Transcript VALUE ADDITION TO FRUITS AND VEGETABLES

VALUE ADDITION TO
FRUITS AND VEGETABLES
DR.V.VIJAYA LAKSHMI
ASSOCIATE PROFESSOR,
DEPARTMENT OF FOODS & NUTRITION,
COLLEGE OF HOME SCIENCE,
HYDERABAD –4
E mail : [email protected]
Introduction:
With the continuous increase in the population, efforts are required to feed
additional 15million people every year.
enhancing food production does not answer this problem because all foods
particularly fruits and vegetables are perishables and seasonal.
unless excess production is processed and preserved, it will be wasted.
today only 1.0% of the total fruits and vegetables produced are processed in the
3000 food industries in the country.
 although India is the second largest producer of fruits and vegetables only 2%
is being commercially processed wastage is estimated to be very high and value
addition is constrained by long chain with too many intermediaries making scale
efficiencies difficult.
Introduction:
much progress has been made in the last two to three decades
regarding the development of processed fruit and vegetable
products.
considerable amount of research and development has been
carried out in research institutions, universities, experimental
stations to standardize varieties, post harvest handling, storage,
transportation, processing, product development, packaging etc.
some of these process technologies and products have
considerable potential for establishing fruits and vegetable industry
in rural areas.
Introduction:
 some of these process technologies and products have
considerable potential for establishing fruits and vegetable industry
in rural areas
In India the food processing is divided into organized and
unorganized sectors. The food processing industry depends upon
agricultural production for supply of raw material and so far the
country has been self sufficient in this aspect.
food industry contributes 18% GNP and employs 1.5million
workers i.e., about 20% of our industrial labour.
 In India, the value addition of food production is only 7%
compared to 23% in China, 45% in Phillipines or 188% in UK
Introduction:
there are two types of procesed foods :
a. Basic foods such as atta (wheat flour), milk, poultry etc.
b. Niche products such as breakfast cereals, jams, sauces etc.
to be competitive in the market whether national or
international, we will have to keep updated about new developments
in food industry abroad, innovate and do R&D to bring un value
added convenient products which should be made available to the
consumer at affordable prices.
Introduction:
the continuous thrust shall be to reduce cost, improve quality,
improve convenience so as to attract consumers to buy.
whenever the price of tomatoes sky rocket, people start
purchasing tomato puree in tetra packs. Otherwise there is no
demand which clearly shows that the prices of the products should
be in tune with market prices of fresh produce to attract consumers.
to be successful, one should not consider preservation as the only
reason for processing. Processed food products have to give
something extra to the consumers and it will have to be explained
and convinced. In season, processed food products have to show
benefits to counter higher prices.
Let us see the various methods of food processing and the
recent trends:
1. Food irradiation : This is a new addition to the methods of food
preservation. It is an effective and safe method in which food is
exposed to ionizing energy under controlled conditions. Irradiation
does not leave any residue in food like chemicals and hence it is safe.
It is cleared in more than 40 countries.
•food irradiation inhibits sprouting in tuber and bulb crops
•delays ripening of fruits eg. Banana
•extends shelf life of meat and meat products
•increases food safety by eliminating non spore forming
microorganisms
• decontaminates spices such as black pepper, red chillies, other
whole spices and spice powder without affecting their aroma
•sterilizes meat and meat products in frozen state packed in
laminated pouches which can then be stored at ambient for long
time.
•generally no nutritional losses take place.
Food irradiation is going to become a very important method of food
preservation in future.
2. Non thermal processes for food processing
a. Membrane technology : Mainly used for water treatment and
waste water treatment. Different types of membranes and
membrane systems have been developed. Nano-filtration, ultra
filtration and reverse osmosis separation processes use membrane
technology. Ultra filtration membranes are widely used in food
industry applications.
Saves huge energy while concentrating fruit and vegetable juices.
For initial concentration membrane technology is used and final
concentration heat processing is used. It saves energy as well as gives
better quality product due to reduced heat treatment.
b. Pulsed electrical fields (PEF): cool pulsed electrical field process developed by
pure pulses technology for antimicrobial treatment of liquids and pumpable foods
results into improved flavor and nutritional properties, extended shelf life and
destruction of both spoilage organisms and pathogens.
c. Ultra high pressure (UHP): used to pasteurize fruit juices for 2 minutes at
60,000 psi. It can handle particulates up to half inch size.
3. Food preservation through packaging innovation :
Controlled modified atmosphere (CA/MA) storage and packaging has emerged as
most significant food preservation technology. This is called modified atmosphere
packaging (MAP).
It extends the shelf life of the product. It does not require any additives and
involves nil or least processing.
4. Enzymes in fruit processing industry :
Enzymes make things happen and at a faster rate. They breakdown
components to make something more useful. Enzymes are used for
cheese making, by citrus processors to decrease viscosity of
concentrate, to increase yield of fruit juices, to dissolve albedo
portion of citrus fruit, to make gelatin from cattle hide, broth and
broth flavors from chicken carcasses.
5. Fabricated foods :
To increase the quantity and variety of foods available to man. Food
fabrication means to put together various nutrients in the desired
proportion and imparting to such a composite, organoleptic qualities
through the use of additives and suitable processing. Results in
development of more economical substitutes of analogs eg.
Margarine to replace butter, textured vegetable protein, soy milk
equivalent to dairy milk.
Fabricated foods are developed to meet the needs of metabolically
handicapped eg. Eggless mayonnaise, lactose free food based on soy
protein, non nutritive sweetners etc.
6. Hurdle technology of food safety :
A combination of factors like pH, temperature etc successively
weaken the target micro organisms thus keeping them under control.
It is often seen that combination of hurdles will act synergistically at
concentrations much lower than those used singly. The usefulness of
hurdle technology lies in the fact that it is possible to achieve high
levels of safety assurance using relatively mild combination
treatments. This allows for the development of fresher, more natural
foods with desired organoleptic characteristics.
7. Heat processing:
In India, major thrust in fruits and vegetables processing is by heat
processing i.e., canning and dehydration. Major units for fruits and
vegetables processing in India is canning.
A. Asceptic packaging : a new technology for asceptic packaging i. e.
processing of fruit juice / concentrate that entered India, is Bag-inBox filling method where a sterile product is filled in sterile pack
under sterile conditions
B. Dehydration : dehydrated products like onion, egg powder,
tomato powder etc did not succeed as yet but only baby foods plants
worked well.
Freeze drying where the product is first frozen and then dehydrated
by applying vacuum is becoming popular because it gives an
excellent quality product.
6. Refrigeration processing :
Freezing technology for fruits and vegetables was used since last 25 years .
Popular for green peas and mango pulp. Method of freezing used is blast freezing.
Now it is Individual Quick Freezing (IQF). In this each piece is frozen by
fluidization. Results in s better quality product. Used
Some value added products of fruits and
vegetables
Fruit Toffees
Fruit Toffee is a highly nutritious product as compared to
sugar boiled confectionery. It is made from pulp of mango
and other fruits along with certain ingredients. Small and
cottage scale manufacture of fruit toffee provides potential
avenues for self employment in the area where the fruits
are available. Although fruit toffees are being made in the
organized sector, there exists a vest potential for cottage
scale production also
Fruit Bars
Fruit bar is a concentrated fruit product
meant for ready consumption. It has a good
shelf life. Any variety of pulpy fruits, e.g.
mango, guava, papaya, banana, apple etc.
singly or in combination can be used for
manufacture. Fruit bars are becoming
increasingly popular due to good shelf life,
taste, flavour and texture.
Fruit Jams and Jellies
These products are prepared by boiling the fruit
pulp with sufficient quantity of sugar to a
moderately thick consistency. The popular varieties
of jam are pineapple, mango, mixed fruit,
strawberry, grape, apricot and among jellies, guava
and apple. The product is used as a bread spread
and is also taken along with chapati, puri or similar
products. Jams, jellies and marmalades share
approximately 17% of the total processed fruit and
vegetable products.
Improved Murabba Making
Murabba is one of the indigenous sweet
preparations of the country. Murabba made from
amla, bael, myrobalan, carrot, apple, mango, citrus
peels are quite popular. The traditional method of
the preparation requires a long processing time and
does not ensure good keeping quality for the
product often spoils due to miocrobial
fermentation. The method has been improved to
obtain murabba in a shorter period with good
keeping quality, attractive translucent appearance
and desirable texture.
Tutty Fruity
Fruits generally used for making preserves/
candies are apple, amla, papaya, mango,
strawberry, raspberry, pear, cherry, etc.
Among these raw papaya is largely used to
make tutti-fruity used in bakery products,
sweetmeats, ice creams, salads and pan.
The candied fruits and vegetables are quite
popular food items. The consumption of these
products is rapidly increasing
Osmo-air dried Fruits
Osmo air- dried fruits are based on a novel approach towards
dehydration. Slices of ber, pineapple, jackfruit, mango, etc. are
processed in two stages. The first phase is the removal of most of the
water using sugar syrup as an osmotic agent. The second phase is air
drying where the moisture content is further reduced to about 15%.
The osmo-air dehydrated product is near to the fresh fruit in terms
of colour, flavour and texture. The product can be used in ready -to –
eat type foods, ice cream, fruit salad, kheer, cakes and bakery
products. Such osmo-air dried fruit based units can be set up in
areas near fruit orchards to the benefit of people. The process is
simple and involves operations like selection of fruits, cleaning,
washing, peeling, curing and slicing/ dicing. The prepared fruit slices
are steeped in sugar solution to remove water by osmosis. The slices
are then drained, dried in a hot air drier and packed in flexible
pouches.
Grape Raisins
Dried grapes are used in various food preparations and
considered as a delicacy for direct consumption.
Manufacture of raisins can be an important industry in the
grape growing areas. An improved method has been
developed which can easily be adopted. The process
consists of washing, alkali treatment, sulphitation, drying
in sun or in dehydraters.
Any grape variety with high sugar and low acid content
can be used yielding a good quality product. No
sophisticated equipment is needed and the unit can be
installed in orchards. It can generate rural employment.
Dry Apricots
Apricot is an important fruit cultivated in the
temperate regions. The dry fruit forms an
important item of confection. The fully ripe fruits
are harvested item of confection. The fully ripe
fruits are harvested and placed in a wooden
sulfuring chamber wherein yellow sulphur is burnt
at the rate 4g/kg fruit. Sulfured fruits are dried in a
solar drier for 5-7 days till the moisture content is
about 17%. The dry fruits are packed in polythene
bags for storage and marketing
Dehydrated Vegetables
Vegetables are seasonal and perishable. Dehydration is one
of the methods to preserve them and make available
throughout the year in hygienic conditions at reasonable
cost. The dehydrated vegetables are easy to transport and
cater to the needs of large catering establishments. They
can be used in various preparations at any season of the
year. Traditional sundrying is time consuming, less
hygienic and climate dependent.
The process for controlled dehydration of vegetables
consists of grading/ sorting, washing, peeling/ trimming,
size reduction, blanching, Chemical treatment,
dehydration and packing in unit can be established.
Anardana
The seed with adhering pulp (arils), when dried yields
Anardana of commerce. The traditional method consists of
manual extraction of arils followed by sundrying. It is
unhygienic, labour intensive and slow. The product cannot
be stored beyond the following monsoon season since
spoilage occurs due to discolouration, moisture ingress and
insect infestation.
The improved processing technique consists of precleaning, mechanised extraction of arils, solar drying and
packaging. The mechanised aril extractor works on ¼ HP
motor and can process 60 kg fruit/hr as compared to
productivity of 5 kg/hr in manual operation.
Prepackaging of fruits and Vegetables
This simple technique involves cleaning, trimming, cutting
of the fresh produce and packing the same in unit
packages in polyethylene bags. Bean, carrot, brinjal, green
chilli, root crops, leafy vegetables, and fruits like orange,
lemon, banana, grape, and flowers like champaka,
chrysanthemum can be prepackaged to obtain 1 to 2 times
extension in shelf life in polyethylene bags under normal
conditions without any refrigeration. The prepacked
produce presents better consumer appeal, longer shelf life
and has considerable handling advantages in transport
and marketing. The major facility required at the farm
level or in orchards is a packing shed.
Wax Emulsion for Fruit & Vegetables
A large number of units in tiny sector can be set up for
improving the shelf life of fresh fruits and vegetables in
villages where they are grown for marketing in the urban
areas.
The wax emulsion is diluted with cold water and used for
dipping fruits and vegetables. It enhances the shelf life,
protects fruit from fungal attack, and reduces desiccation
and weight loss during storage. The emulsion is harmless
and imparts a gloss to fruits and vegetables. The process is
quite simple and economical.
Evaporative Cool Stores
Evaporative cooling system is a simple and cheap method for short
term storage of fruits and vegetables. It does not depend on
conventional energy sources.
A 170 litre capacity EC chamber has been designed and tested. The
special features are dripping system for water, compactness, easy
loading and unloading through door and recycling of water. During
summer months the system maintained a 20-25oC temperature and
90-95 % RH as compared to ambient conditions of 23 –38oC and 3075.5 RH.
The shelf life of commodities is extended upto 20% in EC storage.
The freshness is well maintained due to the high humidity
environment. EC stored tomato and banana develop better colour
and uniform ripening. This system can also be used for various other
purposes like horticulture, plant propagation, mushroom cultivation,
fermentation, sericulture, etc.
Anti fungal Paste
The banana bunches after harvests are cut into banana hands or
clusters. The cut ends get infected. To check this spoilage, an
antifungal paste has been developed. It is harmless and produces no
undesirable odour or flavour.
The latex oozing out from the cut ends is washed in running water
and wiped. The dry cut ends are treated with antifungal paste with
the help of a paintbrush. The paste sticks well and dries in 20-40
minutes in the open air. It protects the cut ends of the bananas for a
period of 15-17 days at room temperature and 21-32 days at 13oC
while untreated cut ends show fungal rotting on 5th day room
temperature and 10 day in cold storage. This antifungal paste
application reduces infection during ripening also. For its
manufacture the ingredients are mixed in a dough mixer to get a
uniform paste. A food colour is also added to the paste to acertain
the treatment of cut ends. The cost of the paste works out minimum
economic unit is 25 kg paste/ batch of 90 min.
Improved Method of Mango Ripening
Mangoes are generally harvested when fully matured but green. The
conventional method of ripening in hay has disadvantages like long
ripening time, excessive handling and high degree of spoilage due to
stem- end rot. The spoilage during ripening period is reported to be
as high as 25 to 30%. In order to improve upon the ripening method,
a simple technique has been worked out. It consists of dipping the
fully matured but green mangoes in hot water at 48 to 54oC for 5
minutes, draining and keeping at room temperature till adhering
surface water evaporates. Fruits are then packed in ventilated boxes/
crates. No hay or other packing material is needed. The ripening
generally starts on 6th day of treatment and is complete on 12th day.
The operation can be made continuous in fruit processing factories
where large quantities of mangoes are handled. The technique has
presently been standardized for Alphonso variety. The hot water
treatment is found to reduce the spoilage to the extent of 50% and
also helps in uniform ripening of fruits. The colour development in
the flesh is better than conventionally ripened fruits.
Pickles and Chutneys
Pickles and chutney have a great importance in the Indian
menu and have now become essential items in any feast
and lunch. Pickling of fruits and vegetables is an old art. A
large variety of these items are method of preparation
varies. The basic method is salt curing of fruits and
vegetables, acidifying, addition of vinegar / oil and the
spices.
Instant Pickles
The traditional pickle making involves elaborate and time
consuming process. A new concept has been worked out for making
an instant pickle mix of lime and mango, which can easily be
reconstituted, into a tasty pickle by the simple addition of oil and
water. The dry mix has the features of convenience, better keeping
quality, relatively low cost of production, reduced packaging and
transportation cost. The ever expanding market for pickles, both in
domestic and export sectors, can be exploited by adopting suitable
market strategies.
The process is simple and consists of the selection of fully matured
commodities for picking, washing, and cutting matured commodities
for pickling, washing and cutting, brine curing at optimal conditions,
drying, addition of dry spice mixes and packing in unit packages.
Potato Flour
Many ready –to -eat products are prepared from potato. Units based
on potato products can easily be established in rural areas and the
market can be exploited in urban and semi urban centres.
Potato flour, granules and mash are used in the preparation of
instant foods, soups etc. as binding materials and also for preparing
kheer, tikki, chops, pakoda, cutlets, stuffed parotha, kofta and other
products. Production of potato flour can be taken up easily using
indigenous equipment’s. The process involves peeling of potato,
cutting, pre-treatment with salt and permitted preservatives,
soaking, granulating and drying. The dried product is ground and
packed. The flour obtained by this process can be easily
reconstituted with boiling water to get the mashed potato and used
for making a variety of products
Potato Chips
Potatoes are grown extensively in the northern region of India.
During the glut season, growers do not get remunerative prices.
Therefore it is advisable to utilize the surplus produce by preparing
potato chips under hygienic conditions.
The product based on developed sun drying technology is superior to
the conventional one both in colour and quality. The process is
simple and can be easily adopted at rural areas
Potato Wafer
Potatoes are grown extensively in the northern
eastern region of India. During the glut season,
growers do not get remunerating prices. Therefore
it is advisable to utilize the surplus produce by
preparing potato chips under hygienic conditions.
The product based on developed sun drying
technology is superior to the conventional one both
in colour and quality. The process is simple and can
be easily adopted at rural level.
Mushrooms
Mushrooms are fruit bodies of fungi that grow abundantly in the
open fields, meadows, marsh edges, farm, yards etc. Some wild
mushrooms are poisonous and narcotic but there are about 2000
edible spices too.
Technologies have been developed for commercial cultivation of
mushrooms under controlled conditions. These are safe and readily
available for the market. Mushrooms are rich sources of easily
digestible protein and minerals, besides being low in calories and
almost fat-free. Profitable mushroom cultivation can be taken up in
the rural areas where agro-waste is easily available. Its cultivation
can provide gainful employment. Mushrooms are highly perishable.
The unmarketable surplus of fresh produce can be preserved and
processed into value added products by canning, dehydration, brine
preservation, conversion into pickles, soup and ketchup in small
scale processing units near the site of production.
Papain
Papain is obtained from the latex of unripe green papaya fruit. It
contains proteolytic (protein digesting ) enzyme. Papain finds wide
applications in different industries. It is used in tenderisation of
meat, manufacture of protein hydrolysate, confectionery items (to
prepare chewing gum), brewing industry (for cheese making). It is
also used in the pharmaceutical, textile, tanning, aroma and perfume
industries and for effluent treatments. Organised papaya
Planatations can be taken up in the rural areas.
The process consists of tapping of latex from papaya fruits, mixing
with potassium metabisulphite and storing under cold temperature.
The latex is refined, vacuum dried and powdered. After testing and
standardisation, it is packed and placed in rigid airtight containers.
Tomato Products
Tomato is extensive grown in India and used for the
preparation of puree, paste, ketchup, sauce and ready- to-
eat products. There is a good domestic and export market.
Since the fast food sector is expanding rapidly the demand,
particularly for tomato ketchup and sauces, is also
increasing
Value added products from bottlegourd:
sweet pickle, hot pickle, tuity –fruity
Low fat bhajias and samosas, aonola supari, safal fruit juice,
Value added products from banana :juice, ripe banana
powderm value addition of banana peel, amylase production,
low fat cheese, all in one spice powder
Mango powder rich in ß-carotene was developed from
baneshan, suvarnarekha and totapuri and their blends
Factors influencing purchasing behaviour of processed foods:
-among sensory attributes, consumers consider color, flavor, and
texture in ghee. In cheese and milk powder, flavor was considered
important.
- an exposure to mass media appeared to be a very important factor
influencing the purchase of health drinks
- the vegetable products purchased by the survey population were
pickle, ketchup and tomato sauce.
-convenience foods/ instant foods require little or no preparation and
save considerable time on cleaning the preparation area along with
variety and high quality i.e., taste, nutrition and safety.
-purchase of baked products is to save time.
Conclusion:
India produces around 150 million tonnes of fruits and vegetables,
but the annual wastage is estimated at Rs. 100 billion, according to a
government task force.
"India wastes more fruits and vegetables than are consumed in a
country like Britain," said the report presented to Union Agriculture
Minister Ajit Singh.
To reduce wastage, fruits and vegetables have to be handled
carefully and post harvest handling and packaging facilities should
be improved, the report states.
Conclusion:
The report says lack of cold chain at the farm level remains a major
problem. It has advised cutting out all rough edges in handling fruits
and vegetables to cushion the produce against damages.
The poor handling of farm produce has led to only 1.8 per cent of
fruits and vegetables being processed for value addition. Farmers
are short changed, while consumers pay almost seven times more
than what farmers receive.
"All this is epitomised in the low level of processing, which is
substantially lower than that of our Asian neighbours," it states,
citing the case of Thailand that processes 83 per cent of produce and
the Philippines (78 per cent).
Conclusion:
To reduce wastage and improve delivery to customers, the task force
has suggested setting up agriculture cooperatives on the lines of the
Gujarat Co-op Milk Marketing Federation, which heralded India's
milk revolution.
What can be more relevant for India would be a better marketing
network.
"Both the system in South Korea and our own milk marketing
system have demonstrated how co-operatives can play a useful role
in streamlining the distribution system and reducing distribution
costs but also providing an extension for farmers," the report states.
India has estimated an investment need of Rs 1,400 billion over the
next decade to increase value addition from the current two to 10 per
cent and to generate employment for 30 million people.