Processing of cereals and millets

1. Processing of Cereals
A.Poshadri
M.Tech (Food Tech.)
Assistant Professor
Department of Food Technology
Prof. Jayashankar Telangana State Agriculture University
Email: poshadri_fst@yahoo.co.in
Cell No: +919492828965

2. Introduction
Cereals are staple foods, and are
important sources of nutrients in both
developed and developing countries
Wheat, rice, and corn are the major
important grains in the human diet.
The minor grains include oats, barley, rye,
triticale, sorghum and millets
Cereals grains are rich sources of fibre,
vitamins, minerals, and photochemicals

3. • After harvest, correct storage of the grain is
important to prevent mould spoilage, pest
infestation and grain germination
• Dehusking (Dehulling) and Milling are the
main processing techniques associated with
cereals

4. Cereals and Millets
– Sorghum
– Maize
– Foxtail Millet
– Pearl Millet
– Finger Millet
– Kodo Millet
– Little Millet
– Proso Millet
– Barnyard Millet

5. Production status
Crop Production (Million Tonnes)
(2012-2013)
Rice 101.8
Wheat 92.2
Sorghum 5.2
Maize 21.0
Pearl Millet 8.1
Finger Millet 1.7
Small Millets 0.4
Ref: Ministry of Agriculture, GOI

6. Nutritional composition
Crop Protein
(g)
Fat
(g)
Fiber
(g)
CHO
(g)
Minerals
(g)
Iron (mg) Calcium
(mg)
Rice raw
milled
6.8 0.5 0.2 78.2 0.6 0.7 10
Wheat 11.8 1.5 1.2 71.2 1.5 5.3 41
Sorghum 10.4 1.9 1.6 72.6 1.6 4.1 25
Maize 11.1 3.6 2.7 66.2 1.5 2.3 10
Foxtail Millet 12.3 4.3 8.0 60.9 3.3 2.8 31
Pearl Millet 11.6 5.0 1.2 67.5 2.3 8.0 42
Finger Millet 7.3 1.3 3.6 72.0 2.7 3.9 344
Kodo Millet 11.0 3.6 10.0 66.6 1.9 0.5 27
Little Millet 7.7 7.6 1.5 9.3 27
Proso Millet 12.5 4.2 2.2 73.0 1.9 0.8 14
Barnyard 12.2 3.85 10.1 55.8 3.2 1.4 24

7. Maize
• It is a cheap form of starch and is
a major energy source for animal
feed
• Commercial important varieties
of maize are
1.dent maize (identified by the
dent in the crown of the kernel);
2.flint maize (hard, round kernels);
3.sweet corn (a dent-type maize);
4.popcorn (flint-type maize which
expands when heated).

8. Sorghum
•It is an important food crop in
sub-Saharan Africa on account
of its drought tolerance
•Low glycemic index and
increase satiety
•Gluten Free foods

9. Foxtail Millet
• Foxtail millet (Setaria italica) is one of the important food
crops in parts of the Indian subcontinent, African countries
and China. Telugu : Korra
• Foxtail millet ranks second in the total world production of
millets.
• Foxtail Millet contains 9–14% protein, 70–80% carbohydrates
and is a rich source of dietary fiber.
• It contains maximum amount of chromium among all the
millets with an account of 0.030mg per 100g.
• Foxtail Millet is a starchy food with a 25:75 amylose to
amylopectin ratio. Lipids are 3-6%having about 50% of the
lipids in the form of polyunsaturated fatty acids

10. Pearl Millet
• India is the largest` producer of pearl millet in Asia, both in
terms of area about 9 million ha and production 8.3 million
tons. Telugu : Sajja
• A pearl millet grain comprises about 8% pericarp, 17% germ
and 75% endosperm .
• Pearl Millet Protein 7.3, Fiber 3.6,Minerals 2.7, Iron 3.9,
Calcium 344 .
• Pearl millet for increasing its acceptability as ready to serve
break-fast food and improving rural economy and health of
rural people .

11. Finger Millet
• Finger millet(Eleusine coracana (L.) Gaertn.) is originally
native to the Ethiopian highlands and introduced into
India approximately 4000 years ago. Telugu : Ragi
• The major producers are Uganda, India, Nepal, and
China.
• Finger millet has high yield potential and grain stores
very well.
• In Indiais cultivated on 1.8 million ha, with average
yields of 1.3 t/ha. The major finger millet growing states
are Karnataka, Andhra Pradesh and Tamil Nadu.

12. Kodo Millet
• Kodo millet (Paspalum scrobiculatum) was domesticated in India
almost 3000 years ago.
• Telugu : Arikelu, Arika
• Kodo millets also contain high amounts of polyphenols, an
antioxidant compound
• The fiber content of the whole grain is very high. It contains 11%
protein and 10% fiber.
• Kodo millet is a nutritious grain and a good substitute to rice or
wheat

13. Little Millet
• Little millet (Panicum sumatrense) was domesticated in India.
• Telugu : Samalu
• Little millet is another reliable catch crop in view of its
earliness and resistance to adverse agro-climatic conditions.
• The stover is a good fodder for cattle.

14. Proso Millet
• Proso millet (Panicum miliaceum L) was domesticated in
Manchuria and introduced to Europe about 3000 years ago.
• Telugu : Variga
• Proso millet is well adapted to many soil and climatic
conditions.

15. Barnyard Millet
• Barnyard millet (Echinochloa colona) is the fastest growing of
all millets and produces a crop in six weeks.
• Telugu : Udalu, Kodisama
• It is grown in India, Japan and China as a substitute for rice
when the paddy crop fails.
• plant has attracted some attention as a fodder in the United
States and Japan.

16. Sector-wise Number of Registered Food Processing Units

17. • Gluten free
• High fibre
• Diabetic foods
• Mineral rich foods
• Multi benefit foods
• Food for life style diseases

18.  Coarseness , colour and overall appearance
 Considered as staple of food of poor
 Difficulty in processing at domestic level
 Non-prestigious
 Non availability of ready to use or easy to
cook foods from millets in the market
 Govt. subsidy to fine cereals

19.  Growing NCD population
 Growing health –conscious population
 Surge in consumption
 Stagnant production
 Likely shortages
 Likely higher prices
 Possibility of importing
Over the past few years, output
has remained stagnant and
there is an urgent need to
promote cultivation of these
crops
( annual economic survey,
prepared by the finance
ministry, India)

20. • Dehulling technology is available for various
capacity dehulling fabrication of machine is
possible
• Whole grain flour
• Dehulled grain flour
• Coarse rawa
• Semolina

21. • Fermented flour and rawa
• Germinated rawa and flour
• Autoclaved rawa and flour for RS3 enhancement
• Composite flours

22. Value-Added Supply Chain
• Excellent food products can be and are made from millets.
The value-added supply chain includes
• Seed supplier (seed production) - quality and purity
• Grain producer
• Harvesting
• Storage
• Handling and transportation
• Processing into products
• Marketing

23. Milling
• The millet was decorticated in pilot-scale rice milling
machinery with suitable adaptations.
• Husking was done in a centrifugal sheller.
• The husked material was debranned in a horizontal emery
cone according.
• The husk and the bran fractions together (seed coat material)
formed 26% of the millet

24.  The process involves grain hydration followed by steaming and
pressing of the grains.
 The grain is soaked to its equilibrium moisture content and is
steamed or roasted to gelatinize the starch and dried to 18%
moisture , conditioned decorticated and then flaked by passing
through an edge runner.
 Thick flakes can be deep fried or dry roasted and this can be used for
uppitu after boiling and seasoning.
 These can be coated with any desired additives for value addition
 Since wet cooking slows down the digestion this feature can be
exploited for preparation diabetic foods at industrial scale

25. Flakes

26. Ref: Dept of food science technology, Kasetsart University, Thailand

28. Mechanical popping can be
done by equilibrating the
grain to 16% moisture and
then exposing to 230 ºC for
a fraction of a minute.
Special millet varieties are
required for popping.
The varieties with hard
endosperm with medium
thick peri carp are suitable.
Some states in India, popped
sorghum and millets are
being marketed.
Can be used for further
value added products like
break fast bars, snack bars
by combining with protein
rich foods

29. • Popped grain
• Chudwa
• Payasam
• Punugulu
• Teepithalikalu
• Laddu
• Barfi
• Muruku
• Pappu Chekkalu
• Namakpara

30. Extrusion process
Different grain flours
Blending (composite flour, 70: 30)
Conditioning (moisture adjustment)
Extrusion cooking
Extrudates
Drying
Cooling
Packing in HDPE bags

31. Cereal and Millets based products
• Crispies
• Cookies
• Cake
• Idly mix
• Dosa mix

32. Sorghum/Pearl millet crispies
Raw materials
(Sorghum/Pearl millete flour and Optional ingredients)
Composite flour preparation
Pre conditioning(moisture adjustment)
Extrusion cooking
Drying of Crispies
cooling
Oil spraying and spicing
Packaging
Storage

33.  Common bakery products such as biscuits , cakes and bread
were prepared and tested using. Dehulled sorghum or millet
grain and milled flour of finer particle size is most amenable for
production of these products.
 Incorporation of 20-30% refined wheat flour produces a product
acceptable on par with wheat biscuits .
 Many tastes can be created
Coconut
Bakery Products

34. Preparation of Cookies

35. Preparation of Cake

36. Preparation of idly mix:

37. Instant Dosa mix

38. Noodles

39. Pasta
Mixing of Wheat flour and Millets
Dough Preparation
Extrusion
Drying
Packaging

40. Vermicelli
Mixing of Wheat flour and Millets
Dough Preparation
Extrusion
Drying
Packaging

41. Flavorings

42. Milk Protein Enriched SnacksMilk Protein Enriched Snacks
Extrusion Cooking
process reduced the
level of phytate as
well.

43. Manufacturing process for Composite milk-Millet RTEManufacturing process for Composite milk-Millet RTE
BreakfastBreakfast
Ground millet Sweeteners Salt
Cooking
Water
Drying (22-250
C)
Flaked cereal
Toasting 150o
C, 25 min
Lump breaking (1-2 cm)
Flaking
Drying (22-250
C)
Dried Powder
Milk
Milk-Millet Slurry
Gelatinization
Drying of Slurry
RTE Composite Breakfast

44. Process for Manufacture ofProcess for Manufacture of Bajra LassiBajra Lassi
Water
Heating
Addition of Stabilizer
Addition of Salt & Spices
Heating
Cooling
Milk
Pasteurization
Addition of Bajra Flour
Heating
Cooling
Incubation
Curd
Mixing
Filling Bajra Lassi Storage

45. Pearl Millet based Raabadi-like Beverage
(Bajra Lassi)
Total Solids
Fat
Protein
Carbohydrates
Ash
Moisture
Acidity (% LA)
8.74
0.65
2.40
4.57
1.28
91.26
0.60
Chemical Composition
Suitable bacterial starter have been
developed that can ferment milk as
well as cereal solids
Process of fermentation reduced the
level of phytate and improved the
bioavailability of minerals

46. Conclusion
• World over increasing number of NCD is leading
to Commercialization of millet products is the
need of the hour
• Ready-to- eat food industry should come
forward to provide a healthy food to the
mankind keeping in view the changing
demography
• Public private partnership helps for better
commercialization
• Farmer encouragement

47. Better Millet Thank you for Your
Kind Attention