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Information about Cashew Processing in IndiaLana Chen

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Information about Cashew Processing inIndia

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Indian Cashew Production

.our centuries ago" when the adventurous Portuguese landed on the Indian coasts" the, broughtwith them the valuable tree nut" cashew& Cashew came" conGuered and too% deep roots in the

entire coastal region of India& It found that the Indian soil more suitable for cashew growth thanits homeland73ra-il& Later it soon spread as a popular cash crop to other parts of India&Cashew is one of the important commercial crops in India" and India has over !!"!!! ha&cashew plantation and has annual output of over N!!"!!! tons of raw cashew nuts& Cashew isgrown in the western and eastern coastal areas and further island" and the maOor production statesare 'erala" 4ndbra" :rissa" Maharashtra" 'arnata%a" 9oa and Tamil 5adu; Meghala,a" Madh,aPradesh also have a small amount of production&India is the largest grower" processor and e?porter in the world& It is also interesting tounderstand" that the new statistics of consumer interests done during !!B has proved India isalso the number one consumer of cashew %ernels in the world overta%ing U04&Cashew %ernels is consumed all over the world as a premium snac% and nowada,s more used as

a preferred ingredient due to its e?cellent flavor and uniGue te?ture in large arra, of foods li%esweets" dates" ice7creams and so on& It can be dried or oil roasted" salted" coated with chocolate"spices" hone," etc&

Overview of the Cashew Processing in India

The products of cashew fruit are cashew apple and cashew nuts%ernels& In India" cashew apple ise?tensivel, used onl, in 9oa to prepare cashew liGuor called feni&The cashew %ernel is covered b, a thin membrane called testa" which contains the non7ediblesubstance tannin and protects the tast, %ernel from the ravages of nature until it is processed& 0o" processing of cashew %ernel is indispensable& The %ernel ,ield is around Q7NQ of in7shellcashew& The maOor b,7product of processing is cashew nut shell liGuid " which

is an important raw material in the manufacture of resin& In India" cashew processing beganduring the first half of the !th centur," and the processing is manual then&Indian cashew process industr, started with famil, wor%shops of small scale" and as time goeson" it graduall, developed into labor7intensive industr, of high organi-ation& /ue to the stead,growth of world demand for cashew nuts" cashew process industr, has become a high7profitindustr,& The cashew nut processing industries are t,picall, located in the rural and bac%wardareas&The number of cashew processing units in India increased rapidl, from ! in BRB to as man,as F"R! in !!R7!!" which scattered in man, states of the countr, provided emplo,ment toover !&R million people" BRQ of these are women" and India processed about &S million MT ofraw cashew seeds at that time& Probabl," the countr, ma, have around N"!!! cashew processing

units&

Cashew Nut Processing

The cashew industries in India emplo, different unit operations methodolog, for processing&Traditionall," the raw nuts are processed manuall, b, the e?perienced semi7s%illed wor%ers&0ince the B!s" the processes came to be mechani-ed for roasting" shelling" and C50Le?traction& 5evertheless" for the most part" cleaning of raw materials and %ernel grading b, si-eshave still remained manual operation&

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Cashew nut processing is generall, done on a home scale and factor, scale in India& In the homescale process" the dried nuts are burnt in an open fire and hand shelled" in which ma?imum over7 burnt and charred %ernels are recovered and the valuable cashew nut shell liGuid is wastedcompletel,& The nut is graded into three or more groups and is conditioned to about Qmoisture b, soa%ing or spra,ing water" and then the nut is roasted either b, drum" or oil bath or

steam roasting methods&

Cashew nuts factory-scale processing

 Raw cashew nut cleaning:

8aw cashew nuts carr, foreign matter of sand" stones" dried apples" etc& b, cleaning the raw nuts"the foreign matter is removed to help high7Gualit, roasting operation& Nut soaking:

This stage is soa%ing cashew nuts in water to avoid scorching them during the roasting operation&4nd this process of covering the nuts with water" standing and draining should be repeated withthe same nuts about three times until a moisture content of BQ is reached& Nut roasting:

It is designed to ma%e the shell brittle" which facilities the e?traction of the %ernel when brea%ingthe shell open& 4nd in this process" the nut shell liGuid will also be released& There are severalmethods of roasting@ open pan roasting" drum roasting" oil bath method and steam roasting&&The earliest roasting process is the open pan roasting" in which the nuts are heated and stirredconstantl, in a metal pan over a basic earth fireplace& /ue to the heat and slight charring" theshells become brittle& 1owever" the pan roasting is not followed in organi-ed sectors of thecashew processing industr,&&/rum roasting is developed from the pan method" completed b, feeding the nuts into a rotatingdrum over a fire with high temperature& The rate of shelling and the output of whole %ernels arever, high in this method" but there is a loss of C50L that has high e?port potential&F&In oil bath roasting" the nuts get roasted b, means of screw or belt conve,or in a bath of

cashew shell liGuid in a tan% heated b, a furnace which uses spent cashew nut shells as fuel" andalso the separated cashew nut shell liGuid released from the nuts is e?tracted and recovered b,continuous overflow arrangement&N&0team roasting is a %ind of improved method adopted in cashew processing& The nuts are steamcoo%ed in a speciall, built steam coo%er so as to ma%e the shell soft an then cut open to get the%ernel& In this process" the cashew nut shell liGuid comes out and gets collected in the coo%er"separatel, removed& Nut cooling:

:nce the raw nuts are roasted" the, are ta%en to a separate place and spread on the floor& Therethe, are %ept two or three da,s so that the, are cooled" and then the, are transferred to the ne?t process& Nut shelling:

The purpose of shelling is to produce clean" whole %ernels free of crac%s& In India" this operationhas alwa,s been done manuall," which is still relevant to the small7scale processor" although themechanical process is an advisable option in all cases&&Manual shelling@ in the manual process" the nuts are crac%ed with a wooden mallet or a lighthammer& +ood ash for covering the shells or gloves are reGuired because of the residue C50Lduring roasting& The s%illed and e?perienced wor%ers can release the %ernels form the shells withno damage and brea%age" with a Gualit, of B!Q whole %ernels&

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&Mechanical shelling@777the semi7mechani-ed process is using a pair of %nives which are shaped in the contour of halfa nut& 3, means of a foot operated lever" the %nives cut through the shell all around the nut"leaving the %ernel untouched&777:ltremare shelling machine is a manuall, chain7fed shelling s,stem that is also based on two

nut7shaped %nives& The nuts are pushed between the %nives and cut" separating the shell halves b, the %nivesJ twisting movement to get the %ernels&777the Cashco s,stem shelling machine is also a chain7fed one" but the nuts can be placed in theright position automaticall," having two %nives that cut the sides of the nut and a pin that iswedged into the stal% end of the nut to separate the shell halves&777centrifugal sheller emplo,s the continuous flow& 4 rotar, paddle proOects the shells against thesolid casing and the impact crac%s open the shell without brea%ing the %ernel& 4ll si-es of nutscan be processed b, this sheller& 1owever" the nuts should be graded in advance" becausedifferent rotar, speed is used for various si-es&Shell and kernel separation:

It is done after shelling to separate the shell pieces and %ernels& Usuall, blowers and sha%ers are

used to separate the lighter shell pieces" at the same time" the unshelled nuts are returned to theshelling process& The recover of small pieces of %ernel stic%ing to the shell is usuall, donemanuall,&'ernel pre7grading@It can be done before or after dr,ing the %ernels and ma, greatl, reduce the final grading wor%&.or large7scale processors pre7grading can be done mechanicall," separating mainl, the wholefrom the bro%en %ernels and sometimes separating the different si-e groups of whole %ernels& Kernel drying:

The %ernel coming from the shelling is covered with a brown cover" %nown as testa" and toremove the testa is for blanched %ernels and protecting the %ernel from pest and fungus attac%" sothe %ernel needs dr,ing process& The moisture content is about Q before dr,ing and FQ after&& 0un dr,ing@ the shelled %ernels are spread out in thin la,ers under strong sunshine to completedr,ing&& 3orma drier@ it is the most commonl, used one and necessar, for medium and large7scale producers& Its chamber is heated directl, b, flue gases from a furnace at the bottom& Cashewshells can be burnt to produce heat& There are mesh7wire tra,s in the chamber" and air vents are provided at the top and sides for the moisture to escape& In order to get uniform dr,ing" the position of tra,s is changed at a interval of !7F! minutes&F& Through7flow drier@ to minimi-e the losses" this drier which totall, avoids the cashew %ernelscorching and reduce dr,ing time" is designed& Kernel Peeling:

It is an operation of removing the %ernel coat which is alread, loosen b, dr,ing&& Manual peeling@ it is done b, gentle rubbing with fingers" and the parts still attached to the%ernel are removed b, the use of a bamboo %nife&& Mechanical peeling@ this process differs widel," including air7blasting" suction" a free-ingoperation and a s,stem of rubber roller& Kernel Grading:

& The common grading standard is based on cashew %ernel si-es& The peeled %ernel usuall,graded manuall," with the e?ception of a few grading aids& The grading standards developed inIndia refer to white whole %ernels and indicate the number of %ernels per lb of

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weight& The largest %ernel comes in the grade of +! and the smallest of theseven grades is +R!! & .or large operations loo%ing towards e?port mar%ets" it isnecessar, to grade the %ernel to an international level&& Power7driven rotar, sieves are one mechanical method" another being two outwardl, rotatingrubber rollers aligned at a diverging angle&

F& Cashew %ernel color sorting machine is an advanced eGuipment with a special attention to preservation of brittle and an aim of highest purit, and Gualit, from products" and this s,stemallows the separation among scorched and unpeeled %ernels without handling the product" thusavoiding costl, brea%age& Kernel rehumidification (optional):

3efore the %ernels are pac%ed" it is necessar, to ensure that their moisture content rises from FQup to around RQ& This is to ma%e the %ernels less fragile" thus lessening the ris% of brea%ageduring transport& In humid climate" the %ernels ma, absorb enough moisture during peeling andgrading" ma%ing a further rehumidification process unnecessar,&Weighing and Packing:

weighing is done for the purpose of pac%ing" and here the nuts are filled in containers" bags" and

 pouches as per the reGuirement& :nce it is done" the containers are ta%en to the pac%ing process&The normal pac%age of e?port of %ernels is in air7tight tins of Rlbs in weight& The pac%ing needsto be impermeable as cashew %ernels are subOect to rancidit, and go stale ver, Guic%l,&4fter filling and weighing" the cap should be soldered on in preparation for the vita pac%J process& This consists of removing all air from the tin and substituting this with carbon dio?ide& The advantages of pac%ing cashew %ernels in carbon dio?ide are twofold& .irstl," carbondio?ide is an inert gas and will not support life& 4n, infestation that ma, have been present istherefore arrested& 0econdl," carbon dio?ide is soluble in cashew oil and goes into solution assoon as the seals are made&0ome processors do not have vacuum pumps and displace the air in the tin b, feeding in carbondio?ide through a small hole in the bottom of a side of the tin& The carbon dio?ide valve is turnedoff when all the air has been replaced" the holes in the tin are then sealed" with the hole at the bottom of the side of the tin being done first" and the one on the top last&

Cashew Oil Production

Cashew oil is an edible coo%ing oil made from cashew nuts& E?tracting cashew oil is a long process" since most of it is done b, hand& 3efore ma%ing cashew oil" the shells and s%ins must befirst be removed& The nuts are collected from the bottom of the fruit& The, can then be roasted ordried in an oven& This process helps remove some of the volatile shell oil" and it ma%es the shells brittle and eas, to brea% open& The s%ins are then removed after the shelled nuts are roasted asecond time& Cashew oil can then be e?tracted from the cashew nuts after the s%in is removed&The oil is obtained b, crushing the cashew nuts& This can be done with a h,draulic or mechanical press&

Cashew Nut Shell Liquid---yproduct of Cashew Nut Process

Cashew nut shell liGuid or cashew shell oil is a versatile b,product of cashew nut processing& The nut has a shell about S inch thic%ness inside which is a soft hone, combstructure containing a dar% reddish brown viscous liGuid& It is called C50L" which is the pericarpfluid of the cashew nut& It is often considered as the better and cheaper material for unsaturated phenols&

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C50L has innumerable applications" including friction linings" paints" laminating resins" rubbercompounding resins" cashew cements" pol,urethane based pol,mers" surfactants" epo?, resins"foundr, chemicals" and intermediates for chemical industr,& It offers much scope and variedopportunities for the development for other tailor7made pol,mers&

Process !sed Cashew Nut Shell as iomass "uel+hen C50L is removed" the deoiled shells are abundantl, available as biomass waste& Thecashew nut shell has calorific value of NR%cal%g& The shell waste generated in cashew processing is utili-ed as a substitute to wood fuel b, ma%ing charcoal with carboni-ation process&

&Carboni-ation@ the carboni-ation of cashew nut shell is carried out in developed small capacit,single drum %iln b, means of direct heating method and indirect heating method achievecarboni-ation&&3riGuetting@ the carboni-ed cashew nut shell is mi?ed with binder" and then it can be made into briGuettes either manuall, or using machines& .or the mechanical briGuetting" load the mi?turedirectl, into the briGuetting mouldmachine to form uniform7si-ed cashew nut shell briGuettes&

Cashew #pple Processing

The cashew apple is a %ind of soft fruit" rich in nutrients" and contains so much vitamin C& It can be eaten fresh" coo%ed in curries or fermented into vinegar" as well as an alcoholic drin%& It isalso used to ma%e preserves" chutne,s" and Oams in India&In 9oa" the cashew apple is mashed" the Ouice is e?tracted and %ept for fermentation for a fewda,s& .ermented Ouice the undergoes a double distillation process& The resulting beverage iscalled feni or fenn,& .eni is about N!Q7NQ alcohol& The single7distilled version is called urrac"which is about RQ alcohol&