Mpkv lecture 1 advances in processing of horticultural produce
1. Advances in Processing of
Horticultural Produce
Dr. R.T. Patil
Former Director, CIPHET, Ludhiana
Chairman, Benevole Welfare Society for Post
Harvest Technology, Bhopal
2. Indian Perspective
• India has 17% of world’s population, has 4% water and
only 2.4% land.
• Agriculture contributes about 15 to GDP, employees 49%
workforce and sustains approx over 58% of the
population
• India produces about 295 million tons of food grains and
315 million tons of fruits and vegetables and ranks second
in world, however due to lack proper storage and
processing the losses are 10% in food grains and upto
25% in horticultural produce. (15 B USD=Rs. 1 Lakh
crores)
• Food processing is employment intensive, creates 1.8
jobs directly and 6.4 indirectly for every USD 25000
investment
• Indian produce is unique with aroma, flavour, taste,
nutritional properties and health benefits, such as Jamun
(Indian blueberry), Bel fruit (wood apple), Jackfruit, Aonla
(Indian Gooseberry), Ber (Indian plum), Pomegranate,
3. Reasons for Losses
• Handling of raw produce through many stages of
middlemen.
• Low level of processing,that too mostly in urban
areas which leads to wastage of valuable by
products.
• Non availability of sufficient cold chain infrastructure.
• Non availability of adequate and efficient equipment
and machinery for small scale processing.
• Lack of facilities for training, incubation and
handholding of entrepreneurs
Higher the processing- Better the Post Harvest
Management - Lower Will Be Losses
4. Food Processing in
Production Catchment
1. Help effective backward linkages with small holder
farmers for processing their raw produce
2. Reduce post harvest losses and increase availability
of by products for further processing.
3. Can provide processed food of highest quality at
affordable cost to consumers
4. Help environment by needing least food miles
5. Ensure traceability of raw materials used for
processed product suitable for export and elite urban
market.
6. Shorten the supply chain, increase the profitability of
farmers and ultimately increase from GDP from
agriculture and help to reduce poverty
5. Unit Operations in PHT of
Horticultural Produce
•Harvesting at Maturity
•Safe harvesting
•Pre cooling & washing
•Surface drying
•Cool/cold storage
•Safe transport
•Safe handling
•Minimal Processing
•Intermediate Processing
•Value Addition & Packaging
7. Garlic Processing Machines
Garlic Flaking MachineGarlic PeelerGarlic Bulb Breaker
Capacity-800 kg/h Capacity-400 kg/h Capacity-40-50 kg/h
Garlic is widely used to prevent for several conditions linked to the
blood system and heart. Garlic is also used for the prevention of many
type of cancers.
8. Method to Prepare Dried Garlic Slices
• The cloves are
separated, peeled and
sliced across the length.
• Slices of 3mm thickness
are dipped in 0.5%
sodium metabisulphite
solution for 15 min at
ambient temperature
and dried to 6% moisture
content (db) in a
fluidized bed dryer
at 600C air temperature.
• Slices thus obtained
should be immediately
packed in airtight
containers.
Plant & machinery :Stainless Steel knives,
Fluidised bed dryer, Work tables, Dipping tanks
etc., Manpower :10-15 kg raw garlic / person for
8 h, Investment: USD 4000 approx.,
Capacity:10-15 kg dried garlic slices / day.
9. Mango Processing Machinery-IIHR
Slices mango 4,6&8 pieces
Capacity – 1 tonne/h
Cost - Rs 100000
Cubes the mango
slices
Capacity – 500 kg / h
Cost – Rs 150000
Peels raw mango
Capacity – 200 kg /h
Cost – Rs. 100000
Raw mango peeler
Raw mango slicer Raw mango
cube cutter
10. Process Technology for Guava Bar
• Guava is perishable in nature
and cannot be stored for
more than a few days during
peak season.
• Guava can be processed into
a number of products like
fruits bar and beverage
• Guava bar acceptable even
after 6 month of storage
Composition: Moisture: 15%, Vitamin C: 120 mg/100g, Acidity:
1.08%, Reducing sugar: 14%, Non-reducing sugar: 46%, Weight
of each bar: 5-10 g, KSM: 0.2%
Very rich source of potassium 417 mg/100g, Vitamin C and
Vitamin A.
13. Small Composite Unit for
Tomato Puree and Fruit Pulp
The machine has components
like a cooker, grinder, mixture,
processor and juicer. The
machine is capable of processing
around 200 kg of herbal products
and fruits in an hour.
Mr. Dharamvir Singh from
Haryana has developed this
machine to extract juice; residue
is used for making candy, sweets
and other items.
He has employed 35 women for his business and also sells units of
the machine. He even trains buyers on how to use it. He earns about
Rs. 24 lakh per year from processed products and the machine is sold
16. Crushed Tomato Technology
• Intermediate processing
technology to produce tomato
puree in production catchment and
its cold storage for further use by
Ketchup or Soup or Juice
Manufacturers is best option to
avoid price crash/distress sale and
provide local employment
• Crushed tomato is an intermediate
product developed by ICAR-IIHR
where inclusion of seed and skin
adds to the consistency and colour
of the product and can be used as
a substitute to the fresh tomato for
various curry preparation
18. Powdering Technology for beetroot
It is beneficial to the blood, the heart, and the
digestive system. It has been regarded as a laxative;
a cure for bad breath, coughs and headaches; and
even as an aphrodisiac. More recently, it has been
advocated as a cancer preventative and as a means
of bolstering the immune system.
19. Banana Chips
• Heat the oil, ideal
temperature for
frying is between
190-200 C, there
should be enough
oil to fully cover
the bananas or
plantains.
• Fry until the chips
get a golden color.
• Remove the chips
from the oil and
remove excess oil
20.
21. Making Flour from Unripe
Bananas
• Peel the good mature green bananas.
• Slice the bananas into 0.5-cm thick pieces
• Soak sliced bananas in a solution of anti-
browning agent.
• Soak the slices for 15 minutes.
• Drain the slices by placing them on trays with
plastic mesh and then place them in the dryer.
• Dry in the sun (solar dryer) or in a hot-air dryer
until dry and brittle.
• Grinding, sifting and packaging
22. Making Flour from Precooked Unripe
Bananas
• Cook unpeeled bananas in a pan of water until
tender.
• Cool cooked bananas in cold water.
• Peel the bananas.
• Slice the bananas into pieces about 0.5 cm
thick
• Dry in the solar dryer or in a hot-air dryer until
fully dry and brittle.
• Grind the dried banana chips in a hammer mill
• Weigh and pack
• Store in a cool, dry place
23.
24. OSMO-CONVECTIVE DEHYDRATION OF KINNOW
SEGMENTS
PROCESS
KINNOW
PEELING
SEPARATING OF SEGMENTS
REMOVAL OF SEEDS
DIPPING IN 60 % SUGAR
SYRUP FOR 6 h
DRAINING OF SYRUP
DRIED SEGMENTS
(60 OC FOR 10-12 h)
25. CIPHET Process of Mechanical
Dewatering and Drying
• Process-The onions were washed,
peeled and mechanically dewatered
prior to drying with centrifugal juicer.
• Partial mechanical dewatering
resulted in as high as 60.98 % less
consumption in energy than
conventional method besides getting
high value products i.e. onion juice
and onion powder.
• The optimum combinations are 60%
dewatering and 60-70 C
temperatures.
• Onion juice was concentrated to
75% solids for increasing its shelf
life.
• Storage studies of onion powder
showed that there has been no
significant loss in quality even after 2
months storage at room
temperature.
26. Shrink Packaging of Fruits and Vegetables
Storage life
Ambient Cold store
Commodity
Shrink wrapped Unwrapped Shrink wrapped Unwrapped
Kinnow 27 13 70 41
Tomato 19 10 39 23
Capsicum 25 4 46 21
27. Process Technology for Ber (Indian Plum)
Preserves
• Excellent natural color
• Very good texture
• Rich in Vit. C
• Rich in minerals
• Least enzymatic
browning
Can keep well up to 6 months
28. Minimal Processing of Pomegranate Arils
Arils are treated with
Chlorinated water for 5
minutes (Sodium
hypochloride 100 ppm) +
Antioxidant for 30 seconds
(5% W/v Citric acid or
Ascorbic Acid) and packed
in 25 μ Semi permeable
film and store at 5 ± 1ºC
Maintains quality, colour
and shelf life up to 16 days
with good physical and
microbiological conditions.
29. •Higher aril extraction capacity; around 5.0 quintal per hour
•Aril extraction/separation efficiency is in the range of 90-94%
•Mechanical damage received by arils is only 1-2%
Mechanical Pomegranate Aril Extractor
including Hand Tool
30. Green Chili Processing into Powder
and Puree
•Chilies powder has higher nutrition and
controlled pungency. The green chilies
have more Vitamin C & A and antioxidant
properties.
•About 130 g of green Chilies powder and
300 ml puree could be prepared from one
kilogram of fresh green Chilies.
•The cost of the plant for the processing
200kg of green chilies per day is
estimated at 713000/-.
•The break even point comes to 49.15%
and pay back period 1.91 years
•1kg of green chilies costing Rs. 15/-, the
value added product of Rs. 100/- could be
marketed.
Chili Puree
Green Chili Powder
31. Aloe Vera Gel Extractor
•Aloe vara gel should be extracted
within 6 hours and processing must
be completed within 36 hours.
•An inner clear gel that contains
99% water and rest made of
glucomannans, amino acids, lipids,
sterols, vitamins etc.
•The equipment capacity 200-
225kg gel/h (900-1000 leaves/h) for
motorised and 100kg gel/h (400-
450 leaves/h) for manual machine.
•The extracted gel is clean and
without any physical damage.
32. Cryogenic Grinder
• The capacity grinder is 30 to 50 kg/h
• The grinding system consists of a self-pressurized liquid
nitrogen cylinder of 185 litre capacity,
• Cryo-precooler of capacity 30-50 kg/h.
• All contact parts of machine are made of stainless steel.
• The ground spice is collected through cyclone system and
immediately sieved into different grades.
• Product with natural flavour & all medicinal attributes is
obtained.
33. Evaporatively Cooled Room for Storage of
Fruits and Vegetables
Compared on the basis of 10%
physiological loss in weight (PLW) the
shelf life inside the room was 34 days
for early kinnow, 23 days for late
kinnow, 11 days for cauliflower and 4
days for spinach as compared to 21,
11, 5 and 2 days respectively in an
ordinary room at the same time.
The cost of the chamber is USD 1500 and capacity is 2 tonnes.
•An evaporatively cooled (EC) room (3x3x3m. size) was developed
for on-farm storage of fruits and vegetables.
•The summer temperature inside the EC room was 5-8C lower than
that inside the ordinary room and winter temperature was 5-8 C
higher than that inside the ordinary room.
34.
35. Conclusions
• India produces variety of nutritious fruits and
vegetables if processed has growing upper middle
class market and also potential for export.
• It can provide 2 direct and 6 indirect jobs with each
10 lakh invested.
• Strengthening the primary processing and value
addition at production catchment will increase the
farmers income substantially while reducing the
post harvest losses.
36. Recommendations cum Appeal
The fruits and vegetables are high value
nutraceutical and functional foods
•Hence increase their consumption in daily
diet
•Consume one seasonal fruit a day to get
vitamins and minerals for good health
•Greet with a basket of fruits so fruit
consumption among Indians is increased
•Consume fruit jam and use it to make milk
shakes to increase consumption of jam
which is an easy to make and healthy
processed food
