Modern Food Processing Tecchnologies- Modern Food Processing Tecchnologies- A Survival Kit for Indian AgricultureA Survival Kit for Indian Agriculture

Dr. R.T. PatilDr. R.T. PatilFormer Director, CIPHET, LudhianaFormer Director, CIPHET, LudhianaChairman & ED, Benevole for PHT, Chairman & ED, Benevole for PHT,

BhopalBhopal

Indian PerspectiveIndian Perspective Value addition to fruits and vegetables only 2% and to

food grain 7% Export market share <1.5% mainly of primary

processed goods with low price realization Indian produce have unique aroma, flavour, taste,

nutritional properties and health benefits, such as Jamun, Bel fruit, Aonla, Pomegranate, Custard Apple etc.

Increase in export potential of Indian processed foods and to meet aspirations of growing middle class highest quality and food safety issues need modernization

Emerging Post Harvest Technologies need to be adopted for indigenous commodities involving proper engineering principles……

Status of Food Processing IndustriesStatus of Food Processing Industries

Size of food market in India - Rs. 8,60,000 Crores Primarily processed food market – Rs. 2,80,000

croreValue added processed food market – Rs. 1,80,000

crore Investment during the 10th plan was about Rs.

62,105 Crores Industry growth rate during the last 10th plan was

about 7.14% against GDP of 6.2% Investment required during next ten years – Rs.

1,10,000 crores Food Quality and Safety Issues are Prime ImportantFood Quality and Safety Issues are Prime Important

Drivers of R&D in Post Drivers of R&D in Post Harvest Sector Harvest Sector

o Preference for Natural, Fresh-like, Minimally processed, Nutritious, Preservative-free and safe Foods

o Environmental Sustainabilityo Improved understanding of dietary

requirementso Breeding of processable varieties

Present Methods of Enhancing Present Methods of Enhancing Shelf Life/ProcessingShelf Life/Processing

Pasteurization (milk, juice, honey etc.) Sterilization (milk, juice, etc.) Canning Hurdle Technology Addition of chemicals as preservative Drying/Dehydration Irradiation

Most of these are thermal techniques, detrimental to the preservation of natural flavour and texture

Emerging Technologies for Food Emerging Technologies for Food Processing Processing

Pulse electric field High pressure processing Ultrasound Cryogenic processing Supercritical fluids including water Ohmic heat processing Irradiation Nano-technology Extrusion processing Microwave and Infrared Processing Nutrigenomics

Microwave Heat ProcessingMicrowave Heat Processing

•Effective for inactivating enzymes, reduced indirect heating requirement and water use•Result in improved product flavour, colour, texture and nutritive value.

Ohmic Heat ProcessingOhmic Heat Processing

•Alternating electrical current is passed through a food sample. •Internal energy generation in foods. •Produces an inside-out heating pattern at different frequencies than MW. •Uniformly heats foods with different densities.

MicronisationMicronisation

•Short time exposure of electromagnetic radiation at a wavelength of 1.8-3.4 µm, •Promotes internal heating and increased digestibility •Instantized product due to increased ability to uptake of water. •Starch is gelatinized, seed microstructure becomes more penetrable and thus short cooking times.

Extrusion ProcessingExtrusion Processing

Extruded Products from Coarse CerealsExtruded Products from Coarse Cereals

Extrusion is a high Extrusion is a high temperature short time temperature short time processed to produce processed to produce expanded & textured expanded & textured productsproducts

CIPHET has modified the low CIPHET has modified the low cost collet extruder to cost collet extruder to produce expanded ready to produce expanded ready to eat snacks using rice and eat snacks using rice and pulse brokens.pulse brokens.

The cost of the unit is Rs 2 The cost of the unit is Rs 2 Lakh, capacity 25 kg/h, cost Lakh, capacity 25 kg/h, cost of accessories Rs. 2 lakh and of accessories Rs. 2 lakh and thus earn about minimum of thus earn about minimum of Rs. 50,000 per monthRs. 50,000 per month

BiotechnologyBiotechnology

Fermenter of 30 litre capacity with controls for temperature, pH, DO and CO2 monitoring installed at CIPHET,

Ludhiana

Bioprocessing Technologies Bioprocessing Technologies for Crop Residuesfor Crop Residues

Efficient process for Efficient process for production of production of ethanolethanol

Production of enzymesProduction of enzymes such as such as cellulase, xylanase, pectinase and cellulase, xylanase, pectinase and proteaseprotease

Production of industrially important Production of industrially important products such as products such as citric acidcitric acid

Single Cell Protein (Single Cell Protein (SCPSCP) production) production

Smart and Bio-degradable Packaging Smart and Bio-degradable Packaging of Foodsof Foods

Controlled release mechanism technology using volatiles of plant origin for shelf-life extension packaging

Food specific packaging having insect-repelling and water absorbing properties

Smart packaging interventions for retention of volatile and flavour in packaged food

Time-temperature indicators and colour code schemes for shelf-life detection of packaged foods.

Poly-lactic acid based bio-degradable clamshell containers and films/coatings for packaging of food materials.

Bio-polymer films embedded with nano-composites (biodegradable smart packaging)

Non-thermal Protocols for Food Non-thermal Protocols for Food Processing and Preservation (PEF&HPP)Processing and Preservation (PEF&HPP)

Enhancement of Shelf Life of Milk and RTS Beverages

Enhancement of diffusivity of enzymes (xylanase, protease; etc.) and effectiveness of modified enzymes on de-hulling and cooking quality of pulses

Development of extraction processes for bioactive mixtures/ compounds from by products and process wastes

High Pressure ProcessingHigh Pressure Processing

•HPP can replace conventional processes, while maintaining safety and quality.

•Effects of HPP are generally marked as retention of color, flavor and fresh appearance

Nano-technologies for Controlled Nano-technologies for Controlled Release and Functional FoodsRelease and Functional Foods

Micro-encapsulation and nano-encapsulation of herbal extracts and bioactive compounds

Nano-composites for food packaging with improved barrier or antimicrobial properties

Nano-emulsions/delivery systems for increased absorption of nutraceuticals and health supplements.

Nano-sensors for traceability and monitoring conditions of foods during transport and storage(Hyper homogenisation, Molecular mixing,

Multi-emulsion technology)

Designer foods using super critical carbon dioxide having desirable texture, flavours and micro nutrients through extrusion processing

Short-time continuous bread making extrusion process without yeast to bread proofing

Super critical carbon dioxide and water as solvent for extraction of

Bio-active compounds, essential oilsAmino acids from fish, meat etc.

Supercritical Fluid in Food Supercritical Fluid in Food ProcessingProcessing

Irradiation Technologies for Irradiation Technologies for Processing and PreservationProcessing and Preservation

Standardize the irradiation protocols for retention of properties and shelf-life enhancement

Optimized irradiation protocol suitable for Sprouting inhibition, Delay in ripening and senescence, Insect disinfestation, Pasteurisation/sterilisation of processed and raw foods, Reduction in anti-nutritional factors and Improved keeping quality of food grains and flours

IrradiationIrradiation

•Gamma - irradiation reduces antinutritional factors •Reduces the phytic acid content and flatulence causing oligosaccharides in leguminous crops•Helps improved keeping quality of food grains and flours

Biosensors for Rapid and Precise Biosensors for Rapid and Precise Quality AssessmentQuality Assessment

Principle: A biosensor is a probe that integrates a biological component, such as a whole bacterium or a biological product (e.g., an enzyme or antibody) with an electronic component to yield a measurable signal.

Characterization of bio-indicators in relation to quality of food and its interaction with electro-mechanical sensing system.

Biosensor based online monitoring system

Use of Artificial Intelligence in the Use of Artificial Intelligence in the Context of Food ProcessingContext of Food Processing

• In artificial intelligence the tolerance for imprecision and uncertainty is exploited to achieve tractability, lower cost, high Machine Intelligence Quotient (MIQ) and economy of communication

• Artificial intelligence makes use of multivalued or fuzzy logic

• Artificial intelligence can deal with ambiguous and noisy data

• Artificial intelligence can yield approximate answers but good enough to solve the practical problems of trade

Artificial IntelligenceArtificial Intelligence•Artificial intelligence can be used to model and analyse very complex problems where conventional methods have not been able to produce cost-effective, analytical, or complete solutions. •In agricultural and biological engineering, researchers and engineers have developed methods to analyse the operation of food processing.

•Fuzzy Logic (FL), •Artificial Neural Networks (ANNs), •Genetic Algorithms (Gas), •Bayesian Inference (BI), •Decision Tree (DT), and •Support Vector Machines (SVMs)

Complex Food Process ControlComplex Food Process Control• A single sensory property like color or texture can be linked individually to

several dimensions recorded by the human brain.• The food industry works with non-uniform, variable raw materials that, when

processed, should shaped into a product that satisfies a fixed standard.• The process control of foods are highly non-linear and variables are coupled.• In addition to the temperature changes during a heating or cooling process,

there are biochemical (nutrient, color, flavor, etc.) or microbial changes that should be considered.

• The moisture in food is constantly fluctuating either loss or gain throughout the process which can affect the flavor, texture, nutrients concentration and other properties.

• Other properties of foods such as density, thermal and electrical conductivity, specific heat, viscosity, permeability, and effective moisture diffusivity are often a function of composition, temperature, and moisture content, and therefore keep changing during the process.

• The system is also quite non-homogeneous and hence detailed input data are not available.

• Often, irregular shapes are present.

ANN for Crispness of Snack FoodsANN for Crispness of Snack Foods

• The crispness was evaluated by acoustic testing.

• The acoustic patterns were generated by crushing the snack samples with a pair of pincers

• The inputs for training the NNs comprised 102 amplitudes of sound signals in 0–7 kHz frequency range at the intervals of about 69 Hz with crispness grades as outputs

• Probabilistic (PNN) models showed good performance in classifying the snack foods into four grades of crispness.

• The prediction accuracy of models ranged approximately from 96 to 98%

Plot of average amplitude of acoustical signal spectrum for different moisture content of Pringles potato chip samples

Detection of Plant DiseasesDetection of Plant Diseases• Electronic nose incorporating Electronic nose incorporating

AI was used to detect plant AI was used to detect plant disease caused by disease caused by Ganoderma Ganoderma boninense boninense fungus fungus affecting oil affecting oil palm. palm.

• The electronic nose, The electronic nose, Cyranose 320, has the front Cyranose 320, has the front end sensors and artificial end sensors and artificial neural networks for pattern neural networks for pattern recognition. recognition.

• The system was able to The system was able to differentiate healthy and differentiate healthy and infected oil palm with a high infected oil palm with a high rate of accuracy.rate of accuracy.

Detection of Spongy Tissue in MangoDetection of Spongy Tissue in Mango• "spongy tissue", affects about

30% of ‘Alphonso’ mangoes• Fruits show no external

symptoms at harvest or on ripening but cutting reveals internal damage which adversely affects fruit quality. Both fully grown green, unripe mangoes and ripe fruits show spongy tissue.

• A non-destructive x-ray inspection can detect affected mangoes.

• The method could be used for quality control for on-line detection and separation

Central Electronics Engineering Research Institute (CEERI)

ANN in image recognition and ANN in image recognition and classification of crop and weedsclassification of crop and weeds

• The images were taken, Colour index values were assigned to the pixels of the indexed image and used as ANN inputs.

• There were 80 images, 100x100 pixels, for training, and 20 images for testing. Many back propagation ANN models were developed with different numbers of PEs in their hidden and various output layers.

• Six different evaluation schemes for two ANN output strategies were used.

• The performance of the ANNs was compared and the success rate for the identification of corn was observed to be as high as 80 to 100%, while the success rate for weed classification was as high as 60 to 80%.

• The results indicated the potential of ANNs for fast image recognition and classification.

• Fast image recognition and classification can be useful in the control of real-world, site-specific herbicide application.

Identification of citrus disease using Identification of citrus disease using color texture and discriminant analysiscolor texture and discriminant analysis• Color co-occurrence method (CCM) with texture based hue, saturation,

and intensity (HSI) color features in conjunction with statistical classification algorithms were used to identify diseased and normal citrus leaves under laboratory conditions.

• The leaf sample discriminant analysis using CCM textural features achieved classification accuracies of over 95% for all classes.

• Although, high accuracies were achieved when using an unreduced dataset consisting of all HSI texture features, the overall best performer was determined to be a reduced data model that relied on hue and saturation features.

• This model was selected due to reduced computational load and the elimination of intensity features, which are not robust in the presence of ambient light variation.

Milestones of AI in Food ProcessingMilestones of AI in Food Processing2004 Brudzewski et al. Classification of milk by an electronic nose

2005 Pierna et al. Classification of modified starches

2006 Chen et al. Identification of tea varieties

2006 Onaran et al. Detection of underdeveloped hazenuts from fully developed nuts

2006 Wang and Paliwal

Discrimination of wheat classes

2007 Zhang et al. Differentiate individual fungal infected and healthy wheat kernels.

2008 Fu et al. Quantification of vitamin C content in kiwifruit

2008 Kovacs et al. Prediction of different concentration classes of instant coffee with electronic tongue

2008 Li et al. Classification of paddy seeds by harvest year

2008 Sun et al. On-line assessing internal quality of pears

2008 Wu et al. Identification of varieties of Chinese cabbage seeds

2009 Deng et al. Classification of intact and cracked eggs

2012 Jha et al. Method of determining maturity of intact mango in tree

Researchable IssuesResearchable Issues• Online non destructive measurement of quality of food

grains, fruits and vegetables using NIR sensors• Electronic nose to assess the quality and authenticity of

food products.• Electronic tongue - for recognition (identification,

classification, discrimination), quantitative multi-component analysis and artificial assessment of taste and flavour of various liquids

• Affordable instrumentation for measurement of spoilage of grain in bags and silos

• Smart labels of food packets to detect their shelf life with automatically changing bar codes

• Simple gadgets like pH meter to detect pollutants in drinking water

• Method to detect adulterants and harmful chemicals in foods

Thank You!!!Thank You!!!With an appeal to support With an appeal to support

demand for mandatory demand for mandatory employment food professional employment food professional

in food establishmentin food establishment