PMG Newsletter (Volume 2. Issue 23)- DIGITAL.pdf

DESIGN+BUILD FOOD FACTORIES. ONE STOP ENGINEERING SOLUTION
TECH-KNOWLEDGE
FOOD & BEVERAGE
INDUSTRY
ENGINEERING
& DESIGN
SCIENCE &
TECHNOLOGY
Vol .02-Issue .23-June 2023
www.pmg.engineering
A
The Official PMG Engineering Newsletter
PMG

CONTENTS
7-8
2-6
9-10
11-14
1. WHITE PAPER
PMG
2. INDUSTRY BUZZ
3. WEEKS HIGHLIGHT
4. DID YOU KNOW?
A. Cocoa Handling & derived products
B. Risk in Non-Manufacturing Dairy Industry
Latest Food Industry News Updates
A Look Into The Main Events Of The Week
Fascinating Food Facts To Expand
Knowledge

COCOA HANDLING &
DERIVED PRODUCTS
Introduction
READ MORE....
PMG
Products derived from cocoa (Theobroma cacao)
are some of the most widely used eatables
amongst food-based consumer goods. While it all
tastes delicious to have a chocolate bar regularly
or once in a while, there’s little factual information
available to the masses regarding the origin,
processing, and handling of cocoa and products
derived from it. So, lets us talk about how the
cocoa beans are taken out from the cocoa pods
and the unit operations in their handling.
Like all the other kinds, cocoa seeds are also found
inside an outer covering- the cocoa pod. Cocoa
seeds are commonly called cocoa beans and are
found in bunches of 30-40 within each cocoa pod.
Each tree produces about 20 pods consisting
melon shaped seed pods attached to the cocoa
tree. In addition, cocoa pods need due care and
cannot wait for more than 4 days to open up. The
pods are hit with a thick wooden stick, the seeds
taken out and carried in a basket to a dry spot. The
left over broken husk on field can be used
efficiently for making a compost.
Common grade (Forastero cocoa): The beans
are comparatively smaller than criollo beans,
have a reddish to purple color with a strong
flavor. They account for 90% of all the cocoa
beans harvested in the world.
Post-harvest handling of beans
1.Fermentation of cocoa beans:
After grading and sorting, beans are fermented
enzymatically or microbiologically to attain the
alluring cinnamon or reddish brown color.
Conventionally it may be done by heaping the
beans in a pyramidal formation and covering
the heap with banana leaves. Characteristic of
plant seeds, cocoa beans also contain the seed
kernel and the germ which are destroyed
during fermentation.
2. Winnowing:
Process of winnowing is equally important-
usually when the outer skin of the cocoa bean is
removed after fermentation, what is obtained is
known as cocoa nib. Now, to convert these nibs
into mouthwatering chocolates, they are grinded
into fine pieces. Cocoa nibs contain edible
substance - Caffeine.
Chocolate manufacturing
The high-grade (Criollo cocoa): The beans are
large, delicately bitter, and brownish in color.
They are processed easily.

PMG
PLATE HEAT EXCHANGER
6. Conching:
To develop increased smoothness, viscosity and
flavor, a process called Conching is done which
basically involves kneading the chocolate scraped
from the rollers, in heated mixture tanks at 60
degrees Celsius.
For packaging of cocoa beans, usually jute bags of
60-65 Kg are used which are then transported
through ship, railroad or trucks. Ideal condition to
be maintained during handling or transportation is
temperature between 15- 30 ˚C and a relative
humidity of 70% - 75 % along with a water content
of between 6 to 9%.
3. Roasting:
Nibs are roasted in between 105-120 Deg. C in
ovens depending upon the end product for which it
shall be used. Roasting gives the characteristic dark
brown color as well as its chocolaty flavor & aroma.
5. Blending:
Manufacturers use chocolate liquor, cocoa butter,
sugar and a minor quantity of vanilla beans, all
combined together and then subjected to refining
by passing through close-clearance revolving
rollers. According to the end product desired,
different blends are taken as follows:
·For Dark chocolate: sugar, cocoa butter, cocoa
liquor, and (sometimes) vanilla are blended.
·For Milk chocolate: sugar, cocoa butter, cocoa
liquor, milk or milk powder, and vanilla are
blended.
·For White chocolate: sugar, cocoa butter, milk or
milk powder, and vanilla are blended.
4. Grinding:
To obtain the chocolate liquid, also known as mass,
roasted nibs are milled. Mass is used as the primary
component for production of any cocoa derived
product.
7. Storage:
Since chocolate is especially temperature and
humidity sensitive, it needs proper storage
conditions. Ideally, storage temperature of 15 to 17
degrees Celsius is preferred with a relative humidity
of less than 50%. This enhances the shelf-life of the
stored chocolate and prevents fat bloom. The shelf
life may range from 2-3 months for Milk chocolate
to about 2 years for Dark chocolate.
Packaging and Transportation
Other major products
1. Cocoa butter is a high-fat-containing product
obtained after the fermentation process. It is the
main cause of fat bloom in chocolates. Cocoa butter
forms about 50-57% of the coca beans and gives
chocolate its characteristic melting properties.
2. Cocoa powder or dry cocoa solids are obtained
after a defatting process of chocolate liquor using a
mechanical or hydraulic press. It can be used in
almost any food product as an ingredient or as a
garnish. For example, Cocoa powder is used in
cakes, mousse and ice cream, biscuits, and many
confectionaries. It also forms the basis of
chocolate’s flavor.
3. Cocoa liquor is obtained from cocoa beans that
have been fermented, dried, roasted and separated
from their skins. The beans are then ground into a
cocoa mass followed by melting into cocoa liquor.

RISK IN NON-MANUFACTURING
DAIRY INDUSTRY
Introduction
READ MORE....
PMG
Dairy supply chain typically involves a huge number
of actors from spatially dispersed places, where
raw food materials will flow from farm-household
producers in rural areas into large-modern food
processors, retailers, and markets in urban area.
Risks exist in every stage of production carried out
by each of the actors along the production chain.
This implies that the success of improving the
performance of the dairy industry will mostly rely
on the actors ability to manage risks.These actors
include farm input suppliers, milk producers, milk
processors, retailers and consumers. Most of the
outbreaks are known to occurs as risks associated
with processing sections are given primary
importance over the one associated with non-
manufacturing section of the production chain.
Milk and its associated products are particularly
rich in nutrients which provides an ideal
environment for growth of many microorganisms.
Due to perishable nature of milk and its associated
products, equal attention is required at all stages
of milk production cycle.
a.Biological Hazards: Animal feed can be a
source of infections in food animals, with various
pathogens, e.g., viruses, bacteria, and parasites,
which subsequently may lead to the
contamination of milk. For instance, improperly
fermented silage (pH>4.5) can transmit Listeria
monocytogenes to ruminants. Infected or healthy
asymptomatic carriers can excrete high numbers
of L. monocytogenes in their feces and
contaminate the environment and ultimately the
milk.
1. Feed:
Animal feed plays an essential role on the health
of food-producing animals and the safety of
products derived from them, namely milk and
dairy products.
Risks
Components
1. Farm input suppliers: They are the first part of
the dairy supply management cycle which provides
feed for livestock (cow, sheep, buffalo, yak, goat,
camel etc.)
2.Milk Producers: Milk Producers are responsible
for managing the herd and producing milk.
3.Milk Processers: These include dairies and co-
operatives, where raw milk is collected and
converted into a wide range of shelf stable
products.
4.Retailers: Retailers distributes the final stable
products to the customers.
5.Customers: The final part of the chain is the
consumption of the dairy product and are the end
users.

PMG
c. Industrial Origin Toxins: Animal feed is also a
potential source of exposure of farm animals to
environmental contaminants such radionuclides,
polychlorinated biphenyls (PCBs) and dioxins.
READ MORE....
b. Naturally Occurring Toxins: Aflatoxin B is a
known human carcinogen present in maize,
peanuts and other crops and their fodders. It is
metabolized and transferred to milk in the form of
aflatoxin M1. Proper drying and storage of the feed
are important measures for preventing growth of
the toxigenic molds such as Aspergillus flavus,
which is mainly responsible for aflatoxin
formation. Other mycotoxins such as ochratoxin, T-
2 toxins, deoxynivalenol and zearalenone may also
be carried over into milk. However, they are more
of concern for animal health rather than milk
safety.
2. Animal Health:
a. Biological Hazard: Milk can harbor a wide range
of microorganisms; therefore, raw milk can be a
direct source of many types of foodborne
infections. Several bacteria can cause mastitis,
including Staphylococcus aureus, Streptococcus spp.,
and Corynebacterium bovis. Other bacteria may
contaminate the milk during the milking process
through contact of the milk with the hide, udder or
milking equipment. Contamination of milk goes
beyond pathogens which are typically transmitted
from the animal reservoir and can include any
fecally transmitted pathogen of human origin,
including viruses, parasites (e.g. Cryptosporidium),
and bacteria such as Shigella and Salmonella typhi.
b.Veterinary Drugs and Hormones: The most
used veterinary drugs associated with milk are
antibiotics, employed to combat mastitis-causing
pathogens in the dairy cow. One of the more
controversial is bovine somatotropin (BST)
(sometimes referred to as bovine growth hormone)
and its genetically engineered counterpart
recombinant BST (rBST).
c. Naturally Occurring Toxins: Mycotoxins pose risks
to both animal and human health and, depending on
the mycotoxin, may have carcinogenic, estrogenic,
neurotoxic, dermonecrotic or immunosuppressive
effects. The exposure of humans to aflatoxins has
resulted in liver damage and cancer. Codex has
adopted a maximum limit (ML) of 0.5µg/kg of liquid
milk but has not set an ML for its precursor aflatoxin
B1 in animal feed. The EU has established MLs for
feed commodities that vary between 0.05 and
0.005mg/kg. Provided that these MLs for aflatoxin B1
(and other mycotoxins) in feeds are observed, there
should be no health problem from residues in milk.
d.Pesticides: These include insecticides, herbicides,
and fungicides. The most common concern is
insecticides including organochlorines,
organophosphates and carbamates. Organochlorine
pesticides enter the food chain as a result of their
lipophilic properties, in this way biomagnifying in the
food chain and bioaccumulating in individuals. The
main route of human exposure to many
organochlorine pesticides is through foods of animal
origin. Typical contaminants of milk are persistent fat-
soluble organochlorine pesticides such as DDT
(dichlorodiphenyltrichloroethane) and other
organochlorine pesticides.
e. Adulterants: The addition of water to milk is
probably one of the oldest forms of economic
adulteration of food. However, other materials, such
as chalk, were often added to mask this fraud. The
most recent variation of this practice was the addition
of melamine to milk. This was done to avoid detection
by the standard analysis of crude protein in milk,
sometimes called total protein, which is used to
monitor and control milk quality in the dairy industry.
f.Physical hazards: These are generally foreign
bodies, include glass, metal, stones, wood, plastic,
dust, dirt, hair, and insect fragments. Although some
technologies are available for the verification of any
incidental contamination, effective removal of
physical hazards at later stages of the processing and
manufacturing is difficult.

Vol .01 Newsletter
PMG
Good farm management should in the first
place be directed toward the prevention of
infectious diseases, such as clinical and
subclinical mastitis, to limit the use of
veterinary drugs.
In the process, the farmer must keep his
animals in sound physical condition by ensuring
proper hygiene and good housekeeping
practices and implementing sound farm
management.
Good transportation practices, maintaining the
cold chain, need to be observed, for sensitive
products.
Efficient Pest Management activities must be
executed inside the warehouse for preventing
the harborage of insects and rodents inside
warehouse.
Most sources of risks for the entire chain arise
from the upstream segment, mostly smallholder
farmers. Under the presence of these risks, these
actors tend to pose risk-minimizing behavior in
producing their products. This situation, in turn, is
manifested itself in the sub-optimal level of
upstream production which is reflected in the
condition of the quantity and quality of raw milk
produced.
3. Transportation:
Collection and transportation of milk is a point in
the food chain where recontamination of milk with
chemical or microbial hazards and/or growth of
microorganisms can occur. Therefore, the bulk
tanks and vessels used for milk transportation
need to be cleaned and disinfected. Care should be
taken that these are not used for any other
purpose, especially the transport of potentially
toxic materials. To minimize growth of
microorganisms, milk should be chilled to a
temperature of 6°C or below and processed as
soon as possible. Transportation is also a point of
vulnerability in the food chain where actions of
sabotage or tampering may occur. Addition of Cl.
botulinum toxin or other chemical hazards in milk
have been considered as potential risks for
bioterrorism or sabotage.
4. Warehouse:
A potential source of contamination of dairy
products in warehouses is pests such as birds,
rodents, cockroaches, flies, and other insects. Pests
are the reservoir for many pathogens; hence,
through their droppings and urine, they are direct
and dangerous sources of contamination of food.
Contamination of products can also occur indirectly
through the environment. Pest management is thus
important both from a general hygiene perspective
as well as for control of specific pathogens. Good
warehouse management is also important to
prevent any accidental contamination of the
products or raw material with industrial chemicals.
Adherence to good agricultural practices (GAP)
is encouraged in the management of natural,
improved and cultivated pastures, and in the
production of forage and cereal grain crops
used as feed or feed ingredients for food-
producing animals. Proper drying and storage of
the feed are important measures for preventing
growth of the toxigenic molds.
5. Control Measures:

FOOD INDUSTRY
INDUSTRY BUZZ
FSSAI increases the pan masala
warning's implementation period
by three months.
'Country spirits or spirits' provisions
are the subject of a draft from the
FSSAI.
The FSSAI has added three months to the timeline for the
FSS (Labelling and Display) Amendment Regulations, 2022,
which pertain to the warning covering on pan masala
container labels. To the announced regulations, pan
masala must bear the warning "CHEWING OF PAN MASALA
IS INJURIOUS TO HEALTH" on the front of the package,
which must account for 50% of the label's surface area.
Beginning on May 1, 2023, these regulations became
binding. The rule also stipulated that this warning phrase
must be audibly and legibly visible in all advertisements
for pan masala. The FSSAI has indicated that the decision
to extend the deadline was made after considering the
stakeholders' representations provided to the food
regulator.
PMG
The draft states that country liquors, Indian liquors, or
spirits are alcoholic drinks made by distilling agriculturally
derived fermentable carbohydrates. Plain country
liquors/Indian-made liquors can be made from alcoholic
distillate obtained from fermented molasses, jaggery (gur), a
mash of cereals, potato, cassava, fruits, juice or sap of
coconut and palm trees, mahua flowers, or any other
carbohydrates of agricultural origin. 'Blended country
liquors/Blended Indian liquors' is a blend of an alcoholic
distillate, rectified spirit, or neutral spirit.
The food authority has listed three undistilled alcoholic
beverages and 28 distilled spirits from India. The draft also
includes a list of 51 Indian liquors with low alcohol content.

Tetra Pak South Asia's new
managing director as Cassio
Simões
2022 REVENUE GROWTH FOR CARGILL OF 23% TO $165 BILLION
In Uttarakhand, Medusa Beverages
introduces its beer.
The debut of Medusa Beer in Uttarakhand is about to be
announced by Medusa Beverages Pvt. Ltd., which brews its
beer 'Medusa' in India. The business will release its first
batch in Uttarakhand in the first week of June. By selling
three lakh cases in their first year in Delhi alone, Medusa
aims to take advantage of the country's rising demand. The
business has one of the fastest beer growth rates in the
nation.
Sustainability is critical for the Indian tea
industry's future.
PMG
Cassio Simões has been named managing director of Tetra
Pak's South Asia Markets, a prominent food processing and
packaging solutions provider. Simes will assume the
position from June 1, 2023, replacing Ashutosh Manohar,
retiring after a distinguished business career spanning
more than four decades, including 20 years at Tetra Pak.
In Indian homes, tea is a standard beverage. Given that it produced more
than 1.3 million tonnes of tea in FY 2021–22, second only to China, the
nation ruled the roost on the international stage. In 2022, Assam and West
Bengal accounted for most of the northern region's yearly tea production
(about 83%), while Tamil Nadu, Kerala, and Karnataka provided the
remaining 17%. Even though tea is one of our favorite drinks, it's crucial to
realize that the tea industry has serious long-term effects on the
environment. There is no choice but to face the realities of climate change
head-on.
The Indian tea sector is attempting to reach sustainability by adjusting at
all levels of its operations, largely thanks to the UN's Sustainable
Development Goals. Additionally, the government has taken the lead in
maximizing the potential of small tea growers by assisting them in moving
up the value chain and adding value to the tea for higher price realization.
The Indian company Medusa has a division for national
marketing, as well as unique and modern packaging. In Delhi,
there are roughly 650 retail locations for beer and some high-
end cafés, with a distribution width of 90%. The brewery for
the brand is in Punjab, and there are more than 2000 retail
locations where it is sold.
Simes has held various positions across Tetra Pak's
multiple businesses over the past 20 years, bringing a
wealth of experience with him. He most recently served as
Tetra Pak Andina's managing director. His knowledge will
be crucial in guiding the company's growth and expansion
in the South Asia region, which includes India, Sri Lanka,
Bangladesh, Nepal, and Bhutan.

N
O
N
-
T
E
C
H
N
I
C
A
L
C
O
N
T
E
N
T
WEEKS
HIGHLIGHT
WORLD ENVIRONMENT
DAY
This day spreads awareness about the threat to the
environment due to rising pollution levels and
climate change. It provides us with an opportunity
to broaden the basis for an enlightened opinion and
responsible conduct by individuals, enterprises, and
communities in preserving and enhancing the
environment.
J
U
N
E
PMG
World Bicycle Day is celebrated on June 3 as the
day recognizes "the uniqueness, longevity, and
versatility of the bicycle, which has been in use for
two centuries. It is a simple, affordable, reliable,
clean, and environmentally fit sustainable means
of transport."
WORLD BICYCLE DAY
3 JUNE
NATIONAL HIGHER
EDUCATION DAY
To raise awareness regarding the importance of
education, National Higher Education Day is
celebrated annually on June 6 across the globe,
encouraging people to help increase their chances of
graduating with a degree.
5 JUNE
6 JUNE

N
O
N
-
T
E
C
H
N
I
C
A
L
C
O
N
T
E
N
T
WORLD OCEANS DAY
World Oceans Day is commemorated on June 8, to
inform the public of the impact of human actions on
the ocean, develop a worldwide movement of
citizens for the ocean, and mobilize and unite the
world's population on a project for the sustainable
management of the world's oceans.
J
U
N
E
PMG
8 JUNE
World Food Safety Day is celebrated annually on 7
June to draw attention and mobilize action to
prevent, detect and manage foodborne risks and
improve human health. This international day is an
opportunity to strengthen efforts to ensure that
the food we eat is safe, mainstream food safety on
the public agenda, and reduce the burden of
foodborne diseases globally.
WORLD FOOD SAFETY
DAY
8 JUNE
WORLD BRAIN TUMOR
DAY
Every year, 8th of June is celebrated as World Brain
Tumor Day. The day is celebrated worldwide to raise
awareness and educate people about brain tumors.
There are lots of myths and misconceptions about
brain tumors among the general population and we
take this opportunity to discuss some basic facts.
7 JUNE

T
E
C
H
N
I
C
A
L
C
O
N
T
E
N
T
Vol .01 Newsletter
DID YOU KNOW?
1/3 2/3
3/3
PMG
J
U
N
E
Fact 1
Canned sausages are typically fully cooked and can
be eaten directly from the can or heated before
consumption. They can be made from various types
of meat, such as pork, beef, chicken, or a
combination thereof.

T
E
C
H
N
I
C
A
L
C
O
N
T
E
N
T
Vol .01 Newsletter
3/3
2/3
1/3
Fact 2
PMG
J
U
N
E
Jam and jelly are both fruit products but the
ingredients, physical form of the fruit, and method of
preparation differ. Jelly is a type of clear fruit spread
made from firmed fruit/vegetable juice and pectin.
Jam is a product made from whole fruit that has been
cut into pieces or crushed. While jams contain fruit
pulp, jellies contain fruit juice.

T
E
C
H
N
I
C
A
L
C
O
N
T
E
N
T
Vol .01 Newsletter
1/3
2/3
3/3
PMG
J
U
N
E
Fact 3
Freeze dehydration, also known as freeze-drying or
lyophilization, is a process commonly used to
preserve and extend the shelf life of various
perishable items, including food. In the food industry,
it is employed to produce instant coffee, fruits,
vegetables, herbs, and ready-to-eat meals.

T
E
C
H
N
I
C
A
L
C
O
N
T
E
N
T
Vol .01 Newsletter
PMG
J
U
N
E
Fact 4
Ultra High Temperature (UHT) plants, also known as
ultra-pasteurization plants, are used for the heat
treatment of food and beverages to extend their shelf
life. There are different types of UHT plants,
depending on the specific product being treated and
the desired outcome mentioned above.
1/3 2/3
3/3

PMG ENGINEERING
About PMG
Delivering End-to-End Engineering
Design & Construction Management
in Food & Beverage Industry
Website Link Follow Us on
Click Here
MAKING CUSTOMERS THE INDUSTRY LEADERS
ENGINEERING MUST CREATE BUSINESS VALUE
MEET THE EXPECTATIONS OF ALL STAKEHOLDERS
OPTIMAL ENGINEERING
About PMG

PMG Newsletter (Volume 2. Issue 23)- DIGITAL.pdf

Recommended

Recommended

More Related Content

Similar to PMG Newsletter (Volume 2. Issue 23)- DIGITAL.pdf

Similar to PMG Newsletter (Volume 2. Issue 23)- DIGITAL.pdf (20)

More from PMG Engineering Private Limited

More from PMG Engineering Private Limited (20)

Recently uploaded

Recently uploaded (20)

PMG Newsletter (Volume 2. Issue 23)- DIGITAL.pdf