Introduction to food processing

1. FOOD TECHNOLOGY

2. Unit-I
Processing of Food & its importance

3. Food Processing in India
The Indian food processing industry was valued at €
92 billion in 2005, a growth of 10% over the previous
year.
Indian food processing industry is becoming an
attractive FDI destination; it attracted around €
790million FDI during 1991-2005 which is 3.3%
of total FDI inflow in India.
The Food Processing Industry sector in India is one of
the largest in terms of production, consumption,
export and growth prospects.

4. Sectorial Overview
India has arable land of 184 million hectares and produces annually 90
million tonnes of milk
150 million tonnes of fruits and vegetables
485 million livestock, 204 million tonnes food grain
6.3 million tonnes fish, 489 million poultry and 45,200 million eggs
processing level is very low i.e. around 2.20% in fruits and vegetables, 35%
in milk, 21% in meat and 6% in poultry products
India's share of processed food is about 1.6%. Hence, there is immense
potential for growth in this sector.

5. Fruits and Vegetable Processing
 The capacity of fruits and vegetables processing increased from 1.1million tons in 1993 to 2.1
million tons in 2006.
Meat and Meat Processing
 Present processing level of buffalo meat is estimated at 21 %, poultry 6 %, and marine
products 8 %.
Dairy Processing
 Milk production is over 90 million tonnes. Per capita milk consumption is 75 Kgs.
Fish Processing
 Long coast line of over 8000 kms., 50600 sq. kms of continental shelf area and 2.2 million sq.
km. of exclusive economic zones, India is rich fishery resources.
Consumer Food Industries
 Production is about 4.00 million tons per year.
 During the year 2005-06, financial assistance was sanctioned by Ministry of Food Processing
for 27 consumer food-processing units.
 The total inflow of FDI in FPI sector up to 2005-06 was € 958 million

6. • Food is any substance consumed to provide nutritional support for the body. It is
usually of plant or animal origin, and contains essential nutrients, such as fats,
proteins, vitamins, or minerals. The substance is ingested by an organism and
assimilated by the organism's cells to provide energy, maintain life, or stimulate
growth.

7. Food in the World
• 30,000 plant species with parts
people can eat
• 15 plants and 8 animals supply 90%
of our food
• Wheat, rice, and corn are half the
calories people eat
• 66% of people eat mainly rice, wheat,
and corn (grains)
• The top third of the economic chain
eats primarily meat.

8. Why process foods?
 Prevent, reduce, eliminate infestation of food with microbes, insects or
other vermin
 Prevent microbial growth or toxin production by microbes, or reduce
these risks to acceptable levels
 Stop or slow deteriorative chemical or biochemical reactions
 Maintain and/or improve nutritional properties of food
 Increase storage stability or shelf life of food
 Make food more palatable and attractive
 Make foods for special groups of people

17. SOURCES OF FOOD
Plant origin

18. • Plant origin
• Animal origin
• Microbial origin
• Some foods not from animal or plant sources include various edible fungi, especially
mushrooms. Fungi and ambient bacteria are used in the preparation of fermented
and pickled foods like leavened bread, alcoholic drinks, cheese, pickles, kombucha,
and yogurt. Another example is blue-green algae such as Spirulina. Inorganic
substances such as salt, baking soda and cream of tartar are used to preserve or
chemically alter an ingredient.
Some causes spoilage, without the activities of microbes there would be no bread,
cheese, beer or chocolate. Friend or foe, food microbes are always on the menu.

19. PLANT ORIGIN
• Plants give us many kinds of food. The fruits, vegetables, cereals, grains, and pulses
that we eat, and the spices that we use in cooking come from plants.
We eat many different parts of plants and we eat fruit of some plants.
We eat the root of some plants. We eat the stem of some plants. We eat the
leaves of some plants. We eat the seeds of some plants. We eat the flowers of
some plants.
We get pulses like arhar, masoor and moong from plants. We get sugar from the
sugarcane and sugar beet plants.
Chilly powder, cinnamon, clove, and saffron are some spices that we get from
plants. We use spice to add flavor to food.
Most oils are made from parts of plants like palm oil, sunflower oil, coconut oil and
mustard oil; these oils are used for cooking and other purposes.
Plants also give us nuts like walnut, cashew and almonds.

20. ANIMAL ORIGIN
• Animal foods include meat, eggs and milk.
• Animals are used as food either directly or indirectly by the products they produce.
• Eg. Meat (chicken, beef, veal, lamb, pork & fish)- Direct, Cheese & yogurt- Indirect
• Milk, eggs, honey, Some cultures consume blood, blood sausage, as a thickener for
sauces, or in a cured, salted form.
Many processed foods use a combination of foods from animal and plant sources.
Biscuits are made from flour (food from a plant) while also containing butter and
milk (food sourced from an animal).

21. CEREALS & PULSES
• Grains or cereal grains are grasses whose grain (generally from families Poaceae or
Gramineae) - provide more food energy they are therefore staple crops. In their
natural form (as in whole grain), they are a rich source of vitamins, minerals,
carbohydrates, fats and oils, and protein. Usually ground into flour, these grains
provide bread, pasta, and other staple carbohydrates essential to nutrition.
• On the other hand pulses are leguminous species producing edible seeds. primary
source of protein. The country grows a variety of pulses crops such as peas, lentils,
urad, tur, moong, yellow peas, chicken pea, pigeon pea and beans under different
agro-climatic conditions.

22. CEREALS & PULSES

23. • Fruits are more acidic than vegetables- food spoilage organisms cannot grow in
acidic environment. Vegetables are less acidic than fruits and food poisoning
bacteria are able to grow in many vegetable products.
• Processing (canning, drying, freezing, and preparation of juices, jams, and jellies)
increases the shelf life of fruits and vegetables.
• Processing steps include preparation of the raw material (cleaning, trimming, and
peeling followed by cooking, canning, or freezing. Plant operation is often seasonal
FRUITS & VEGETABLE PROCESSING

24. Classification of fruits
Depending upon physical characteristics fruits are classified as:
Sr.
no.
Category Examples
1. Berries Blackberries, Cranberries,
Blueberries, Gooseberries,
Strawberries, Grapes
2. Citrus fruits Oranges, Grapefruit, Limes, Lemons
3. Drupes Cherries, Peaches, Apricot, Plums,
Nectarines, Prunes
4. Melons Watermelon, Casaba, Persian,
Honeydew
5. Pomes Apple, Pears, Quince
6, Tropical fruits Papayas, Mangoes, Pomegranates,
Pineapples, Guava, Bananas

25. Classification of Vegetables
Vegetables can be classified as below:-
Sr. no. Category Examples
1. Earth vegetables roots Sweet potatoes,, carrots
2. Modified stem tubers Potatoes
3. Modified buds tubers Onions, garlic
4. Herbage Vegetables
Leaves Cabbage, spinach, Lettuce
Petioles(Leaf stalk) Celery, rhubarb
Flower buds Cauliflower
Sprouts, Shoots(young stems) Asparagus, bamboo shoots
5. Fruits Vegetables
Legumes Peas, green beans
Cereals Sweet corn
Vine fruits Squash, cucumber
Berry fruits Tomato

26. • dried fruit (pineapple and banana for export)
• fruit wines
• fried snacks (banana chips)
• juices
• squashes and cordials
• tomato sauce.
• jams, jellies and marmalades
• bottled fruits
• chutneys and pickles
• purees and pastes
FRUITS & VEGETABLE PROCESSING

28. FRUITS & VEGETABLE PROCESSING

29. FRUITS & VEGETABLE PROCESSING
Fermentation Pasteurization

30. • Milk- valuable nutritious food- highly perishable- short shelf-life and requires
careful handling.
• excellent medium for the growth of microorganisms – particularly bacterial
pathogens – that can cause spoilage and diseases in consumers.
• Milk processing allows the preservation of milk for days, weeks or months and
helps to reduce food-borne illness.
• Pasteurization is a heat treatment process that extends the usable life of milk and
reduces the numbers of possible pathogenic microorganisms to levels at which
they do not represent a significant health hazard.
• A number of products like ghee, butter, paneer, whey, cheese, cream, toned milk,
double toned milk, skimmed milk, can also be manufactured.
MILK

31. MILK

32. MILK

33. • Meat - animal flesh - eaten as food. Humans are omnivorous, and have hunted and
killed animals for meat since prehistoric times. The advent of civilization allowed
the domestication of animals such as chickens, sheep, pigs and cattle, and
eventually their use in meat production on an industrial scale.
• Meat is mainly composed of water, protein, and fat, and is usually eaten together
with other food. It is edible raw, but is normally eaten after it has been cooked and
seasoned or processed in a variety of ways. Unprocessed meat will spoil or rot
within hours or days as a result of infection with and decomposition by bacteria
and fungi.
ANIMAL FOOD

34. • Meat processing, also known as further processing of meat, is the manufacture of
meat products from muscle meat, animal fat and certain non-meat additives.
• Meat processing “adds value” to products. Value-added meat products display
specific flavour, taste, colour or texture components, which are different from
fresh meat.
• In meat-product manufacturing, the basic processing technologies, such as cutting
and mixing, are accompanied by various additional treatments and procedures,
depending on the type and quality of the final product. Such treatments involve
curing, seasoning, smoking, filling into casings or rigid containers, vacuum
packaging, cooking or canning/sterilization.
ANIMAL FOOD

36. • Seaweeds or Macroalgae are consumed by coastal people
• In Asia, Gim (Korean food) (김, Korea), nori (海苔, Japan), zicai (紫菜, China) are
sheets of dried Porphyra used in soups or to wrap sushi. Chondrus crispus
(commonly known as 'Irish moss' or carrageenan moss) is another red alga used in
producing food additives, along with Kappaphycus and gigartinoid seaweeds.
Porphyra is a red alga used in Wales to make laver. Laverbread, made from oats and
the laver, is a popular dish there. In northern Belize, edible seaweeds are mixed with
milk, nutmeg, cinnamon, and vanilla to make a common beverage affectionately
called "dulce" (or "sweet").
• Seaweeds are also harvested or cultivated for the extraction of alginate, agar and
carrageenan, gelatinous substances collectively known as hydrocolloids or
phycocolloids.
• Hydrocolloids have attained commercial significance as food additives. The food
industry exploits their gelling, water-retention, emulsifying and other physical
properties. Agar is used in foods such as confectionery, meat and poultry products,
desserts and beverages and moulded foods. Carrageenan is used in salad dressings
and sauces, dietetic foods, and as a preservative in meat and fish products, dairy
items and baked goods.
SEAWEED

37. SEAWEED

38. • Spirulina (Arthrospira platensis) is a blue-green microalgae high in protein and other
nutrients, finding use as a food supplement and for malnutrition. Spirulina thrives in
open systems and commercial growers have found it well-suited to cultivation. The
plants produce a variety of nutrients and high amounts of protein. Spirulina is often
used commercially as a nutritional supplement.
• Chlorella, another popular microalgae, has similar nutrition to spirulina. Chlorella is
very popular in Japan. It is also used as a nutritional supplement with possible effects
on metabolic rate.
• Irish moss (Chondrus crispus), often confused with Mastocarpus stellatus, is the
source of carrageenan, which is used as a stiffening agent in instant puddings, sauces,
and dairy products such as ice cream. Irish moss is also used by beer brewers as a
fining agent.
• Sea lettuce (Ulva lactuca), is used in Scotland where it is added to soups and salads.
Dabberlocks or badderlocks (Alaria esculenta) is eaten either fresh or cooked in
Greenland, Iceland, Scotland and Ireland.
• Aphanizomenon flos-aquae is a cyanobacteria similar to spirulina, which is used as a
nutritional supplement.
• Extracts and oils from algae are also used as additives in various food products. The
plants also produce Omega-3 and Omega-6 fatty acids, which are commonly found in
fish oils, and which have been shown to have positive health benefits.
ALGAE

39. • Oilseed presses essentially extrude or ‘press’ vegetable oil from oil-bearing seeds, which include
soybean, sunflower, peanut, safflower, canola, sesame, niger, castor bean, linseed, mustard,
coconut, olive, and oil palm to get oil and meal for food applications.
• Processing involves cleaning, sorting, dehulling, crushing, filtration, solvent extration,
degumming etc.
• After the oil is removed from the oilseed, an oilseed meal or cake remains. This valuable by-
product is especially rich in protein.
• Soy bean meal possess an excellent amino acid profile,a low fibre content,high digestibility,and
high crude protein levels ranging from 44 to 50%.soybean meal accounts for 63% of the protein
feed sources that are utilized globally.
• In addition to the meal, the oil that is procured from oilseed presses possesses nutritive
benefits. vegetable oils are composed mainly of unsaturated fats which include the essential
omega-3 and -6 polyunsaturated fatty acids.Animal-based fats, in contrast, contain saturated
fats,which are linked to cardiovascular disease.
• Different oilseed species possess unique fatty acid profiles.This same principle applies to the oil
contents of various oilseeds as well. For example, while canola typically exhibits an oil content
of around 40-45 %, soybeans consist of about 20% oil.
OILSEED

40. OILSEED PROCESSING

41. • Sugar is the generalized name for sweet, short-chain, soluble carbohydrates, many
of which are used in food. They are carbohydrates, composed of carbon, hydrogen,
and oxygen.
• There are various types of sugar derived from different sources. Simple sugars are
called monosaccharides and include glucose (also known as dextrose), fructose
and galactose. The table or granulated sugar most customarily used as food is
sucrose, a disaccharide. (In the body, sucrose hydrolyses into fructose and
glucose.) Other disaccharides include maltose and lactose. Longer chains of sugars
are called oligosaccharides.
• Sugars are naturally present in fruits and vegetables (sucrose, glucose and
fructose), honey (fructose and glucose), as well as in milk and dairy products
(lactose and galactose) and to a lesser extent in cereals (maltose)
SUGAR PROCESSING

42. • Icing sugar- baking & confectionary
• Sugar syrups- base for fruits sausages, topping & flavorings
• Can be used as a preservative
• Production of alcoholic beverages-production of wine, beer and whisky, mead and
ciders respectively.
SUGAR PROCESSING

43. • Tea- two types- Black Tea & Green Tea
• Black Tea- fermented
• Green Tea- not feremented
• Black Tea- two types- orthodox & CTC tea
• Apart from Black & Green Tea, powder tea which is known as Instant Tea
(manufactured from green tea leaves & tea waste
TEA PROCESSING

44. TEA PROCESSING

45. • Coffee production is the industrial process of converting the raw fruit of the coffee
plant into the finished coffee. The cherry has the fruit or pulp removed leaving the
seed or bean which is then dried.
• Processing of coffee involves cleaning, sorting, pulping, fermentation, drying,
filtration & concentration, extraction, drying, packing etc.
COFFEE PROCESSING

46. COFFEE PROCESSING

48. • Chocolate is one of the most favorite food in the world. It is produced by
processing cocoa.
• The process involves harvesting coca, refining coca to cocoa beans, and shipping
the cocoa beans to the manufacturing factory for cleaning, coaching and grinding.
• Cocoa mass is the main ingredient of chocolate, in the form of chocolate bars,
chocolate vermicelli, or bonbons, cocoa powder is the ideal flavouring agent in ice
cream, dairy products, bread spreads, biscuits and sweets. Cocoa provides the
finishing touch to food products ranging from special confectionary to cappuccino
coffee and is processed in numerous other food products.
COCOA PROCESSING

50. • Spices are used for flavour, colour, aroma and preservation of food or beverages.
• Spices may be derived from many parts of the plant: bark, buds, flowers, fruits,
leaves, rhizomes,roots, seeds, stigmas and styles or the entire plant tops.
• Spices are often dried and used in a processed but complete state. Another option
is to prepare extracts such as essential oils by distilling the raw spice material (wet
or dry), or to use solvents to extract oleoresins and other standardized products
• some of the names of Indian spices are clove, cinnamon, chilly powder, oregano,
fenugreek, garlic, ginger, cardamom, pepper, mint, mustard, curry leaves, nutmeg,
turmeric, fresh coriander, etc.
SPICES PROCESSING

51. SPICES PROCESSING

52. SIGNIFICANCE OF FOOD PROCESSING

53. • Typical operations using in converting raw fruits
and vegetables to processed- ingredients for
packaging and preservation or prior to a further
heat treatment processing are as follows:
• Harvesting or Gathering -- > Transport -- >
Storage -- > Washing -- > Size Grading -- > Peeling
(Removal of outer surface) -- > Size Reduction -- >
Separation of waste -- > Sorting Inspection-->
Storage

54. Concerns in food processing
• High in added sugar
• High in salts (sodium, nitrite etc)
• High in saturated fats, trans fats
• Low in fiber
• Made with refined grains