Csir cftri

1. DEVELOPMENT OF MACHINERY
FOR TRADITIONAL FOODS -A
CONTINUOUS CHAPATI (INDIAN
UNLEAVENED FLAT BREAD)
MACHINE
Dr. B S Sridhar
Department of Food Engineering
CSIR-CFTRI
Mysore – 570 020

2. Prelude
• Chapatis are the traditional staple diet of large segment of Indian
population & many Asian countries
• Great demand exists for hygienic and large scale short time
production of these types of foods to cater to the need of
industrial canteens, institutional kitchens, railway canteens,
hospitals, mid-day meal schemes and mass feeding centres
• Mechanizing the preparation of chapatis as Ready-to-Eat and
Easy-to-Carry foods for marketing in unit packs similar to bread
has enormous commercial potential due to growth in
industrialization & mushrooming of nuclear families in present
times as well for facilities for cooking are limited and practically
non-existent
• Many machines available for continuous production of chapatis
are not suitable due to inherent defects like dough stickiness,
complicated cleaning and non -uniformity in quality

3. CONTINUOUS CHAPATI MAKING MACHINE
The machine has a chapati forming unit and a baking unit. The dough is
extended into a sheet and punched to obtain discs. The discs are
baked in a three tier oven where it is heated by conduction on both
sides before exposing to the flame via a mesh conveyer to obtain
puffed and baked chapatis. Sizes of chapatis: 150 - 200 mm dia. and 1.2
-1.5 mm thickness; Capacity – 1200 chapatis/h

4. Innovative features
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Avoidance of manual handling of the dough eliminating
human factors and making the entire operation hygienic
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Higher production capacity than any other systems and the
chapatis produced are of uniform quality, diameter and
thickness
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Continuous operation with provision of material recycling
eliminating separate re-handling of the dough
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Versatile, high tolerance for variation of moisture content,
fat and type of flour
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Easy control of baking temperature and residence time
depending on thickness and moisture content
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Hygienic design and construction – No stickiness of the
dough to any part of the device The parts of the machine
can be easily dismantled and assembled so that contact
parts can be cleaned and inspected regularly

5. Operational Excellence
• There is reduction in the cost of chapatis and savings in
labour accrues indirectly as the consumption of raw material as
well as labor for the preparation of chapatis can be optimised
while large quantities are prepared.
• Energy efficient and is designed for continuous operation. Due to
mass production, there is significant reduction in energy
consumption
• Unit does not need skilled persons for operation A single
operator is enough to prepare and feed the dough continuously
and operate the machine
• Low cost machine, needs low investment and less floor space.
No pollution
• Increased production rates and brings in hygiene into chapati
preparation by eliminating human factors

6. Self reliance aspects
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Promotes the spirit of self employment and entrepreneurship among rural
and urban women of the developing countries and growth of small and
medium scale entrepreneurship (SME) since the present development
elevates the operation of chapati preparation form home scale to industrial
scale
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Reduction of drudgery – Housewives need more time in the current social
environment. The machine offers ready- to-eat and easy-to-carry chapatis,
saving time and drudgery in the preparation of chapatis
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The various sectors benefiting from the development include: Industrial
canteens, Institutional kitchens, Large hotels, Mass feeding centres and
Small & Medium Scale Entrepreneurs. The system is energy efficient and is
designed for continuous mechanized operation. Due to mass production,
there is significant reduction in energy consumption and cost
•
In times of natural catastrophes and calamities like, Earthquakes,
Cyclones, Famines & Tsunami like disasters where large mass feeding is
essential & in times of war this machine can put to good use to prepare
huge quantities hot chapatis in a lesser time under hygienic conditions

7. Impact of the development
•
Licensee(s) / beneficiary utilizing /benefitting from the development
number at present with a licence fee – Rs. 1,000,00 (Rs. One lakh only)
•
The machine has been sold to many industries and organizations across India by
the licensees including export to Middle east countries Some important buyers
include MTR, WIPRO, Mysore Paper Mills Ltd., INS Vendirutti, Kochi, Mata
Amritanandamayi Mutt, Ramakrishna Ashram students' hostel and school, South
western Railway workshop canteen, Karnataka Police academy, Mysore many
colleges and Hospitals across India. The estimated value of annual output/benefit
derived by a one of the licensees amounts to Rs. 2,01,55,940 (Rupees Two Crore
One Lakh Fifty Five Thousand Nine Hundred and Forty Only)
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The machine offers ready- to-eat and easy-to-carry chapatis, saving time and
drudgery in the preparation of chapatis
thus promoting the spirit of self
employment and entrepreneurship amongst rural and urban populace including jail
inmates. Recently central prison, Bangalore planned to hit market with plan to hit
market with 1,000 ready-to-eat chapatis per hour (Ref: Bangalore Mirror, July 15,
2013, Page 6)
•
Machine was put to good use during Tsunami, Gujarat Earth quate and Uttrakhand
Floods relief activities. Ready-to-eat chapatis were prepared from the indigenously
developed chapati making machine, on a large scale ranging from30,000 to 1,50,000
numbers and sent to various relief centres, significantly contributing to the spirit of
societal mission of the self and organization.
are 6 in

8. Future readiness
•
Five different models based on the principles of extrusion, rolling and cam
assisted pressing mechanisms and technology to increase shelf life of chapatis to
10-12 days has been developed; Capacity variants – 600 - 3000 chapatis/h
•
In times of war and natural catastrophes and calamities like, Earthquakes,
Cyclones, Famines & Floods where large mass feeding is essential this machine
can be put to good use to prepare huge quantities hot chapatis in a lesser time
under hygienic conditions with quality comparable to home made chapatis
•
The machine can be used in large industrial canteens, institutional kitchens,
railway stations, hospitals and midday meal scheme centres, where large quantity
of chapatis are required to be produced in a short time and served fresh and hot
to the consumers
•
Housewives need more time in the current social environment, requiring them
also to take up jobs. The machine offers ready- to-eat and easy-to-carry chapatis,
saving time and drudgery in the preparation of chapatis and can be preserved &
consumed as such where cooking facilities are limited and non-existent
•
The chapatis produced from the machine can complement as ‘Food Aid’ to meet
the global crisis of malnutrition, tackling extreme poverty and hunger ensuring
that all citizens can afford the cost of basic nutrition

9. Different models of chapati making machine developed
(Capacity :60 – 3000 per hour)
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10. Customer list of some licensees
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M/s Neoconcept Enterprises
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Acharya Institute – Bangalore,
Air Force Technical College, Bangalore.
Biocon India Ltd., - Bangalore.
BMS College – Bangalore.
Deloitte Consultancy, Hyderabad.
Ghousia College of Engg, Bangalore,
Intuit India Product Development Centre,
Bangalore.
INS Mandovi, Goa.
IISST - Trivandrum, 2machines.
MVIT College, Bangalore,
New Baldwin Residential School, Bangalore.
Om Shanti Dhama Gurukul, Sangam -Bangalore
RNS Institute – Banglore.
REVA Institute - Bangalore,
Sri Ramakrishna Vidyalaya– Bangalore & Mysore.
Sri Venkateshwara Education Society, Bangalore.
Siddaganga Institute of Technology, Tumkur.
Sri Siddhi Vinayaka Residential School,
Kundapur, Udupi.
Shaheen college, Bidar.
Shranabasaveshwar residential School,
Gulbarga,
Sapthagiri Egg College, Bangalore.
1Sri Channabasveswara College, Bhalki Bidar.
Tata Consultancy Services, Hyderabad.
Vydehi Institute of Medical Sciences, Bangalore
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M/s Durai Engineering Products
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Avinashalingam Deemed University,
Coimabatore
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Subaramaniam Catering Service, Tenkasi
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Durooverseas Trading House, Coimbatore
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Mohan Food Industries, Mangalore
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Hotel Geetham, Pondicherry
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KSB Pumps Limited, Coimbatore
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INS Vendirutti, Kochi
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Kongu Engg. College, Erode
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St. Michaels Engineering College,
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Sivaganga
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South Western Railway Workshop,
Mysore
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Police TrainingAcademy, Mysore
M/s Vasanth Engineering Works
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Amritanandamayi Mutt, Kollam
Wipro Technologies, Bangalore
MTR Food Products, Bangalore
Link Middle East Ltd. Dubai
Elite Breads Pvt Ltd. Thrissur
Ashok Leyland Limited, Hosur
The Hindu Canteen, Chennai
The Mysore Paper Mills Limited Bhadravathi
Laxmi Enterprises, Goa
Ajit Insutreis, Bangalore
Taj Industreis, Pune
Ittina Community Kitchen Limited, Bangalore

11. Commercialization and Societal Activities
Chapatis prepared Uttrakhand relief victims

12. Commercialization and Societal Activities

13. A movie clipping showing the working of the machine at a
staff cafeteria
Click on the video clipping to play