Current and emerging opportunities for innovation and product development using pulses

1. CURRENT AND EMERGING OPPORTUNITIES FOR
INNOVATION AND PRODUCT DEVELOPMENT USING
PULSES AS A CASE STUDY
Dr. Devinder Dhingra
Principal Scientist (Process Engineering)
Indian Council of Agricultural Research
New Delhi
Canada and India Pulse Workshop – Strengthening Scientific Partnerships

2. Production of Pulses in India
Pulses/Year 2014-15 % of the total
production
2015-16 % of the total
production
2016-17 % of the total
production
Tur 2810 16.38 2560 15.65 4780 20.82
Gram 7330 42.74 7060 43.18 9330 40.65
Moong 1580 8.74 1590 9.72 2160 9.41
Urad 1960 11.42 1950 11.92 2800 12.20
Other 3550 26.69 3190 19.52 3880 16.90
Total 17150 16350 22950
(In Thousand tonnes)

3. Pulses
• Rich source of vegetable Proteins, carbohydrates, minerals (iron, potassium, magnesium and zinc)
• Free from gluten, contain vitamins
• Legumes: AA score >100 (AA Score Rice:78; Wheat:60; Millets: 50)
• Veg. proteins: Low digestibility and limitation in one or more EAA
• Cereals deficient in lysine; Pulses deficient in Methionine
• Cereals + pulses – compensate each other (KHICHDI)
• Per capita availability: 30-35 g per day; RDA 7.5 g (infants) to 90 g (adults)
• Production has touched around 22.9 MT in the year of 2017-18.
• Chickpeas contributes the single largest share in India’s export basket of pulses registering
85.64% and 84.87% share in the total pulses export during 2014-15 and 2015-16 respectively whereas
Peas (Matar) forms a major share in the total import of pulses.

4. Opportunities for Innovations
• Milling of pulses (pre- treatments, de-husking, splitting, drying, grading,
packaging) – recovery is less than theoretically possible
• Storage of pulses – insect infestation – whole pulses
• Utilization of by-products (husk) for high value products
• Product development

5. Pulse Milling Operations
PULSES
CLEANING
PITTING
PRE-TREATMENT WITH OIL
CONDITIONING
DEHUSKING AND SPLITTING
GRADING
POLISHING
GRADE I – PULSES
CHAFF, DIRT
MIXTURE OF HUSK AND BROKENS
MIXTURE OF HUSK,
BROKENS AND POWDER

6. Dal Mill (small capacity)

7. State Capacity ton/day Type of machinery used by mills across the country Pulses processed
Andhra Pradesh 10 to 20 Graders, rollers, vertical burr mills Urad, Moong, Tur
1.5 to 3.0 Vertical chakkies (plate mill), roller, aspirator
Gujarat 20 to 30 Smooth and rough emery rollers, size graders, impact
splitters
Tur
1.5 to 2 Emery rollers and stone chakkies
Madhya Pradesh 1 to 8 Agra type dhal mill roller, size grader, mixer, vertical plate
mill and polisher
Tur, Gram,
Moong, Urad
Maharashtra 1 to 2 Mostly modernized (rollers and chakkies), mechanical
driers
All pulses
0.1 to 0.15 Combined emery rollers and horizontal chakkies, CFTRI
designed pulse de-husker
Rajasthan 10 Emery rollers, Disc shellers reel sieves Gram, Moong,
Moth bean1.5 to 2
Uttar Pradesh 2 to 5 Agra type machinery, under runner disc sheller, vertical
plate mill tapered rolls
Gram, peas,
Moong, Urad
(splits), Tur Lentil1 to 2 Units from Kanpur vertical plate mills / burr mill
Status of dal milling in India
1ton = 1000 kg

8. Milling of Pulses
• Increase yield
• Standardise pre-treatments
• Minimize power consumption, dust pollution
• Increase level of mechanisation
• Utilization of SPV in processing & value addition
Storage
• Warehouse
• Farmers level

9. Ethnic Products from Pulses
IDLI DHOKLA THEPLA
DOSA PAPAD CHAKKLI

10. Unit Operations in Value Addition / Product Development of Pulses
Unit
Operations
Boiling
Roasting
Frying
Puffing
Steaming
Germination
Fermentation
Baking

11. Boiling/cooking-
• In India, dhals are often cooked until soft, mashed, then mixed
with water and reboiled to give a consistency of a soup.
• Mung bean paste prepared from de-hulled boiled beans is used to
make a variety of dessert dishes.
Roasting –
• Roasting refers to the method in which usually whole, husked, or
unhusked grains are exposed to dry heat.
• Whole grains are commonly roasted and eaten as snacks. Mixture
of pulses with the dry fruits.

12. Frying-
• Black gram often prepared into doughs or paste, which are deep fried into
crispy products. In addition, mung bean or dhal is also fried in a little fat and
eaten as a snack. (e.g. Mung dhal fritters, namkeen, Chakli, Sev, Boondi,
etc.)
Puffing-
• Whole unhusked grains are more commonly used for this process. Puffs
snack can be prepared by chick pea and black gram flour e.g. Tortilla chips,
puffed gram soup mix, puffed chick pea flour.
Steaming-
• Cow peas and chick peas are basically used to make paste and flours in the
preparation of some traditional foods. Hummus is a Levantine dip or spread
made from cooked, mashed chickpeas or other beans, blended with tahini.
Fried chickpeas
Puffed Tortilla chips

13. Germination-
• Germination of pulses is simple and popular technique to enhance
the palatability, digestibility and nutritive value of seeds.
• Sprouted pulses are gaining popularity among people in India.
Fermented processed products-
• Fermented soya bean powder, badi, and papad are the products in
the pulses processing.
• Supplemented foods, beverages and soups with the innovative
ingredients can be prepared by the pulses.
Baking-
• Consumers are very much ready for pulse breads. Beans, chick pea
and lentil flour can be directly replacement for wheat flour in baked
goods which also leads to increase in amino acid profile.

14. Product Development
Health and Supplemented food products
• Breads , Cakes ,Cookies, Biscuits, Energy Bars.
• Therapeutic foods – Gluten free products
Speciality products
• Canned pulses
• Crackers
• Beverages
• Premixes
Ready To Eat products
• Nuggets
• Soup mixes
• Chips, etc.

15. • Chocolate fudge – protein icecream ( pea proein)
• Muffins (grounded peas and dried pea powder)
• Pulse pasta (chick pea flour and whole wheat flour)
• Gluten free berry muffin (chick pea flour)
• Pasta ( chick pea bean and yellow pea flours)
• Pulse noodles
• Cookies (Kabuli chickpeas)
• Strawberry mousse cake (pea starch and pea protein)

17. Nutritional Value
Pulses Protein
(g)
Carbs (g) Fibre (g) Minerals (mg)
Ca Ph Fe
Gram 24 60 1 56 331 5
Cow Pea 24 54 3 77 414 9
Khesari 28 57 2 90 317 7
Lentil 25 59 1 69 293 7
Peas 7 16 4 20 139 1
Rajmah 23 61 5 260 410 5
Soyabean 43 21 4 240 690 10
Chick pea 27 52 6 82 394 5