Technologies for SMEs in Food Processing

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Technologies for SMEs in Food Processing

CSIR-Central Food Technological Research Institute is one of

the largest R&D institutions devoted to Food Science and

Technology under the aegis of Council of Scientific & IndustrialResearch (CSIR), Ministry of Science & Technology, Govt. of

India, New Delhi. Established in the year 1950, the Institute is

also an associated institution of United Nations University,Tokyo. The focus of the Institute has been towards developing

cost-effective technologies targeted to Small & Medium

Enterprises, utilization of newer agri-resources, value additionto agri-produce for ensuring food & nutritional security and

innovative food processing with an underpinning on food safety

to provide health and nutrition to all section of the population.

The Institute has been focusing on the development of

technologies beneficial to farmers and growers and ultimatelythe society as a whole. The present scenario in the country is

very vibrant with rising capital investment in food industry which

is expanding at a rapid pace due to demands in rural, semi-urban and urban markets for processed foods with a focus on

traditional as well as eco-friendly technologies along with

underutilized agro-produce for value addition.

R&D Programmes of the Institute

• Cereal products and confectioneries

• Ready-to-eat foods

• Bioactive molecules from plant and microbial sources

• Food ingredients, additives and flavours

• Meat & marine-based products technology

• Automation of traditional food processes & Machinerydesign

About CSIR-CFTRI

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• Biochemical and molecular level intervention for enhancing

the shelf-stability of fruits

• Minimizing post-harvest loss of cereals, spices and herbs

• Value-addition to rice, wheat, coarse and pseudo-cereals,

legumes and seaweeds

• Ecofriendly technologies

• Enzyme and microbial technology

• Analytical methods for food safety and quality

• Bioprocess engineering and biosensors

• Food protectants, storage and food packaging

• Understanding of plant protein structure

• Value addition to oilseed meals

Unique Facilities

• Nodal Codex Food Analysis Laboratory

• Sophisticated Central Instruments Facility

• Cell Culture Facility

• Experimental Irradiation Facility

• Controlled Atmospheric Storage

• Functional Laboratory for Food Packaging

• Scale-up Facility for Food Processing

• Modern Food Engineering Centre

• Computerized Wheat Mill

• Solid State Fermentation Facility

Technology Landscape

• Infant food formulations Amul, Balahar, Energy food

• Automated production of traditional foods Dosa, Idli, Chapati

• Mini Dhal Mill

• Dry Maize Milling Plant

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• Fruit juice evaporation plants

• Sunflower dehulling machine

• Leaf cup/ plate machine

• Fluidized bed roaster

• Reverse osmosis and ultra-filtration units

• Processes for Spirulina, Natural colourants, High protein

biscuits, Spice oils, Oleoresins, Black pepper, Virgin

coconut oil, Nutri-oil blend, Coconut milk powder, Coconutdietary fiber, Fructooligosaccharides and Ready-to-eat food

products

Innovative Processes/Products

Fructooligosaccharides

The Institute has developed a process for the production offructooligosaccharides (FOS), a class of prebiotics. The unique

features of the process are utilization of sucrose, a widely

available substrate and Aspergillus oryzae (GRAS). The instituteholds various patents and products involving FOS, besides

successful transfer of the process to the industry.

Virgin Coconut Oil

Virgin Coconut Oil, extracted from fresh coconut meat without

thermal treatment is colourless with intense coconut aroma. Itis rich in lauric acid and vitamin E. Its FFA and peroxidase

values are less than 0.2% and 1, respectively.The product has

many pharmaceutical and cosmetic applications. Thetechnology has been commercialized.

Spirulina - Alleviation of Protein Malnutrition

Biomass from alga sources are known for their applications infood and other non-food items. Their outdoor cultivation with

enhanced attributes has been standardized in the laboratory.

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These include Spirulina with enriched iron content of high

bioavailability; Dunaliella as a rich source of beta-carotene,

Haematococcus pluvialis as a source of astaxanthin andBotryococcus braunii for hydrocarbon source. A few of these

have been transferred to industries.

Nutraceutical Enriched Oils

Lipase catalyzed interesterification process was used for the

resultant homogenized blend of oils, containing oryzanol, beta-

carotene, tocopherols, tocotrienols and lignans.

Bottled Sugarcane Juice

India offers itself a potential market for soft beverages and fruitbased beverages. A process has been developed for the

preservation of sugarcane juice as a bottled beverage. The

beverage, being natural, possesses a lot of medicinal andcurative properties and it is calorific and nutritive.

Technology Protocols for Export of Fruits

The Institute has standardized pre- and post-harvest technology

protocols for the export of fresh mangoes, bananas and

pomegranate by surface transport.

Energy Food

Energy Food developed by the Institute is a ready-to-eatsupplementary food based on cereals, legumes and defatted

protein-rich oilseed meals. The mixture is fortified with vitamins

and minerals. The product is useful as a weaning/nutrition foodfor children and pregnant women.

Liquid Fruits (Clarified fruit juices - Guava, Banana,

Grapes, Apple)

Liquid fruits provide a natural alternative to synthetics and can

be used by proper dilution and carbonation as effective soft

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beverages. Removal of pulpy material from the juice makes it

easier to preserve by pasteurization and amenable to

carbonation. In order to convert these fruits into RTS beveragesand concentrate, process for the production of clarified fruit

juices from pulpy fruits like banana, guava, grapes, apple etc.,

are standardized by enzymatic hydrolysis.

Human Resource Development

The Institute is affiliated to United Nations University (Tokyo)and academic programmes offered include :

• Ph.Ds under AcSIR and University streams

• M.Sc. (Food Technology)

• Certificate course in Milling Technology

• Short-Term Courses

Institutional Linkages

CSIR-CFTRI has been a vibrant partner with various nationalinstitutions and bodies viz. Department of Biotechnology,

Department of Science & Technology, Ministry of Food

Processing Industries, Coconut Development Board and variousother Ministries under Central and State Governments.

The Institute also has been collaborating with leadinginternational research agencies and organisations for pursuing

topics of mutual and strategic interest in food and allied areas.

Services

Services offered from the Institute include technology transfer,

contract R&D and testing of food samples for the benefit ofMSMEs and cottage industries.

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Outreach programmes

The Institute organizes number of outreach programmesthroughout a year for the benefit of targeted group/communities.

These include entrepreneurship development programmes

(EDPs), awareness programmes and demonstration oftechnologies for the benefit of farmers and other groups. As a

part of the major outreach initiative, nine of the proven and

commercially viable technologies were offered free for downloadby making the technology dossiers available from the Institute’s

web site. Also under CSIR 800 programmes, large numbers of

farmers-specific programmes were conducted on a continuousbasis.

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Selected RuralTechnologies

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About the Product

Virgin coconut oil (VCO) is prepared from fresh maturecoconuts. VCO is colourless and having an intense coconutscent, it is rich in lauric fatty acid, which is a proven antiviraland anti-bacterial agent. The high-grade VCO has a long shelflife due to presence of natural anti-oxidents in coconut oil.Coconut oil is in great demand in the cosmetic industry andinternational culinary. It is valued mainly for its characteristicnutty flavour and also for its nutritional values.

Process and Novelty

Coconut milk is extracted from deshelled, pared anddisintegrated coconuts. Further, coconut cream is separated,which is subjected to tempering, conditioning and separationtechniques to separate VCO. The novelty of the invention isthat the VCO is obtained without heat treatment of coconutmilk or fermentation of coconut cream, thereby keeping itscharacteristic flavour and nutrients intact.

VIRGIN COCONUT OIL

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Commercial Potential

In order to protect the farmer from the losses from the fallingprice of coconut, there is a need to look for diversified coconutproducts and large scale integrated processing. Thedevelopment of this product is an effort in the direction to developvirgin coconut oil, so that better quality of the oil can be providedto customers and consumption of coconut oil can be increased,while increasing the profit margin to producers in terms of valueaddition.The technology for the manufacture of VCO is availablefrom CFTRI.

Process Economics

Economic capacity : 5000 coconuts/day/shift

Production / Day : 300 L

No. of working days : 300 days / Year

Project cost : Rs. 3.3 lakh

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About the product

Sugarcanes are crushed to obtain juice. The fresh juice isdispensed either as such or with the addition of lime juice and/or fresh ginger extract in glasses by the vendors. The majorproblem encountered in this operation is the lack of hygieneresulting in contamination of the juice with the heavy load ofmicro-organisms, which arise due to improper cleaning of thesugarcanes and handling of the finished product. Raw sugarcanejuice is a carbohydrate rich, low acid food and is thereforesusceptible to the growth of yeasts, spoilage by pathogenicbacteria. Contamination of raw juice by these bacteria can occurby the food handlers, by the equipment used or by theenvironment in which it is prepared. Freshly crushed juice cannotbe preserved even for a few hours, since it is prone to browningand fermentation very quickly. The juice with its delicate aroma

can be used as a refreshing beverage.

Process

Freshly harvested sugarcanes are thoroughly washed with waterand the ends are trimmed to remove roots and shoots. Canesare scrapped with SS knives, and the cleaned canes are pre-

SUGARCANE JUICE IN GLASS BOTTLES

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treated in soaking solution to reduce the initial microbial load.Canes are washed with water and crushed in SS crusher toobtain the juice. Acidity of the juice is adjusted after suitabledilution and blending with certain additives and filled in glassbottles and crown corked. The filled bottled are subjected to

thermal treatment. The product has a shelf life of four months.

Process Economics

Capacity of raw material : 2.5 Tonsprocessing

Finished product /day : 1000 L of juice

Working days : 250 days

Land (Rented shed) : 10 lakh

Plant and machinery : 13.20 lakh

Working capital margin : 7 lakh

Total Project cost : 30.20 lakh

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About the product

Pickles are adequately spiced unfermented preparations of fruitsand vegetables. Preservation of fruits and vegetables in the formof pickles is an old art. The process of making instant picklemix, which can be converted to a palatable pickle at homewithout any difficulty by simple addition of water and oil hasbeen standardized. The dry mix is a convenient product to pack,transport and handle in the trade channel. A variety of dry picklemix can be developed by using dehydrated mango, lime (lemon),Green chillies, tomatoes, carrots, different type of leaves suchas gongura, coriander, etc. However, the instant pickle (dry)mix is a new concept, yet to become popular. By virtue of itsquality, convenience to handle this product may become popular

and acceptable.

Process

Fruits and vegetables are available during different seasons,which varies from product to product, in abundance. The rawmaterials are to be processed during the season, prepared,cured, dehydrated and stored for the ready use all-round the

INSTANT PICKLES

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year. Powdered spices are the other raw materials of importancein instant pickle preparation. Dry powdered salt is to be used.All the materials can be locally procured. Packaging materialsalso form an important input.

Process Economics

For 250 kg of Instant Pickles/day (8 hr shift)

Total fixed capital : Rs.13.75 lakh

Working capital margin : Rs 2.70 lakh

No. of working days/annum : 300

Capacity utilization : 70%

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About the product

Jackfruit bulbs are a rich source of vitamins and mineralconstituents especially calcium. Much of the raw jackfruit isconsumed locally for curry preparation and after ripening thebulbs are relished as such. It is considered to be a goodappetizer. Products such as fruit bars, jam, candy, etc., canbe prepared from this fruit. However, it has not so far been fullyexploited by the fruit preservation industry.

The osmo-air dried product prepared from jack fruit bulbs maybe consumed as snack. It can also find use in military rationsin suitable packing. The osmo-air dried fruit products can beused in ready-to-eat type of foods, ice-creams, fruit salad, kheer,cakes and bakery products.

Process Economics

Capacity : 200 kg / shift

Working days : 150

Installed capacity per annum : 30 tones

Total fixed capital : Rs. 22.00 lakh

Working capital margin : Rs. 2.70 lakh

OSMO AIR-DRIED JACKFRUIT

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About the product

Cauliflower, cabbage, beans and carrot are some of the mostpopular but seasonal vegetables which are used to make curry,as such or in combination with other vegetables. An attempthas been made to dehydrate these vegetables and prepareinstant curry mixes with spices such that the curry would beready in 10 min. time by emptying a packet of curry mix intorequired quantity of boiling water. All the above curries go wellwith chapati, purri or can be adjuncts for rice.

Process

The process for manufacturing of instant dehydrated vegetablecurry mixes involves following steps:

Dehydrated vegetables

Vegetables Washing Peeling Blanching Sulphiting Drying Packing Sealing

DEHYDRATED VEGETABLECURRY MIXES

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Spice mix

Precleaning of ingredients Roasting Grinding Packing Sealing

Curry preparation

Seasoning onion in oil, adding 225 water, allowed to boil andthe contents of the packet are emptied into it. The contents aresimmered for 10 min. and the curry is ready to serve.

Process Economics

Capacity of Produciton : 1000 kg/day

Cost of Plant/Equipment : Rs 8.0 lakh

Total project cost : Rs. 25.0 Lakh

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About the product

Carrots are highly nutritious vegetable. It is a good source ofvitamin A. Several carrot based formulations such as carrotjuice beverage, carrot juice beverage blends with suitable fruitjuices and flavours and spiced carrot juice beverages areavailable. The products are cloud stable and acceptable.Packed in 200 ml bottles can be sold to health consciouscustomers. Plain and blended juices can be consumed as agood drink for energy and strength.

Process

The carrots are sorted to remove damaged portions and cleanedwith water to remove soil. The prepared carrot pieces are crushedafter proper treatment and then disintegrated. The same isfurther ground to a fine pulp and the juice expressed. Method ofpreparation of various products is standardized.

Machinery & Equipments

Vegetable washer, fruit mill, homogeniser, hydraulic press, S.S.jacketed kettle, Heat exchanger, bottling line and laboratoryfacilities are required.

CARROT JUICE BEVERAGE & RTSBEVERAGE FORMULATION

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Process Economics

Depending on the size of operation envisaged, at least 5,000bottles per day may be reasonable.

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About the product

Tomato is one of the most versatile fruit. The surplus productionduring seasons could be suitably processed and preserved inbottles and cans in the form of tomato juice, paste or puree,ketchup/sauce, tomato chutney and tomato pickles which arepopular ready-to-serve products relished very much in local aswell as export markets. The products are mostly utilized in thedomestic market. With fast-food sector expanding, the demandfor tomato ketchup and sauces is estimated to have expandedas indicated by the trend. Service sectors like flight cateringand hospital catering, armed rations etc. are the potentialmarkets for tomato products.

Process

The main raw material is tomato and only sound fully ripetomatoes, Pusa rubi or similar variety is to be used. Tomatoconcentrate can also be converted as juice, Ketchup/sauce,chutney etc. Other raw material needed are sugar, salt, aceticacid (glacial), onion, garlic, sodium benzoate and spice powder– the spice powder mix consist of clove, cinnamon, black pepper,cardamom, cumin, mace, red chilli powder, etc. Except tomatojuice all the other products are packed and marketed in bottles.

TOMOTO PRODUCTS

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Tomato juice can also be bottled and marketed as RTS juice(spiced/salted &plain/salted). Tomato juice is packed in OTScans (425 and 800 ml).

Process Economics

No. of working days : 300 days/annum

Installed capacity : 750 kg/day

Total Fixed Capital : Rs. 16.6 lakh

Total working capital : 15.0 lakh

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About the products

Ginger products such as preserve, candy, ginger amla syrupand beverage, ginger honey syrup and beverage, chips, pickle,paste, powder, in brine etc. can be made in very small quantitiesin village or rural sector by a group of trained village womenentrepreneurs.

Process and Novelty

The general process includes cleaning of the fresh rhizomes inwater and by rubbing against a rough surface to make it freefrom mud, sand, skin and fine free roots. The prepared materialcan be stored in 12% covering brine containing 1% acetic acid.In case of preparation of pickles and paste, the prepared piecesare ground in a wet grinder or stone grinder or in a mixer alongwith other ingredients. In the preparation of preserves and candythe prepared ginger pieces are cooked gradually in sugar syruptill the strength of sugar syrup comes to 70% around. Thisprocess will take around 15-20 days time depending upon thesize of the ginger pieces. While the preserve is packed inbottles along with the syrup, the candy is prepared after drainingthe syrup and drying in shade and then packing in polyethylene

FRESH GINGER PRODUCTS

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bags. The salted dry chips are made by sun drying the soakedginger chips in salt acid solution, to the required dryness.Specific process can be demonstrated separately for eachproduct.

Commercial potential

These products can be successfully marketed in urban areaswhere the convenience products are becoming popular.Preserve, candy and salted dry ginger chips can be used asmouth freshener and in confectionery products. Ginger in brinecan be a replacement to fresh ginger. Ginger pickle and pastecan be used as appetizers.

Packaging material

Glass bottles, HDPE jars, Polypropylene/ polyethylene pouchesetc. can be used for ginger products.

Process Economics



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About the products

Paushtik atta is a nutritive product prepared by blending wheatflour and soy flour fortified with vitamins and minerals to meetthe nutritional requirements. Common salt is added to improvethe taste of the product. Paushtik atta is acceptable as wholewheat flour for common food preparation. It contains higheramount of proteins 14% as compared to whole wheat flour(12%). It can be used for the preparation of puris and chapathisin the same way as ordinary atta.

Process and Novelty

The process involves very simple steps and does not requireexpensive equipment. The production units can be set up evenin small towns with low capital. The equipments required toprocess Paushtik atta are cleaner, destoner, impact pulversier,mixer, roaster and heat sealer. All the raw materials andequipments are available in India.

Process Economics

Production / Day : 100 kg/batchNo. of working days : 300 days / YearPlan and machinery cost : Rs.4.00 lakh

PAUSHTIK ATTA

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About the product

Finger millet (Eleusine coracana L.) also known as Ragi in Indiais one of the important cereals which occupies the highestarea under cultivation among the small millets. Ragi is a cropwhich can withstand severe drought conditions and can be easilygrown throughout the year. Nutritionally, ragi, as a whole grain,contains high protein and minerals in comparison to all othercereals and millets. Composite ragi bread is a nutritious bakeryproduct, which could be consumed for breakfast and also couldbe a snack item. It is prepared from ragi flour, wheat flour, yeast,sugar powder, salt, hydrogenated fat and some of thepermissible additives. The bread has a pinkish brown crumbcolour and characteristic flavor. The composite ragi bread shouldhave the normal shape of bread with fairly good crumb grainand texture, easy to slice with moisture content in the range of37-39%.

Process

The process parameters include mixing of wheat flour - ragiflour blends with other ingredients to get optimum consistency.The optimally mixed dough is fermented, remixed, scaled and

COMPOSITE RAGI BREAD

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proved in the pans. The optimally proved bread doughs are bakedand cooled. It is sliced and packed.

Process Economics

50 kgInput 450 kg Output 400 kg (1000 loaves) Moisture & gas loss

100 kg raw material would give 220 loaves

Average cost of production per kg (Rs.) : 41

Cost of selling per kg (Rs.) : 42

Break-even, % capacity : 69

Simple return on investment (%) : 21

Payback period : 5 Years

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About the products

Ready formulation and processing conditions for high proteinbuns is provided. The buns have mold free shelf life of 8 days.

Nutritional facts of the product are energy 263 kCals, protein14 g, carbohydrate 45 g, fat 3.0 g, minerals 1.2 g and dietaryfibre 10 g per 100 g of protein enriched buns.

Process and Novelty

The ingredients are weighed and mixed till well developed doughis formed with water. The bun dough is fermented for 90 min.at 30°C and 75 % RH and is remixed. The dough is scaled to65 g dough pieces to get 50 g buns. Then the dough pieces arerounded proofed (30 – 40 min, 30°C, 85 % RH). Baking is doneat 200 °C for 15 min. the buns are cooled for 2 –3 hours andpacked.


These products can be successfully marketed in urban areaswhere the convenience products are becoming popular.

HIGH PROTEIN BUNS

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Process Economics

Economic capacity : 24,990 buns of 55g out of 8500 kg flour/day/shift


Average cost of : Rs. 167/-production per kg buns

Cost of selling : Rs. 180/-at per kg buns

Payback period : 2.17 years

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About the product

The product is aimed for children of age group below 3 years. Itis a ready-to-cook product based on malted grains whichcontains partially digested carbohydrates. The product can becooked in water or milk to form porridge of spoon feedingconsistency. The product is of low viscosity compared to theproprietary products and hence forms a low bulk diet. The proteinand minerals present in this product are of high biological value.It is a nutrient dense food which can be easily fortified withvitamins and minerals.

Process

The basic ingredients are ragi and green gram which are malted,roasted, milled and blended to formulate the product. The blendwas fortified with vitamins and minerals.

Salient features

• The product is based on malted ragi, which is a good sourceof amylase enzymes which brings down the viscosity ofthe product on cooking.

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• Low viscosity of the product reduces the bulk of the dietand hence more food can be given per serving

• The product contains natural calcium present in ragi whichhas high biological value

• The product contains 12% protein and 70% carbohydratesand provides 347 Kcal per 100 g

Process Economics

Capacity : 250kg/h


Cost of production : Rs. 25/kg

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About the Mill

Mini dhal mill is a small-scale integrated pulse milling systemsuitable to de-hull pulses efficiently and could easily be usedunder rural conditions. The mill consists of a de-hulling unit,an aspirator and a dhal separator, all run by a 1 HP single-phase motor. The de-husking unit is based on the principle ofabrasion and consists of an emery-coated cone, which rotatesinside a wire mesh cage. Preconditioned pulses are first dehulledand split and cleaned dhal is finally obtained after aspiration ofhusk and separation of broken from the millstream. This minidhal mill is suitable for efficient de-hulling of bolder pulses likepigeon pea, chickpea, pea, soybean, etc. The quality of dhalobtained is comparable to that from large-scale dhal mills.

Product Novelty

The novelty of this unit is that by altering the clearance betweencones, different sized grains can be handled with good efficiencyof dehulling (96-99%), yield of dhal (77-80%) and less brokengrains (1-2%). The mill is very easy to operate, maintain andrepair. The pre-milling treatments required i.e. soaking, gradingand sun-drying are very simple and easy to carry out. Since

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this unit is compact, it requires very less floor space(2 m x 4 m) and can easily be accommodated within a smallroom.


The mini dhal mill with a capacity of 100-150 kg/h is suitablefor cottage-scale or as a small cooperative venture. The lowcapital investment with good profit makes it ideal for adoptingat rural level. By-products (husk and broken) obtained duringmilling can be used as cattle feed, which can fetch additionalfinancial benefits. The design know-how has been transferredto many licensees across the country and units could easilybe procured through them.

Process Economics

Capacity : 100 kg/hr

Cost of the mill : Rs. 0.75 lakh

Cost of processing : Rs. 30/quintal

Net annual income : Rs. 0.90 lakh

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About the Mill

Dhal milling is probably the third largest of food processingindustry in India, after rice and wheat. The Mini Versatile DalMill, developed at this institute, has been designed to processall type of pulses including minor ones. The Mini Versatile DhalMill consists of three principal assemblies namely, Dehullingsystem, Aspiration system and Grading system. Theseassemblies are mounted on a sturdy frame for trouble freeoperation. The dehulling system and aspiration & grading systemare driven separately by 1HP single phase motors. Pulsesare pre-conditioned prior to dehulling. Conditioned pulses getdehusked and split simultaneously in the dehusking systemand then pass through the discharge hopper at the bottom toenter the expansion chamber of the aspiration system. Theblower carries off the husk by suction and the aspirated products(dhal and broken) fall on to the reciprocating grader. The gradingsystem removes the broken, separate the dhal and the materialremaining on the screen would be the unsplit pulse which ismilled again.

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Product Novelty

Mini Versatile Dhal Mill is designed for a capacity of 130–150kg/h and is ideally suited for adopting at rural level. The unit isversatile and can handle all types of pulses with both dry andwet pre milling treatments. The unit requires relatively less power(1HP single phase motor) with very high yield of dhal is 75-77%with 98% dehulling. The arrangement for adjusting the gapbetween abrasive surface and outer screen helps it to processdifferent sized grains. The arrangement to collect husk, powderand dust minimizes air pollution.


The versatile dhal mill has good potential in pulse growing statesof India, especially in Maharashtra, Orissa, Madhya Pradesh,Bihar and Uttar Pradesh and will certainly prove beneficial topulse farming community. Since it is a versatile unit with veryhigh efficiency, this could be used in cottage industry or as asmall cooperative venture. The low capital investment with goodprofit makes it ideal for adopting at rural level. By-products (huskand broken) can be used as cattle feed in village, which canfetch additional financial benefits.

Process Economics (may be given from user’s point ofview, like mini dhal mill)

Capacity : 130-150 kg/hr

Cost of the mill : Rs. 1.25 lakh

Cost of processing : Rs. 40/quintal

Net annual income : Rs. 1.30 lakh

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About the product

Papad is a thin wafer-like snack food particularly popular inSouth and South-East Asian countries. It is made from doughcontaining legume flours such as blackgram, horsegram orcereal flours such as rice, ragi etc. along with salt, khar andspices. It is either toasted or deep fat fried to an attractivecrispy wafer like product that is commonly used as an adjunctto a full meal. Currently papad production and sale are carriedout at home level or as a tiny scale industry, which is mostly inthe unorganized sector.

Process Novelty

The present process focuses on using gadgets/machineriesthat are semi-automatic to increase production besidesovercoming drudgery of manual operation. CFTRI hasstandardized the technology and general methods of processingpulse based papads. This processing technology providesinformation about quality control, packaging and packagingmaterial specifications and equipment details. This processinvolves grinding of black gram, mixing with ingredients,kneading the dough in a kneader, shaping in pedal/hand operated

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presses, drying at room temperature and packing in suitablepackaging material.


The demand for papad exists throughout the year and isincreasing steadily. It peaks during festival season and in themarriage season and a number of players spring up during thisperiod. The total market is about four tonnes per day. With theincreasing awareness about quality, the demand for hygienicallyprepared, appropriately packed papad is on the rise. Thisprovides a good demand for papad prepared using processeslike the one developed by CFTRI.

Process Economics

Economic capacity : 30 tonnes of papad per year

Production / Day : 100 kg of papad

No. of working days : 300 days/Year


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About the product

Niger seeds (Guizotia abyssinica cass) commonly known asSarguia, Tilangi, Karel and Ramtil and Huchellu in Kannada,are eaten fried and are used in many food preparations. Nigerseed oil is used for cooking, burning lamps, in making soapand paint, etc. The niger cake is used for livestock feed. Nigerseed contains about 30% oil and 24% protein. The niger oil ispale yellow in colour, odorless and has nutty taste. The oil isrich in oleic (26%) and linoleic acid (55%).

Process

An integrated process has been developed to obtain quality oiland cake with low fiber and high protein content for food use.Niger seeds are dehulled with a dehulling efficiency of 96-98%.Niger seeds are cleaned and treated with steam using hot lye.After washing these are dehulled. The dehulled kernels alongwith hull fractions are given mild acidic wash and drained. It iswashed and dehulled seeds and hulls are separated by gravitysettling and dehulled and kernels and hulls are collectedseparately. The obtained dehulled seeds are dried in a through-flow/ cross-flow drier. The dried dehulled seeds were aspiratedin air classifier to remove hull fractions.

DEHULLING OF NIGER SEEDS

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The oil obtained from the dehulled niger seeds resulted in lightcolored without affecting the quality of the oil. The oil is nutritiousand contains higher levels of unsaturated fatty acids (oleic andlinoleic acids), which reduce blood cholesterol. The protein isrich in sulphur containing amino acids. The protein has good invitro digestibility and nutritional quality.

Process Economics

Economic capacity : 1000 kg/day in 2 shifts

No. of working days : 300 days/annum

Working capital : Rs. 4.50 lakh

Project cost : 35.00 lakh

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About the process

There is a large market for banana fruits and, therefore, there isthe demand for planting material. Plant tissue culture (PTC)has direct impact on present day agriculture. Through PTC it ispossible for enormous supply of desired type of planting/sowingmaterial obtained by mass micro propagation. The presentprocess of mass propagation of banana plants by TC has beensuccessfully tested at filed level. Banana TC plants had noabnormalities and were better than conventionally propagatedones in overall performance.

Process

The process involves the following steps: Collection of healthyplant material from the field, surface disinfection and cutting ofmeristems/buds aseptically, culturing the shoot buds/meristems and continuing the culture of said meristems/smallshoot buds, harvesting the shoots that are formed, re-culturingand transferring the shoots for partial hardening.

MASS PROPAGATION OF BANANA BYTISSUE CULTURE TECHNIQUE

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Process Economics (Rs. in lakh)

Land (4000 Sq. m) : 3.20

Building (450 m2) : 9.56

Plant and machinery : 1.29

Miscellaneous fixed assets : 1.34

Pre-operative expenses : 0.78

Total fixed capital : 16.16

Working capital margin : Nil

Total project cost : 16.16

Production capacity : 10 lakh banana plants per annum

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About the products

Spirulina, a blue green alga (cyanobacterium) is used as ahealth food and a dietary supplement. It is a concentratedsource of protein (65-70%), vitamins, especially B

12, Provitamin

A (β carotene) and Vitamin E, minerals, especially iron. It isalso rich in gamma linolenic acid (GLA), and omega 3 fattyacid. The amino acid profile of Spirulina protein is similar tothat of egg and compares well with Food and AgricultureOrganisation (FAO) recommendations. It contains essentialamino acids (viz., Lysine, Cysteine, Methionine, Phenylalanineand Threonine), which are not produced in humans and are tobe supplied through food. Spirulina has a low nucleic acidcontent and a very high digestibility due to lack of cellulose cellwall. It is categorized as generally Recognised as Safe (GRAS).Initiatives to use Spirulina to combat malnutrition have beentaken up in various parts of India.


It is used as

• Health food and dietary supplement

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• Protein supplement in feeds for poultry, cattle, pig andaquaculture

• Food colorant

A natural package of proteins, vitamins and minerals, Spirulinais extremely popular as a health food. Without any side effectsand non habit- forming. Spirulina tablets are taken by busyexecutives in the US and Japan, as they are by sportsmen,trekkers and joggers for instant energy synthesis. SinceSpirulina provides all the essential nutrition without excesscalories and fats, those wanting to control obesity take Spirulinatablets.

Process Economics

Economic capacity : 1 - 1.2 ton/annum

Production / Day : 3 - 4 kg

No. of working days : 300 days / year


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About the Product

Wafers are the convenience snack food liked by people of allage groups. Varieties of potato wafers are available in the market.Chicken wafers or egg wafers or wafers from any source ofmeat including fish or prawn will be a delicacy. The ready-to-eat wafers can also be produced without deep fat frying usinglatest techniques.

Product Novelty

The ready-to-eat meat wafers are not just the conveniencesnack, but also could be popularized as a nutritious product,as it is rich in quality protein. It can be made available in differentseasoning flavours e.g. garlic, ginger, tomato, pepper, mint, orspicy traditional masala etc., to meet customers’ needs. Theproduct has high sensory acceptance and good shelf-life whenpacked in flexible laminated pouches.

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This product has edge over other ready-to-eat snacks and willhave potential market as its nutritive value is higher. The waferscan be made available either in ready-to-eat (fried) or ready-to-use (without frying) forms. Products with different flavour andreasonably high shelf-life (up to 6 months) could boost its marketpotential.

Process Economics

Economic capacity : 500 kg /day/shift

No. of working days : 300 days/year

Cost of machinery : Rs. 10-11 lakh


CSIR-CFTRI, Mysore

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About the Product

Egg paneer is prepared from egg albumin or egg yolk eitherseparately or in combination i.e. whole egg, stabilizers andbinders.The mix is processed under optimized conditions andmade in to cubes. Further, the cube pieces are dried and packedunder metalized pouches. This product can be used in currypreparation. During curry preparation, the cubes are rehydratedand appear like paneer. The product can also be used undervarious nutritional programmes as high protein foods.

Product Novelty

This product made from egg albumin or egg yolk eitherseparately or in combination, is first of its kind. Egg crunchybites can be used as ready-to-eat nutritious snack item. Itprovides convenience of use and can bemade available indifferent flavours like onion, garlic, and pepper. The product hasa good shelf-life of six months at ambient temperature.

SHELF STABLE DEHYDRATED EGGPANEER/CUBES AND EGG

CRUNCHY BITES

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The process is simple and can easily be adopted on a cottagescale. Product can be popularized under shelf stable ready-to-use food and can be marketed in supermarket and fast foodrestaurants. As this product is free from chemicals or syntheticpreservative and rich in high quality protein it can have nichemarket.

Process Economics

Economic capacity : 150 tonnes/year

Production/Day : 500 kg/day/shift

No. of working days : 300 days/year

Cost of machinery : Rs. 12.00 lakh


Technologies for SMEs in Food Processing

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