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

Toxin removal Longer shelf-life Easing marketing and distribution tasks Increase in off-season availability of foods Ease 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- Used mainly for cleaning and separation. -Finds application in juice, dairy and beverages

Contd
Osmotic dehydration- Helps in reducing moisture content, thereby increasing shelf life of foods. -Finds application in almost everywhere Processing by radio frequency electric fields- Usedwhere thermal application is unfeasible owing to loss of food quality or nutrition. -Involves radio frequency to sterilize and

Current scenario Production

52% cultivable land compared to 11% world average All 15 major climates in the world exist in India Largest livestock population

Largest producer of milk

46 out of 60 soil types exist in India

Largest producer cereals

Significant Opportunity India as a global sourcing hub

20 agri-climatic regions Sunshine hours and day length are ideally suited for round the year cultivation

Second-largest fruit and vegetable producer Among the top five producers worldwide of rice, wheat, groundnuts, tea, coffee, tobacco, spices, sugar and oilseeds.

Current Scenario Processing

Category
fruits and vegetales Poultry Marine products Milk products

% of processed of total production

2.2 % 6% 8% 35%

Current scenario Consumption

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Food Consumption in India

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Segments of food processing

Fruits and vegetable processing Dairy Grain processing Meat and Poultry processing Confectionery

OVERVIEW
Industry size 70 Billion USD Contributes 6.3% to Indias GDP 9% share in Indias total industrial production Large growth potential out of total agricultural produce, currently only 2% is processed

Source : MOFPI website

Structure of Indian Food Processing Industry

Fruits and vegetables

Sector Insights
Installed capacity of fruits & vegetables processing industry has increased from 1.1 million tonnes in January 1993 to 2.1 million tonnes in 2006 The processing of fruits and vegetables is estimated to be around 2.2% of the total production in the country Majority of processing firms are cottage, household and small-scale sector, having small capacities of up to 250 tonnes per annum

Improvements required
Consumption of value added fruits & vegetables are low compared to primary processed foods, fresh fruits & vegetables. The inclination towards processed foods is mostly visible in urban centres due to a high purchasing power A remarkable push can be given to this sector by strengthening linkages between farmers and food processors The poor and weak linkage between farmers and markets, as well 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 Policies for Fruits & Vegetables

No industrial license required for setting up Fruits & Vegetables Processing Industries (except if its a 100% export oriented unit) 51% FDI allowed for processing of tomatoes, mushrooms & other frozen vegetables, fruits, nuts, fruit-peel, fruit jellies, marmalades, juices etc. Sector is regulated by Fruit Products Order, 1955 (FPO), issued under essential commodities act Products like pickles & chutneys, tapioca sago and tapioca flour are reserved for exclusive manufacture in small scale sector Export is freely allowed

BASIC PROCESSING TECHNIQUES FOR FRUITS AND VEGETABLES

Cleaning Peeling Blanching Pickling Dehydration

Value Added Products From Fruits and Vegetables

Fruit pulps and juices Fruit based ready-to-serve beverages canned fruits and vegetables Jams Squashes Pickles Chutneys Dehydrated Vegetables processed mushrooms curried vegetables

Fruit beverages
Easily digestible, highly refreshing, thirst quenching, appetizing and nutritionally far superior to many synthetic and aerated drinks.

Unfermented beverages
Fruit juices which do not undergo alcoholic fermentation Include natural and sweetened juices, RTS, nectar, cordial, squash, crush, syrup, fruit juice concentrate and fruit juice powder.

Fermented beverages Fruit Juices which undergo alcoholic fermentation by yeast E.g. wine, champaigne, port, sherry, tokay, muscat, nira and cider

Squash
Fruit beverage containing at least 25% fruit juice or pulp & 40-50% total soluble solids Also contains about 1% acid & 350 ppm sulphur dioxide or 600 ppm sodium benzoate It is diluted before serving. Commercial usage - Mango, orange and pineapple It can also be prepared from lemon, bael, papaya, etc. using potassium meta bisulphite (KMS) as preservative or from jamun, passion-fruit, peach, plum, raspberry, strawberry, grapefruit, etc. with sodium benzoate as preservative.

FLOWCHART FOR PROCESSING OF SQUASH

READY-TO-SERVE (RTS)
Contains at least 10 per cent fruit juice and 10% total soluble solids besides about 0.3% acid. It is not diluted before serving, hence it is known as ready-toserve (RTS).

Flow-sheet for processing of RTS beverages

Cordial
It is a sparkling, clear, sweetened fruit juice from which pulp and other insoluble substances have been completely removed. It contains at least 25% juice and 30% TSS, 1.5% acid and 350 ppm of sulphur dioxide. Suitable for blending with wines. Lime and lemon are suitable for making cordial.

FLOWCHART FOR PROCESSING OF CORDIAL

Nectar
Contains at least 20 per cent fruit juice / pulp and 15 per cent total soluble solids and also about 0.3 per cent acid. It is not diluted before serving. Sr No 1 2 3 4 5 6 Fruits Mango Papaya Guava Bael Jamun Amla Juice/Pulp % 20 20 20 20 20 Amla pulp 20 Lime juice 2 Ginger juice 1 Quantity of water required (litre) Quantity of finished product (litre) Quantity of (juice (litre) + sugar (kg) + acid (kg) used

Fermented Beverage- Wine

Beverage resulting from fermentation by yeasts of grape fruits with proper processing Alcohol content 7 to 20 %

FLOWCHART FOR PROCESSING OF WINE

JAM
Made by boiling fruit pulp with sufficient amount of sugar to a reasonably thick consistency Apple, pear, sapota(chikku), peach, papaya, carrot, plum, strawberry, raspberry, mango, tomato, grapes and muskmelon It can be prepared from one kind of fruit or from two or more kinds.

FLOWCHART FOR PROCESSING OF JAM

JELLY
Semi-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, Apricot, pineapple, strawberry, raspberry.

FLOWCHART FOR PROCESSING OF JELLY

MARMALADE
Fruit jelly in which slices of the fruit or its peel are suspended. Generally used for products made from citrus fruits like oranges and lemons in which shredded peel is used as the suspended material. Citrus marmalades are classified into1. Jelly marmalade The following combinations give good quality of jelly marmalade: i. Sweet orange (Malta) and khatta or sour orange (Citrus aurantium) in the ratio of 2:1 by weight. Shreds of Malta orange peel are used. ii. Mandarin orange and khatta in the ratio of 2:1 by weight. Shreds of Malta orange peel are used. Iii. Sweet orange (Malta) and galgal (Citrus limonia) in the ratio of 2:1 by weight. Shreds of Malta orange peel are used. 2. Jam marmalade The method of preparation is practically the same as that for jelly marmalade. In this case the pectin extract of fruit is not clarified and the whole pulp is used. Sugar is added according to the weight of fruit, generally in the proportion of 1:1. The pulp-sugar mixture is cooked till the TSS content reaches 65 per cent.

CANDY
A whole fruit / vegetable or its pieces impregnated with cane sugar or glucose syrup, and subsequently drained free of syrup and dried, is known as candied fruit / 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. A certain amount (25-30 per cent) of invert sugar or glucose, viz., confectioners glucose (corn syrup, crystal syrup or commercial glucose), dextrose or invert sugar is substituted for cane sugar. The total sugar content of the impregnated fruit is kept at about 75 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 sweetening chutneys, sauces and pickles and in vinegar making.

Glazed candy
Covering of candied fruits / vegetables with a thin transparent coating of sugar, which imparts them a glossy appearance. Process
Cane sugar and water (2:1 by weight) are boiled in a steam pan at 113114C and the scum is removed as it comes up. Thereafter the syrup is cooled to 93C and rubbed with a wooden ladle on the side of the pan when granulated sugar is obtained. Dried 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 warm dry room. Can also be dried in a drier at 49C for 2-3 hours. Packed in airtight containers after they become crisp

 Candied fruits/ 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 . Process
The candied fruits are placed on a wire mesh tray which is placed in a deep vessel. Cooled syrup (70 per cent total soluble solids) is gently poured over the fruit so as to cover it entirely. The whole mass is left undisturbed for 12 to 18 hours during which a thin coating of crystallized 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 wire mesh trays and dried at room temperature or at about 49C in driers.

Crystallized candy

Pickles
The preservation of food in common salt or in vinegar is known as pickling. One of the most ancient methods of preserving fruits and vegetables. Good appetizers, add to the palatability of a meal. Stimulate the flow of gastric juice and thus help in digestion. At present, pickles are prepared with salt, vinegar, oil or with a mixture of salt, oil, spices and vinegar.

MEAT PACKAGING INDUSTRY

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Introduction

High Hydrostatic Pressure (HHP) treatment is an athermic decontamination process which consists in subjecting packaged food to water pressures from 100 to 900 MPa. The pressure applied is isostatically transmitted inside a pressure vessel.

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Diagram of the HHP equipment

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Food that can be HHP treated

Solid foods, mainly vacuum packed - Dry-cured or cooked meat products - Cheese - Fish, seafood, marine products - Ready to eat meals, sauces - Fruits, marmalades / jams - Vegetables Liquid foods, in flexible packaging - Dairy products - Fruit juices - Nutraceutical formulations
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Food that can not be HHP treated

Solid foods with air included - Bread - Mousse Packaged foods in completely rigid packaging - In glass - Canned Foods with a very low water content - Spices - Dry fruits
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Main technological effects of HHP in meat products

About color: In fresh or marinated meat, the iron in the myoglobin changes from ferrous to ferric and globin is denatured: the red color is lost About texture: Inhibition or stimulation of the proteolytic activity in musclesactivity muscles (depending on processing conditions) Proteins are partially denaturized in products where proteins have not been previously modified by other process: heating, drying, fermentation About fats and lipids: Reversible crystallization
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Treated beef samples (1)

Top view of the fresh and frozen beef samples treated by HHP
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Treated beef samples (2)

Cooked samples: view from the top (a); view of the inside (b) 47

Treated commercial beef products samples

Commercial beef products before and after HHP treatment

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Processing or formulation factors that can modify the effect of high pressure (1)
Temperature:
High temperatures increase the effect of high pressure against microorganisms and meat components Sub-zero temperatures can protect fish products components, keeping reasonable microbial inactivation capacitykeeping capacity pH: Low pH values increase the effect of high pressure against microorganisms and meat components

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Processing or formulation factors that can modify the effect of high pressure (2)

Bacteriocins: Some bacteriocins, and specially nisin, are very effective combined with high pressure, even on Gram bacteria

Water activity: With higher water activity, more effectiveness of high pressure processing, but also more recovery from sub lethally injured microorganisms
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Processing or formulation factors that can modify the effect of high pressure (3)

Preservatives: Lactate addition reduce the initial inactivation of the microorganisms but it delays its later recovery

Combination with other technologies: Combined processes can improve high pressure effects on microorganisms
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Benefits of high pressure

Adapted to sanitize products where heat processing is inappropriate (dry cured ham, fermented meat products, sliced ready to eat meat products, etc.)

Alternative to heat treatments to process foods, inactivating micro organisms without changing the sensory qualities or the nutritional values of foods

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Other advantages of high pressure

Very low use of energy

No residues: uses only tap water

Safe for workers

Accepted by consumers and retailers

Does not produce

new chemical compounds radiolytic by-products

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Present range of pressures available

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Processing temperatures

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Economic data
MODEL Wave 6000/55 Wave 6000/150 Wave 6000/300 Wave 6000/420 Productivity (a) 170 kg/h 425 kg/h 850 kg/h 2 000 kg/h Cost (b) 0,19 / kg 0,14 / kg 0,11 / kg 0,05 / kg

(a) Filled at 50% volume and processing time 3 minutes at 600 MPa (b) Calculated for 5 years depreciation, production 280 days/year, 16 h/day 56

Industrial motivations to use High Hydrostatic Pressure treatment

Higher microbiological safety Significant reduction of the risks associated with the presence and growth of pathogens Additional preservation treatment applied to the products after packaging Better sensorial quality Significant reduction of the sensorial risks associated to the presence and growth of alteration microorganisms (fresher flavour)
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Reasons for the industrial use of HHP

Consumer satisfaction Fresher flavor Healthy or convenient attributes Legal requirements Related to food safety Related to export regulations As a reaction in front a food crisis To meet costumers specifications Shelf life extension Image of innovative company Both to retailers and end users Producing safer and reliable products Technology fully accepted by consumers
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Examples of uses of HHP

Dry-cured meat:

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Examples of uses of HHP

Cooked meat: cooked ham, roasted chicken, turkey breast, cooked sausages

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Examples of uses of HHP

Ready meals:

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Obstacles for the implementation of HHP (1)

Low level of public knowledge about the technology Attitude of the public administrations in Europe Legal risk perception: no explicit authorization in most cases Lack of an explicit support for a wider use of the technology Image of high cost Real costs are lower than perceived costs Need of processing centers providing HPP contract processing to SMEs False image of high technological sophistication
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Obstacles for the implementation of HHP (2)

Reduced number of suppliers for equipments More options available would encourage a more active market Perception of economical risk Doubts about mechanical and structural reliability (unjustified) Some fear about the usual quick obsolescence for the first versions of industrial equipments Initial high investment cost (mainly for big companies with need for simultaneous purchasing of multiple equipments) It explains why the average user of high pressure is a medium size company managed by the owners Its necessary to offer to food companies approved protocols and process validation services for different food matrixes
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Bakery Industry

Bakery Industry Overview

 India a 3000 Crore market and 3rd largest producer of Bakery products after USA and China. Per capita consumption in our country is 2.1 Kg., compared to more than 10 kg in the USA and is 1.90 kg. in China.

Biscuits
Organized : Unorganized sector is 55% : 45% ratio. Popular Brands: Britannia, Parle, Priyagold, Dukes, Windsor etc. Annual Production & Growth:
In Lakh MT 2005-06 2006-07 2007-08 2008-09 2009-10 2010-11 14.29 16.14 17.44 16.57 18.25 19.1 2005-06 2006-07 2007-08 2008-09 2009-10 2010-11 14% 13% 15% 10% 14% 15%

Industry

 Rural-Urban penetration growth of Biscuit

1. Urban Market: 75% to 85% 2. Rural Market: 50% to 65%

Ingredients
a) Major ingredients:
Provide bulk to the product, overall structure, body etc. and consist mainly of wheat flour (heart of each recipe in bakery), sugar, fat, salt, water, egg (optional), soya flour, and starch. 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. Broad categories are enzymes, emulsifiers & stabilizers, preservatives, chemical improvers, nutritional ingredients (vitamins, minerals, fibers, sweeteners), flavors, etc.

a) Minor ingredients:

Ingredients concentration

Process

 Pre-Mixing:
Addition of ingredients, sugar, milk, flour, additives.

Mixing:
Mixed properly, mixing time is checked and dough concentration level is checked consistently.

Forming:
Through the use of cutters and sheet reductors, proper shape is given to the biscuits.

 Baking:
Biscuits are then baked in large baking ovens @ pre-described temperatures for a predecided amount of time. Through steam extractors, the steam is extracted from the output. Baking time and baking temperature is of utmost importance. Then proceeded to cooling.

 Cooling:
Cooled for a particular amount of time in cooling conveyors.

Packaging:
Biscuits are fed into packing machines in continuous stacks with the help of auto feeders. Biscuits are fed into packing machines in continuous stacks this is achieved through stacker which converts free flowing biscuits into uniform achieved through stacker which converts free flowing biscuits into uniform stacks.

Major functioning of packaging

1. Protect from mechanical damage in transit and loading and unloading processes. 2. Protect from any loss of moisture or any foreign odour contamination. 3. Legal compliance for values and ingredients for customers. 4. Advertisements.

Various packing machines

Horizontal flow rap machine

Roll wrapping machine

Types of packaging
PVC Trays Shrink wrapped

Plant Layout

Food and regulatory measures

Approval additives HACCP, GMP (Good Manufacturing practices), GHP (Good Hygienic practices) Society for Indian Bakers recently issued ABC of FSSAI

ABC of FSSAI
Educate the staff on the Act Exhibit food safety posters in the factory Remove expired date goods because it is a health risk and provide clean and proper uniforms Conduct medical examination for all Whitewash premises periodically Use processed water for manufacture Take special attention in preparing the labels Take effective pest control measures and mandatory use of gloves

Trade related aspects

Exports
The export market comprises of south-east Asian countries (Thailand, Philippines, Taiwan, and Malaysia), Nepal, Bangladesh, Sri Lanka, and Pakistan, USA, and African countries (Brazil, Chile, and Peru) and Arab countries.

Imports
Food ingredients and raw materials are being imported from countries like China, France, Germany, USA, Brazil, Taiwan, Italy, Turkey, Chile, and the Netherlands.

Challenges and Prospects

Unorganized sector:
a. Local manufacturers with numerous local brands cater to the populous segment. b. Low margins, high level of fragmentation are the main features in the bakery industry. c. Volumes, brand loyalty and strong distribution networks are the main drivers of growth. Organized sector:

a) Low margins of profit due to escalating prices of major raw materials, particularly wheat flour, vegetable oil, sugar, and milk.