"
--/M& and the scum is removed as it comes up.
< Thereafter the syrup is cooled to @6M& and rubbed )ith a )ooden ladle
on the side of the pan )hen granulated sugar is obtained.
< 7ried candied fruits passed through granulated portion of the sugar
solution$ one by one$ by means of a fork$ and then placed on trays in a
)arm dry room.
< &an also be dried in a drier at /@M& for 2"6 hours.
< 3acked in airtight containers after they become crisp
&rystalli=ed candy

&andied fruits6 vegetables when covered or coated

with crystals of sugar, either by rolling in finely
powdered sugar or by allowing sugar crystals to
deposit on them from a dense syrup .

3rocess
< The candied fruits are placed on a )ire mesh tray )hich is
placed in a deep vessel.
<
&ooled syrup E=1 per cent total soluble solidsF is gently
poured over the fruit so as to cover it entirely.
<
The )hole mass is left undisturbed for -2 to -5 hours during
)hich a thin coating of crystalli*ed sugar is formed.
<
The tray is then taken out carefully from the vessel and the
surplus syrup drained off.
<
The fruits are then placed in a single layer on )ire mesh trays
and dried at room temperature or at about /@M& in driers.
3ickles

The preservation of food in common salt or

in vinegar is known as pickling.

8ne of the most ancient methods of

preserving fruits and vegetables.

+ood appeti=ers, add to the palatability of a

meal.

2timulate the flo) of gastric juice and thus help

in digestion.

.t present$ pickles are prepared )ith salt$

vinegar$ oil or )ith a miture of salt$ oil$ spices
and vinegar.
/1
8)%, '%&?%+#*+
8)%, '%&?%+#*+
#*0/!,(3
#*0/!,(3
/-
Introduction
Introduction
High Hydrostatic Pressure (HHP) treatent is an atheric
decontaination process -hich consists in su!.ecting pac/aged food
to -ater pressures fro 011 to 211 'Pa,
The pressure applied is isostatically transitted inside a pressure
3essel,
/2
7iagram of the ((3 equipment
7iagram of the ((3 equipment
/6
Food that can be ((3 treated
Food that can be ((3 treated

Solid foods, mainly vacuum packed

- Dry-cured or coo/ed eat products
- #heese
- Fish) seafood) arine products
- 4eady to eat eals) sauces
- Fruits) aralades 5 .as
- 6egeta!les
Liquid foods, in flei!le packa"in"
- Dairy products
- Fruit .uices
- 7utraceutical forulations
//
Food that can not be ((3 treated
Food that can not be ((3 treated
Solid foods #it$ ai% included
- Bread
- 'ousse
&acka"ed foods in completely %i"id packa"in"
- (n glass
- #anned
Foods #it$ a ve%y lo# #ate% content
- $pices
- Dry fruits
/+
4ain technological effects of ((3
4ain technological effects of ((3
in meat products
in meat products
@ A!out colo%:
8 (n fresh or arinated eat) the iron in the yoglo!in changes
fro ferrous to ferric and glo!in is denatured& the red color is lost
' A!out tetu%e:
8 (nhi!ition or stiulation of the proteolytic acti3ity in usclesacti3ity
uscles (depending on processing conditions)
8 Proteins are partially denaturi9ed in products -here proteins ha3e not
!een pre3iously odified !y other process& heating) drying) ferentation
:
' A!out fats and lipids:
8 4e3ersi!le crystalli9ation
/0
Treated beef samples E-F
Treated beef samples E-F
Top vie) of the fresh and fro*en beef samples treated by ((3
/=
Treated beef samples E2F
Treated beef samples E2F
#oo/ed saples& 3ie- fro the top (a); 3ie- of the inside
(!)
/5
Treated commercial beef
Treated commercial beef
products samples
products samples
#oercial !eef products !efore and after HHP treatent
/@
3rocessing or formulation factors that can
3rocessing or formulation factors that can
modify the effect of high pressure E-F
modify the effect of high pressure E-F
@ (empe%atu%e:
8 High teperatures increase the effect of high pressure against
icroorganiss and eat coponents
8 $u!-9ero teperatures can protect fish products coponents)
/eeping reasona!le icro!ial inacti3ation capacity/eeping capacity
' p):
8 <o- pH 3alues increase the effect of high pressure against
icroorganiss and eat coponents
+1
3rocessing or formulation factors that can
3rocessing or formulation factors that can
modify the effect of high pressure E2F
modify the effect of high pressure E2F
@ *acte%iocins:
8 $oe !acteriocins) and specially nisin) are 3ery effecti3e
co!ined -ith high pressure) e3en on Gra 8 !acteria
' +ate% activity:
8 =ith higher -ater acti3ity) ore effecti3eness of high pressure
processing) !ut also ore reco3ery fro su! lethally in.ured
icroorganiss
+-
3rocessing or formulation factors that can
3rocessing or formulation factors that can
modify the effect of high pressure E6F
modify the effect of high pressure E6F
@ &%ese%vatives:
8 <actate addition reduce the initial inacti3ation of the
icroorganiss !ut it delays its later reco3ery
' Com!ination #it$ ot$e% tec$nolo"ies:
8 #o!ined processes can ipro3e high pressure effects on
icroorganiss
+2
>enefits of high pressure
>enefits of high pressure

>dapted to saniti9e products -here heat processing is

inappropriate (dry cured ha) ferented eat products) sliced
ready to eat eat products) etc,)
>lternati3e to heat treatents to process foods) inacti3ating
icro organiss #it$out c$an"in" t$e senso%y qualities o%
t$e nut%itional values of foods
+6
8ther advantages of high pressure
8ther advantages of high pressure
6ery lo- use of energy
7o residues& uses only tap -ater
$afe for -or/ers
>ccepted !y consuers and retailers
Does not produce
< ne) chemical compounds
< radiolytic by"products
+/
3resent range of pressures
3resent range of pressures
available
available
++
3rocessing temperatures
3rocessing temperatures
+0
#conomic data
#conomic data
8"0)2 'roductivity (a) &ost (b)
4ave 60006;; -=1 kgLh 1$-@ N L kg
4ave 600069;0 /2+ kgLh 1$-/ N L kg
4ave 60006<00 5+1 kgLh 1$-- N L kg
4ave 60006A:0 2 111 kgLh 1$1+ N L kg
EaF Filled at +1, volume and processing time 6 minutes at 011 43a
EbF &alculated for + years depreciation$ production 251 daysLyear$ -0 hLday
+=
Industrial motivations to use (igh
Industrial motivations to use (igh
(ydrostatic 3ressure treatment
(ydrostatic 3ressure treatment
@ )i"$e% mic%o!iolo"ical safety
8 $ignificant reduction of the ris/s associated -ith the
presence and gro-th of pathogens
8 >dditional preser3ation treatent applied to the
products after pac/aging
' *ette% senso%ial quality
8 $ignificant reduction of the sensorial ris/s associated to
the presence and gro-th of alteration icroorganiss
(fresher fla3our)
+5
:easons for the industrial use
:easons for the industrial use
of ((3
of ((3
Consume% satisfaction
8 Fresher fla3or
8 Healthy or con3enient attri!utes
' Le"al %equi%ements
8 4elated to food safety
8 4elated to e?port regulations
' As a %eaction in f%ont a food c%isis
' (o meet costume%s, specifications
' S$elf life etension
' Ima"e of innovative company
8 Both to retailers and end users
8 Producing safer and relia!le products
' (ec$nolo"y fully accepted !y consume%s
+@
#amples of uses of ((3
#amples of uses of ((3
0ry-cured meatB
01
#amples of uses of ((3
#amples of uses of ((3
&ooked meatB cooked ham$ roasted chicken$ turkey breast$ cooked
sausages
0-
#amples of uses of ((3
#amples of uses of ((3
(eady mealsB
02
8bstacles for the implementation
8bstacles for the implementation
of ((3 E-F
of ((3 E-F
@ Lo# level of pu!lic kno#led"e a!out t$e tec$nolo"y
' Attitude of t$e pu!lic administ%ations in -u%ope
8 <egal ris/ perception& no e?plicit authori9ation in ost cases
8 <ac/ of an e?plicit support for a -ider use of the technology
' Ima"e of $i"$ cost
8 4eal costs are lo-er than percei3ed costs
8 7eed of processing centers pro3iding HPP contract processing
to $'@As
' False ima"e of $i"$ tec$nolo"ical sop$istication
06
8bstacles for the implementation
8bstacles for the implementation
of ((3 E2F
of ((3 E2F
@ Reduced num!e% of supplie%s fo% equipments
8 'ore options a3aila!le -ould encourage a ore acti3e ar/et
' &e%ception of economical %isk
8 Dou!ts a!out echanical and structural relia!ility (un.ustified)
8 $oe fear a!out the usual "uic/ o!solescence for the first
3ersions of industrial e"uipents
8 (nitial high in3estent cost (ainly for !ig copanies -ith need
for siultaneous purchasing of ultiple e"uipents)
8 (t e?plains -hy the a3erage user of high pressure is a ediu
si9e copany anaged !y the o-ners
8 (tAs necessary to offer to food copanies appro3ed protocols and
process 3alidation ser3ices for different food atri?es
>akery Industry
>akery Industry
8vervie)

India < a 6111 &rore market and 6

rd

largest producer of >akery products after
%2. and &hina.

3er capita consumption in our country is

2.- Ig.$ compared to more than -1 kg in
the %2. and is -.@1 kg. in &hina.
>iscuits
Industry

8rgani*ed A %norgani*ed sector is ++, A

/+, ratio.

'opular $randsB >ritannia$ 3arle$

3riyagold$ 7ukes$ ;indsor etc.

.nnual 3roduction B Gro)thA

#n 2akh 8,
211+"10 -/.2@
2110"1= -0.-/
211="15 -=.//
2115"1@ -0.+=
211@"-1 -5.2+
21-1"-- -@.-
:00;-06 9A7
2110"1= -6,
211="15 -+,
2115"1@ -1,
211@"-1 -/,
21-1"-- -+,

(ural-/rban penetration growth of

$iscuit
-. %rban 4arketA =+, to 5+,
2. :ural 4arketA +1, to 0+,
Ingredients
a) 8aCor ingredientsB
<
3rovide bulk to the product$ overall structure$ body etc. and
consist mainly of )heat flour Eheart of each recipe in bakeryF$
sugar$ fat$ salt$ )ater$ egg EoptionalF$ soya flour$ and starch.
a) 8inor ingredientsB
< Functional ingredients generally added to improve the physical
attributes of the bakery products and also help to overcome
seasonal variations$ process variations.
<
To give similar quality product each time and to reduce the
processing time.
<
>road categories are en*ymes$ emulsifiers B stabili*ers$
preservatives$ chemical improvers$ nutritional ingredients
Evitamins$ minerals$ fibers$ s)eetenersF$ flavors$ etc.
Ingredients concentration
3rocess

3re"4iingA
<
.ddition of ingredients$ sugar$ milk$ flour$
additives.

4iingA
<
4ied properly$ miing time is checked and
dough concentration level is checked
consistently.

FormingA
<
Through the use of cutters and sheet reductors$
proper shape is given to the biscuits.

>akingA
<
>iscuits are then baked in large baking ovens
O pre"described temperatures for a pre"
decided amount of time.
<
Through steam etractors$ the steam is
etracted from the output.
<
>aking time and baking temperature is of
utmost importance.
<
Then proceeded to cooling.

&oolingA
<
&ooled for a particular amount of time in cooling
conveyors.

3ackagingA
<
>iscuits are fed into packing machines in
continuous stacks )ith the help of auto feeders.
>iscuits are fed into packing machines in
continuous stacks this is achieved through
stacker )hich converts free flo)ing biscuits into
uniform achieved through stacker )hich converts
free flo)ing biscuits into uniform stacks.
4ajor functioning of
packaging
-. 3rotect from mechanical damage in transit
and loading and unloading processes.
2. 3rotect from any loss of moisture or any
foreign odour contamination.
6. !egal compliance for values and ingredients
for customers.
/. .dvertisements.
9arious packing
machines
(ori*ontal flo)
rap machine
:oll )rapping
machine
Types of
packaging
'1& ,rays !hrink wrapped
3lant
!ayout
Food and regulatory measures

.pproval additives

(.&&3$ G43 EGood 4anufacturing

practicesF$ G(3 EGood (ygienic
practicesF

2ociety for Indian >akers recently issued

G.>& of F22.IH
G.>& of
F22.IH

#ducate the staff on the .ct

#hibit food safety posters in the factory

:emove epired date goods because it is a health

risk and provide clean and proper uniforms

&onduct medical eamination for all

;hite)ash premises periodically

%se processed )ater for manufacture

Take special attention in preparing the labels

Take effective pest control measures and

mandatory use of gloves
Trade related aspects

)>ports
<
The eport market comprises of south"east .sian
countries EThailand$ 3hilippines$ Tai)an$ and
4alaysiaF$ Depal$ >angladesh$ 2ri !anka$ and
3akistan$ %2.$ and .frican countries E>ra*il$
&hile$ and 3eruF and .rab countries.

#mports
<
Food ingredients and ra) materials are being
imported from countries like &hina$ France$
Germany$ %2.$ >ra*il$ Tai)an$ Italy$ Turkey$
&hile$ and the Detherlands.
&hallenges and 3rospects

/norgani=ed sectorB
a. !ocal manufacturers )ith numerous local
brands cater to the populous segment.
b. !o) margins$ high level of fragmentation are the
main features in the bakery industry.
c. 9olumes$ brand loyalty and strong distribution
net)orks are the main drivers of gro)th.

"rgani=ed sectorB
aF !o) margins of profit due to escalating
prices of major ra) materials$ particularly
)heat flour$ vegetable oil$ sugar$ and milk.