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Quality and Processing of Plantation crops

The document discusses various plantation crops grown in India including their processing methods. It provides area and production statistics for major crops like coconut, arecanut, cashewnut, tea, and coffee. For coconut, it describes the components and different processing steps to produce copra, coconut oil, and other products. Similar processing details are provided for arecanut and case studies on drying coconut kernels and developing a arecanut dehusking machine. Processing of palm products like neera, toddy and jaggery are also summarized along with a case study on palm jaggery preparation. The document concludes with a brief overview of tea processing steps.

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Master’s seminar (PSM-591) QUALITY AND PROCESSING OF PLANTATION CROPS Speaker Sahil Pathania H-19-88-M MSc. 2nd year Spices, Plantation, Medicinal and Aromatic Plants
Parthasarthy et al., 2006 INTRODUCTION Plantation crop - denotes the extensive cultivation of crops like tea, coffee, coconut, arecanut, cashewnut etc. These crops are all restricted in geographical distribution to tropics mostly between 200 N & S.  They have great potential for utilization of waste land like rainfed dry land, hilly, arid and coastal areas India is one of the largest producers of the plantation crops in the world Generally consumed only after processing Quality is a measure of the degree of excellence or acceptability by the consumer
AREA AND PRODUCTION OF PLANTATION CROPS - ALL INDIA (2018-19) Area in ‘000 Ha Production ‘000 MT (https://teacoffeespiceofindia.com & Horticulture Statistics, 2019) Crop Area Production Coconut 2151 14682 Arecanut 522 901 Cashewnut 1105 743 Tea 567 1350 Coffee 454 319 Cocoa 94 24
TOP 5 STATES IN AREA AND PRODUCTION OF PLANTATION CROPS 337.02 1043.28 970.23 619.8 252.05 1205.93 4105.84 5490.32 3786.02 290.05 0 1000 2000 3000 4000 5000 6000 Andhra pradesh Karnataka Kerala Tamil nadu Odisha Area Production Area in ‘000 Ha Production ‘000 MT Horticulture Statistics, 2019
 Family - Arecaceae Chromosome no. 2n = 32 •Kalpavriksha (tree of heaven) •Origin – South East Asia •Known as King of Palms •Coconut of commerce is drupe •Grown in more than 80 tropical countries • In India, highest productivity is in Tamil Nadu •Highest area and production is in Kerala •70 % of coconut is used for edible purpose Chadha, 2001 COCONUT (Cocus nucifera)
Coconut consist of :  Exocarp (outer part)  Mesocarp (Husk)  Endocarp(thin hard layer)  White endosperm (Kernel)  Large cavity (Filled with water)
PROCESSING Coconut can be processed for different final products  Copra  Copra cake  Coconut virgin oil  Coconut milk  Coconut water  Coconut cream  Toddy vinegar  Desiccated coconut powder Parthasarthy et al., 2006
PROCESSING FOR COPRA  Storage (in heaps under shade) Husking become easier Moisture content of meat decreases and thickness increase Yield of copra and oil increases Improves quality  Dehusking Usually done with the sharp pointed shard of steel  Nut splitting Hard shell is exposed and can be split open into two halves using a machete Shanmugavelu et al., 2002
 Drying : copra is obtained after drying the coconut kernel.  Reducing the moisture content from 50 to 6 percent  Three common methods of drying are 1. Sun or solar drying 2. Kiln drying 3. Indirect drying
Sun drying  Produce good quality product if whether conditions permit  Used for small quantity of products  No expense for fuel  Cheap method Solar drying  Reduced the drying time up to 50% compared with open sun drying  Reduces losses due to sudden rain and windy climate
KILN DRYING Two type of kiln dryer used  Direct type • The coconut shells used as fuel burned under the grill • To provide heat for vaporization of moisture • Copra- dark, sooty with smoke and scorched  Semi direct type • Dryer has a combustion pit located about 3 feet away from the drying bed • The hot combustion product is channelled to the drying bed via an underground tunnel • Capacity of 2000 nuts • Dries in 24-25 hours with resultant moisture of 6% Romulo and Arancon, 1996
COPRA DRYING USING HOT-AIR DRYER Smoke does not come in contact with kernel Produced clean and white copra Cocopugon hot-air brick copra dryer is most common hot-air design The heat is passed through the brick tunnel The surface is made up of bricks (split nuts are kept ) 30 hours needed for one batch to obtain 6% moisture Romulo and Arancon, 1996
TODDY Palm tree Cut 10-15 cm from top inflorescence Tapping (Cutting the end of spadix ) Collection of sap each day Neera Drink fresh Fermentation Toddy Kumari et al., 2016
VIRGIN COCONUT OIL Selection of nuts • Fully matured nuts are selected Splitting and grating • For small scale it is done by using motorized coconut grater De-shelling And crushing • For medium and large scale • Brown testa is removed , washed in hot water and crushed in fine shredder Drying • Dried to moisture level of 5% in a hot air vacuum dryer and sun drying • Require 3-4 hours for one batch maintaining temperature below 700C
Drying • Necessary to remove residual moisture in addition • This increases the shelf life of oil Filtration • After settling of oil for 1-3 days filtration is done using 3-4 layers of filter cloth Jayasekara and Gunathilake, 2007 Extraction of oil • Done in vertical screw type or hydraulic oil press manually (small scale) • Electrically operated screw type cold press expeller (large scale)
VALUE ADDED PRODUCTS Coconut water Coconut oil cake Coconut coir Coconut flour Shanmugvelu et al., 2018 Coconut milk Coconut jaggery Coconut candy Coconut jam
CASE STUDY-1 • Results showed that the quality of coconut kernel can be effectively obtained by drying at 700 C temperature •This technology will be more helpful for the industrialist and small scale farmers to dry the copra in a short time with good quality nuts Characteristics 600 C 700 C 800 C 900 C sun dried copra Impurities, % by wt, Max 1 0.5 0.5 1 9 Mouldy cups, % by count, Max 5 2 2 2 25 lack cups, % by count, Max 3 2 7 8 2 Wrinkled cups, % by count 2 2 7 8 2 Chips, % by wt, Max 1 3 7 9 1 Moisture content % by wt, Max 6.2 6.51 6.34 6.42 7 Oil content (on moisture free basis), % by wt, Min 65.27 67.1 42.7 40.1 FFA 0.5 0.5 0.8 0.9 63.1 Peroxide value, meq/kg 2 2 7 10 0.8 Specific gravity 0.93 0.92 0.9 0.89 0.93 Iodine value 8.1 8.2 8.5 8.9 8.7
 Family - Arecaceae  Chromosome no. 2n = 32  Fruit of arecanut is single seeded berry  Source of chewing nut  Popularly known as betel nut or supari  Used in religious practices and social ceremonies  Used against cough, leprosy, anaemia and obesity  4th most commonly addictive substance Gupta et al., 2018 Arecanut (Areca catechu)
HARVESTING  Harvested at different stage of maturity (6-7 months and 9 months)  In kerala fresh fruits are generally stored by steeping in water  Kernel chewed as both raw and processed  Three main processed products of Arecanut are as 1. Kottapak 2. Kalipak 3. Scented supari Parthasarthy et al., 2006
KOTTAPAK Good quality product contain  Absence of immature nuts and surface cracking  Good cutting feel, inside structure and taste
KALIPAK ‘Kempadike’ and ‘kalipakku’  Harvested at 6-7 months maturity  Nuts are soft and finger nail can be pressed into it  Outer skin is dark green colour  Good quality product contain crisp chewing feel, glossy appearance and absence of over mature nuts
SCENTED SUPARI Popular in North & Central India Shanmugavelu et al., 2002
LEAF SHEATH  Its is another raw material obtained from arecanut palm  In a year, a palm sheds 5-6 leaves. About 1000 million leaf sheath weighing about 2,33,000 tonnes are available annually in India alone  The CFTRI, Mysore has developed a machine for making cups and throw away plates which can substitute the non-biodegradable plates now being used Annamalai and Nayar, 1982 Anon, 1977
Nuts having light brown skin colour are considered superior Greying and yellowing are indications of poor quality The presence of dried tender nuts with a darker colour is also a defect. GRADING Shanmugavelu et al., 2002 and Bhat et al., 2017 Grade Characteristic Premimum Premium grade product at 98-99% excellence Superior Quality guaranted at 94-97% excellence Grade A Plus Quality guaranteed at 90% – 93% excellence Grade A & Grade A Quality guaranteed at 85% – 90% excellence Normal Split Quality assurance at 80% – 84% excellence Grade B Quality assurance at 70% – 74% excellence Reject Quality (Lali) Poor quality pieces Grade C “Zero” Dark red and black pieces
CASE STUDY 2 Experiment Size Rotating Speed (rpm) No. of blades Result Experiment 1 Small, medium and large 125 2 Experiment 2 Small, medium and large 62 1 Experiment 3 Small, medium and large 125 1 • Dehusking arecanut machine is developed and tested successfully • Results compared and 3rd experiment was best method • Concluded that the machine has an efficiency of 74% with single cutter at 125 rpm.
 Family – Palmae  Native to West Africa  Produces most edible oil in the world  Highest yielding among oil bearing trees  60-80 feet in height  Commercial cultivation of this crop in India started during 1970  To be processed with in 24 hour • Because the quality of oil extracted deteriorates owing to the development of FFA • Results in poor quality oil OIL PALM (Elaeis guineensis) Shanmugavelu et al., 2002
PROCESSING FLOW CHART Poku, 2002
 Family – Arecaeae  ‘Tree of life’ and ‘Kalpaga tharu’  Grows on every type of wasteland including rocky areas  Adult palmyra palms mostly used for tapping sap (toddy)  Sometime used as wind break  In tropical region adds beauty to the landscape  State tree of Tamil Nadu since 1978 Davis, 1985 PALMYRAH PALM (Borassus flabellife)
COLLECTION OF NEERA Tapping of inflorescence ↓ Collection of sap ↓ Filtration ↓ Pasteurization ↓ Consumption Neera •Sap known as neera •Highly nutritious •Transparent, pleasant smelling and sweet in taste •Free of sucrose (does not cause diabetes) •Poor man’s beverage Mani et al., 2018
Collection of sap from inflorescence ↓ Provision of yeast culture ↓ Fermentation ↓ Toddy Toddy •Toddy is fermented product •Sap collected by tip of unopened flower •Sap oozes out and collected in small pot tied underneath •In 6-8 hours it is formed as a result of fermentation •Alcohol content is estimated in range of 4-6% •Sugar is converted to ethyl alcohol during fermentation Mani et al., 2018
PALM JAGGERY  Neera is collected from the plant  Half the quantity of juice is boiled at 400C  Declined to pH 7 (using triple super phosphate solution)  After boiling other half of juice is added and when temperature reaches at 850C it is neutralized (pH 5)  Boiled to crack 1000C  Transfer to settling tank  Clear juice is siphoned Clarification
 Clear juice is boiled again  The scum is removed  Juice is stirred to help rapid evaporation  Pan taken out and striking the pan is done  Gur sets in 15-20 minutes Boiling The keeping quality of jaggery can be improved by storing in humidity-controlled chamber maintaining the RH below 65% Vengaiah et al., 2013
VALUE ADDED PRODUCTS Neera Palm candy Toddy Jaggery Palm cola
CASE STUDY 3 Sample no. Treatment conditions Quality attribute Time (min.) Temp. (0 C) Lime (%) Colour Taste Flavour Texture S1 174 111 0.9 5 7 8 8 S2 150 124 1.5 5 5 6 6 S3 150 117 2.5 2 3 2 5 S4 126 111 2.1 8 9 8 9 S5 174 121 0.9 7 7 7 8 S6 150 117 0.5 6 8 3 7 S7 174 121 2.1 7 8 8 9 S8 150 117 1.5 5 6 5 6 S9 126 121 0.9 8 8 4 3 Control Traditional practice 7 7 5 6 •The best treatment for preparation of solid jaggery was 2.1% lime, processing temperature of 1110C and processing time of 126 minutes with an average sensory score of jaggery i.e. 8.5 (highest among all)
 Native to South East Asia  Became common beverage in China during seventh century  Assam contributes highest area under tea cultivation  Planted on large scale in North India in 1834  Commercially started in various regions like Nilgiris (1859) Waynad (1859)  Only plantation crop grown in Himachal Pradesh TEA (Camellia sinensis) Shanmugavelu et al., 2002
PROCESSING  The manufacturing of tea starts in the field from the time of plucking  The processes involved in tea manufacturing are 1. Withering •Done to prepare the leaf for subsequent processes of manufacture •Leaves undergoes a period of dehydration •Artificial withering also done in drum •Leaves should not produce cracking sound when squeezed •When leaves are pressed with hands they should form a compact ball •Withered leaf will be like a silk hand kerchief to touch and feel
2. Rolling •Carried out by machine •Leaf attain a twist and rolled •The polyphenol substances contact with enzymes during the breaking of leaf •In presence of oxygen, the polyphenol oxidised •Changes to highly coloured substances (theaflavins and thearubigins) •After 1st roll,the leaves are spread over sifter •Done to seprate the fine tea from coarse •The fine one is sent to fermentation room •The coarse tea is given second rolling •Teas are rolled 2-3 times for 30-40 minutes
] ] 3. Fermentation •Leaves spread on concrete bed or aluminium trays •Fermentation vary from 1-3 hours •Low humidity causes blackening of leaf •Usually tea growers judge it by smelling, touching and feeling 4. Drying •Undergoes a process of drying in oven called as ‘driers’ •136-1550 C initially then reduced to 1050 C •Leaves are dried for 30-40 minutes •Final drying done at 73.750 C before packing Shanmugavelu et al., 2002
CUT, TEAR & CURL METHOD  Short noted as CTC process  Two rollers meshing closely against each other  8-12 teeths per 3cm  Roller crush the leaves  Teeth tear and finally they are dried  Bits size 1-1.25 cm
GREEN TEA  Preferred mostly in China and Japan  Heated quickly after harvesting  Cooled, rolled, heated and dried to 4% moisture content  Olive or pale yellow in colour  Strong pungent BRICK TEA On high demand in Tibet and China  Long and tough leaves  Coarse leaves heaped on cement floor to generate heat  Black fungus grows  Responsible for peculiar taste Soni et al, 2015
GRADING IN TEA www.teaboard.gov.in
 Arabica coffee - Coffea arabica  Chromosome no. – 2n = 44  Origin – Ethiopia  Robusta coffee - Coffea canaphora  Chromosome no. – 2n = 22  Origin – Central Africa Cultivated mainly in Karnataka, Kerala, Tamil Nadu and Andhra Pradesh COFFEE differnce between coffee arabica robusta - Bing images and Chadha, 2002
Coffee Board, 2020
PROCESSING Coffee is processed by two methods • To prepare plantation or parchment coffee Wet method • To obtain cherry coffee Dry method
WET METHOD  Ripe berries are preferred  Pulped on same day to avoid Fermentation  Mucilage break down  24-36 hours for arabica  More than 72 hours for robusta  Takes longer time in cool weather  They are washed with clean water 3-4 times  The parchment should not stick by hand after washing Natural fermentation Gosh and Venkatachalapathy, 2014
Treatment with alkali Removal of mucilage by friction
 Soaking in water for 24 – 42 hours  Improves quality  Sun drying for 7-10 days  Surface drying takes 24-48 hours  Hulling  Polishing  the beans are packed into clean new gunnies Gosh and Venkatachalapathy, 2014
DRY METHOD Gosh and Venkatachalapathy, 2014
•Family- Sterculiaceae •Native to South America •‘Gift of god’ •Name cocoa derived from plant caucault in Mexico during15th century •Intoduced to India in early 1963 •Large scale cultivation started in 1970s Cocoa (Theobroma cacao) Shanmugavelu et al., 2002
PROCESSING  The splitting of pods is done within 2-3 days of harvesting  Pods are banged by some hard objects  Opening with knife damages the beans  Pre-fermentation inside the pod is hastened during harvesting and splitting  10-12 pods gives 1 kg wet beans  3 kg of wet beans gives 1 kg of fermented and dried beans Guechi et al., 2010
 Pulp or mucilage covering the bean is removed  Simple process but carried out properly in order to maintain the quality of bean  Flavor compounds and flavor precursors like free amino acids and reducing sugars are formed during fermentation.  The amount of these compounds is a confirmation of the well- fermented process and is responsible for the flavor profile of the finished chocolate Afoakwa et al., 2008 and Lefeber et al., 2012 Fermentation
 Best method for small quantity of beans  4-5 trays required at one time  Tray can be 60 cm long and 25 cm wide  10 kg of wet beans required to fill one tray  Top tray covered with leaves  Gets completed in 4-5 days  2-6 kg beans can be fermented  Bamboo baskets of diameter 20 cm and height 15 cm are used for 2 kg of wet beans  Unripe beans not ferment properly  After 24 hours it is covered with gunny bags and applied weight on it  Beans are fermented in 6 days and on seventh day they are taken for drying b. Basket method a. Tray method
Drying  After fermentation beans are dried under sun or by artificial means  2-3 cm thin layer for sun drying and time to time stirring  Dried up to 6-8% moisture  To check dryness of beans take beans in hand and crush them the characteristic sound indicates the correctly dried beans Shanmugavelu et al., 2002 and Saltini et al.,2013 Quality and flavor of cocoa products strongly depend on the various stages of cocoa processing
VALUE ADDED PRODUCTS Chocolate liquor Cocoa powder Chocolate Cocoa nibs Cocoa butter
CASE STUDY 4 storage 6 12 18 24 Quality parameters BNTPE F NA TPEF BNTP EF NA TPEF BNTPE F NA TPEF BNTP EF NA TPEF Pod weight 310 505 400 450 400 265 525 350 350 434 300 454 Bean./pod 46 48 49 38 40 50 56 47 45 54 44 54 Bean wet wt./pod 95.62 141. 36 127.1 68.69 36.8 2 88.2 125.27 97.2 91.3 117.6 55.8 117.6 Average bean wt. 2.08 3.0 3.6 1.80 2.2 1.80 2.23 1.6 2.02 2.2 1.3 2.2 % of pods with browning/de cay 4.16 0 0 8.30 0 0 8.30 4.16 0 16.7 8.30 0 Odour 0.1 0 0.1 0.5 0.3 0.1 2.1 0.5 0.3 3.5 1.6 1.2 •The percentage browning/decay of cocoa pods were affected by storage environment and storage days •Beans stored in TPEF did not have any sign of decay throughout the periods of storage.
•Family – Anacardiaceae •Chromosome no. 2n = 42 •Native to Brazil •Introduced to Malabar coast of India in 16th century •Grown in tropical and sub- tropical region •Considered as ‘Gold mine of the waste land’ •Cultivated on large scale in Brazil, East Africa and India CASHEW NUT (Anacardium occidentale)
PROCESSING  Before processing the nuts should be dried immediately under sun  If the surface is of cement concrete drying for two full day is sufficient  If it is of mud drying for 3-4 days is necessary  Easily broken in the processing Karthic et al., 2014
CLEANING AND GRADING  Raw nuts are cleaned  Graded into three types:- small, medium and large  In most area this grading is not done before processing Karthic et al., 2014
ROASTING  To make shell brittle  It was the earliest process  Nuts heated on metal pan in open fire  Due to heat and slight charring the shell become brittle  Not followed in organized sector of industries Open pan roasting
 Fed into rotating hot drum  Ignites the shell portion of nut  Maintains temperature because of oil oozing out of the nuts  The roasted nuts still burning are covered with ash  To absorb the oil  Drum kept rotating for 2-4 minutes  Main disadvantage is loss of CSNL Shanmugavelu et al., 2002 Drum roasting
 Easiest and commonly used technique  Broken kernel will be 3-4 %  No loss of CSNL  Roasted for 25-30 minutes at 100 lb pressure  Require 12-24 hours of cooling under natural air Steam roasting
SHELLING  Shelled by labour  Outer hard skin is removed  Easily removed after roasting PEELING  Extracted kernels have thin outer skin  Brown and pinkish in colour  Removed by hands  Become easier if heat treatment is given for 4 hours in drying chamber
GRADING W - 180, is the ' King of Cashew ' - They are larger in size and very expensive. W - 210, are popularly known as ' Jumbo ' nuts. W - 240, it is an attractive grade which is reasonably priced.
W - 320, are the most popular among cashew kernels and highest in terms of availability, worldwide. W - 450, are the smallest and cheapest white whole kernels and hence the favorite among low priced whole grades. www.cashewindia.org
PACKING  Done in tins  The air inside tin is exhausted  Recharged with Co2  Before sealing air tight  Each tin contain 10 kg of kernels Shanmugavelu et al., 2002
CASE STUDY 5 Test Number of nuts fed into the shell Completely shelled nut Whole kernels recovered Broken kernels recovered Shelling time (s) 1 50 48 40 10 25 2 50 47 34 16 25 3 50 49 36 14 25 4 50 50 32 18 25 5 50 46 33 17 25 Mean 50 48 35 15 25 •The average shelling efficieny of machine is 95% (higher than the motorised sheller) and whole kernel recovery is 70% (higher than mannual sheller ) •Beneficial for large scale production
CONCLUSION High value industrial crops which have great potential for the utilization of waste land The processing plays an important role in plantation crops as they are generally consumed only after processing The quality of plantation crops depends upon the processing methods. The new techniques, methods and improved machineries play an important role in enhancing the quality viz., improved drying method, machineries, optimized storage period etc.
THANK YOU

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Quality and Processing of Plantation crops

  • 1.
    Master’s seminar (PSM-591) QUALITYAND PROCESSING OF PLANTATION CROPS Speaker Sahil Pathania H-19-88-M MSc. 2nd year Spices, Plantation, Medicinal and Aromatic Plants
  • 2.
    Parthasarthy et al.,2006 INTRODUCTION Plantation crop - denotes the extensive cultivation of crops like tea, coffee, coconut, arecanut, cashewnut etc. These crops are all restricted in geographical distribution to tropics mostly between 200 N & S.  They have great potential for utilization of waste land like rainfed dry land, hilly, arid and coastal areas India is one of the largest producers of the plantation crops in the world Generally consumed only after processing Quality is a measure of the degree of excellence or acceptability by the consumer
  • 3.
    AREA AND PRODUCTIONOF PLANTATION CROPS - ALL INDIA (2018-19) Area in ‘000 Ha Production ‘000 MT (https://teacoffeespiceofindia.com & Horticulture Statistics, 2019) Crop Area Production Coconut 2151 14682 Arecanut 522 901 Cashewnut 1105 743 Tea 567 1350 Coffee 454 319 Cocoa 94 24
  • 4.
    TOP 5 STATESIN AREA AND PRODUCTION OF PLANTATION CROPS 337.02 1043.28 970.23 619.8 252.05 1205.93 4105.84 5490.32 3786.02 290.05 0 1000 2000 3000 4000 5000 6000 Andhra pradesh Karnataka Kerala Tamil nadu Odisha Area Production Area in ‘000 Ha Production ‘000 MT Horticulture Statistics, 2019
  • 5.
     Family - Arecaceae Chromosomeno. 2n = 32 •Kalpavriksha (tree of heaven) •Origin – South East Asia •Known as King of Palms •Coconut of commerce is drupe •Grown in more than 80 tropical countries • In India, highest productivity is in Tamil Nadu •Highest area and production is in Kerala •70 % of coconut is used for edible purpose Chadha, 2001 COCONUT (Cocus nucifera)
  • 6.
    Coconut consist of:  Exocarp (outer part)  Mesocarp (Husk)  Endocarp(thin hard layer)  White endosperm (Kernel)  Large cavity (Filled with water)
  • 7.
    PROCESSING Coconut can beprocessed for different final products  Copra  Copra cake  Coconut virgin oil  Coconut milk  Coconut water  Coconut cream  Toddy vinegar  Desiccated coconut powder Parthasarthy et al., 2006
  • 8.
    PROCESSING FOR COPRA Storage (in heaps under shade) Husking become easier Moisture content of meat decreases and thickness increase Yield of copra and oil increases Improves quality  Dehusking Usually done with the sharp pointed shard of steel  Nut splitting Hard shell is exposed and can be split open into two halves using a machete Shanmugavelu et al., 2002
  • 9.
     Drying :copra is obtained after drying the coconut kernel.  Reducing the moisture content from 50 to 6 percent  Three common methods of drying are 1. Sun or solar drying 2. Kiln drying 3. Indirect drying
  • 10.
    Sun drying  Producegood quality product if whether conditions permit  Used for small quantity of products  No expense for fuel  Cheap method Solar drying  Reduced the drying time up to 50% compared with open sun drying  Reduces losses due to sudden rain and windy climate
  • 11.
    KILN DRYING Two typeof kiln dryer used  Direct type • The coconut shells used as fuel burned under the grill • To provide heat for vaporization of moisture • Copra- dark, sooty with smoke and scorched  Semi direct type • Dryer has a combustion pit located about 3 feet away from the drying bed • The hot combustion product is channelled to the drying bed via an underground tunnel • Capacity of 2000 nuts • Dries in 24-25 hours with resultant moisture of 6% Romulo and Arancon, 1996
  • 12.
    COPRA DRYING USINGHOT-AIR DRYER Smoke does not come in contact with kernel Produced clean and white copra Cocopugon hot-air brick copra dryer is most common hot-air design The heat is passed through the brick tunnel The surface is made up of bricks (split nuts are kept ) 30 hours needed for one batch to obtain 6% moisture Romulo and Arancon, 1996
  • 13.
    TODDY Palm tree Cut 10-15cm from top inflorescence Tapping (Cutting the end of spadix ) Collection of sap each day Neera Drink fresh Fermentation Toddy Kumari et al., 2016
  • 14.
    VIRGIN COCONUT OIL Selection ofnuts • Fully matured nuts are selected Splitting and grating • For small scale it is done by using motorized coconut grater De-shelling And crushing • For medium and large scale • Brown testa is removed , washed in hot water and crushed in fine shredder Drying • Dried to moisture level of 5% in a hot air vacuum dryer and sun drying • Require 3-4 hours for one batch maintaining temperature below 700C
  • 15.
    Drying • Necessary toremove residual moisture in addition • This increases the shelf life of oil Filtration • After settling of oil for 1-3 days filtration is done using 3-4 layers of filter cloth Jayasekara and Gunathilake, 2007 Extraction of oil • Done in vertical screw type or hydraulic oil press manually (small scale) • Electrically operated screw type cold press expeller (large scale)
  • 16.
    VALUE ADDED PRODUCTS Coconut water Coconut oilcake Coconut coir Coconut flour Shanmugvelu et al., 2018 Coconut milk Coconut jaggery Coconut candy Coconut jam
  • 17.
    CASE STUDY-1 • Resultsshowed that the quality of coconut kernel can be effectively obtained by drying at 700 C temperature •This technology will be more helpful for the industrialist and small scale farmers to dry the copra in a short time with good quality nuts Characteristics 600 C 700 C 800 C 900 C sun dried copra Impurities, % by wt, Max 1 0.5 0.5 1 9 Mouldy cups, % by count, Max 5 2 2 2 25 lack cups, % by count, Max 3 2 7 8 2 Wrinkled cups, % by count 2 2 7 8 2 Chips, % by wt, Max 1 3 7 9 1 Moisture content % by wt, Max 6.2 6.51 6.34 6.42 7 Oil content (on moisture free basis), % by wt, Min 65.27 67.1 42.7 40.1 FFA 0.5 0.5 0.8 0.9 63.1 Peroxide value, meq/kg 2 2 7 10 0.8 Specific gravity 0.93 0.92 0.9 0.89 0.93 Iodine value 8.1 8.2 8.5 8.9 8.7
  • 18.
     Family -Arecaceae  Chromosome no. 2n = 32  Fruit of arecanut is single seeded berry  Source of chewing nut  Popularly known as betel nut or supari  Used in religious practices and social ceremonies  Used against cough, leprosy, anaemia and obesity  4th most commonly addictive substance Gupta et al., 2018 Arecanut (Areca catechu)
  • 19.
    HARVESTING  Harvested atdifferent stage of maturity (6-7 months and 9 months)  In kerala fresh fruits are generally stored by steeping in water  Kernel chewed as both raw and processed  Three main processed products of Arecanut are as 1. Kottapak 2. Kalipak 3. Scented supari Parthasarthy et al., 2006
  • 20.
    KOTTAPAK Good quality productcontain  Absence of immature nuts and surface cracking  Good cutting feel, inside structure and taste
  • 21.
    KALIPAK ‘Kempadike’ and ‘kalipakku’ Harvested at 6-7 months maturity  Nuts are soft and finger nail can be pressed into it  Outer skin is dark green colour  Good quality product contain crisp chewing feel, glossy appearance and absence of over mature nuts
  • 22.
    SCENTED SUPARI Popular inNorth & Central India Shanmugavelu et al., 2002
  • 23.
    LEAF SHEATH  Itsis another raw material obtained from arecanut palm  In a year, a palm sheds 5-6 leaves. About 1000 million leaf sheath weighing about 2,33,000 tonnes are available annually in India alone  The CFTRI, Mysore has developed a machine for making cups and throw away plates which can substitute the non-biodegradable plates now being used Annamalai and Nayar, 1982 Anon, 1977
  • 24.
    Nuts having lightbrown skin colour are considered superior Greying and yellowing are indications of poor quality The presence of dried tender nuts with a darker colour is also a defect. GRADING Shanmugavelu et al., 2002 and Bhat et al., 2017 Grade Characteristic Premimum Premium grade product at 98-99% excellence Superior Quality guaranted at 94-97% excellence Grade A Plus Quality guaranteed at 90% – 93% excellence Grade A & Grade A Quality guaranteed at 85% – 90% excellence Normal Split Quality assurance at 80% – 84% excellence Grade B Quality assurance at 70% – 74% excellence Reject Quality (Lali) Poor quality pieces Grade C “Zero” Dark red and black pieces
  • 25.
    CASE STUDY 2 ExperimentSize Rotating Speed (rpm) No. of blades Result Experiment 1 Small, medium and large 125 2 Experiment 2 Small, medium and large 62 1 Experiment 3 Small, medium and large 125 1 • Dehusking arecanut machine is developed and tested successfully • Results compared and 3rd experiment was best method • Concluded that the machine has an efficiency of 74% with single cutter at 125 rpm.
  • 26.
     Family –Palmae  Native to West Africa  Produces most edible oil in the world  Highest yielding among oil bearing trees  60-80 feet in height  Commercial cultivation of this crop in India started during 1970  To be processed with in 24 hour • Because the quality of oil extracted deteriorates owing to the development of FFA • Results in poor quality oil OIL PALM (Elaeis guineensis) Shanmugavelu et al., 2002
  • 27.
  • 28.
     Family –Arecaeae  ‘Tree of life’ and ‘Kalpaga tharu’  Grows on every type of wasteland including rocky areas  Adult palmyra palms mostly used for tapping sap (toddy)  Sometime used as wind break  In tropical region adds beauty to the landscape  State tree of Tamil Nadu since 1978 Davis, 1985 PALMYRAH PALM (Borassus flabellife)
  • 29.
    COLLECTION OF NEERA Tappingof inflorescence ↓ Collection of sap ↓ Filtration ↓ Pasteurization ↓ Consumption Neera •Sap known as neera •Highly nutritious •Transparent, pleasant smelling and sweet in taste •Free of sucrose (does not cause diabetes) •Poor man’s beverage Mani et al., 2018
  • 30.
    Collection of sap from inflorescence ↓ Provisionof yeast culture ↓ Fermentation ↓ Toddy Toddy •Toddy is fermented product •Sap collected by tip of unopened flower •Sap oozes out and collected in small pot tied underneath •In 6-8 hours it is formed as a result of fermentation •Alcohol content is estimated in range of 4-6% •Sugar is converted to ethyl alcohol during fermentation Mani et al., 2018
  • 31.
    PALM JAGGERY  Neerais collected from the plant  Half the quantity of juice is boiled at 400C  Declined to pH 7 (using triple super phosphate solution)  After boiling other half of juice is added and when temperature reaches at 850C it is neutralized (pH 5)  Boiled to crack 1000C  Transfer to settling tank  Clear juice is siphoned Clarification
  • 32.
     Clear juiceis boiled again  The scum is removed  Juice is stirred to help rapid evaporation  Pan taken out and striking the pan is done  Gur sets in 15-20 minutes Boiling The keeping quality of jaggery can be improved by storing in humidity-controlled chamber maintaining the RH below 65% Vengaiah et al., 2013
  • 33.
  • 34.
    CASE STUDY 3 Sampleno. Treatment conditions Quality attribute Time (min.) Temp. (0 C) Lime (%) Colour Taste Flavour Texture S1 174 111 0.9 5 7 8 8 S2 150 124 1.5 5 5 6 6 S3 150 117 2.5 2 3 2 5 S4 126 111 2.1 8 9 8 9 S5 174 121 0.9 7 7 7 8 S6 150 117 0.5 6 8 3 7 S7 174 121 2.1 7 8 8 9 S8 150 117 1.5 5 6 5 6 S9 126 121 0.9 8 8 4 3 Control Traditional practice 7 7 5 6 •The best treatment for preparation of solid jaggery was 2.1% lime, processing temperature of 1110C and processing time of 126 minutes with an average sensory score of jaggery i.e. 8.5 (highest among all)
  • 35.
     Native toSouth East Asia  Became common beverage in China during seventh century  Assam contributes highest area under tea cultivation  Planted on large scale in North India in 1834  Commercially started in various regions like Nilgiris (1859) Waynad (1859)  Only plantation crop grown in Himachal Pradesh TEA (Camellia sinensis) Shanmugavelu et al., 2002
  • 36.
    PROCESSING  The manufacturingof tea starts in the field from the time of plucking  The processes involved in tea manufacturing are 1. Withering •Done to prepare the leaf for subsequent processes of manufacture •Leaves undergoes a period of dehydration •Artificial withering also done in drum •Leaves should not produce cracking sound when squeezed •When leaves are pressed with hands they should form a compact ball •Withered leaf will be like a silk hand kerchief to touch and feel
  • 37.
    2. Rolling •Carried outby machine •Leaf attain a twist and rolled •The polyphenol substances contact with enzymes during the breaking of leaf •In presence of oxygen, the polyphenol oxidised •Changes to highly coloured substances (theaflavins and thearubigins) •After 1st roll,the leaves are spread over sifter •Done to seprate the fine tea from coarse •The fine one is sent to fermentation room •The coarse tea is given second rolling •Teas are rolled 2-3 times for 30-40 minutes
  • 38.
    ] ] 3. Fermentation •Leaves spreadon concrete bed or aluminium trays •Fermentation vary from 1-3 hours •Low humidity causes blackening of leaf •Usually tea growers judge it by smelling, touching and feeling 4. Drying •Undergoes a process of drying in oven called as ‘driers’ •136-1550 C initially then reduced to 1050 C •Leaves are dried for 30-40 minutes •Final drying done at 73.750 C before packing Shanmugavelu et al., 2002
  • 39.
    CUT, TEAR &CURL METHOD  Short noted as CTC process  Two rollers meshing closely against each other  8-12 teeths per 3cm  Roller crush the leaves  Teeth tear and finally they are dried  Bits size 1-1.25 cm
  • 40.
    GREEN TEA  Preferredmostly in China and Japan  Heated quickly after harvesting  Cooled, rolled, heated and dried to 4% moisture content  Olive or pale yellow in colour  Strong pungent BRICK TEA On high demand in Tibet and China  Long and tough leaves  Coarse leaves heaped on cement floor to generate heat  Black fungus grows  Responsible for peculiar taste Soni et al, 2015
  • 41.
  • 42.
     Arabica coffee- Coffea arabica  Chromosome no. – 2n = 44  Origin – Ethiopia  Robusta coffee - Coffea canaphora  Chromosome no. – 2n = 22  Origin – Central Africa Cultivated mainly in Karnataka, Kerala, Tamil Nadu and Andhra Pradesh COFFEE differnce between coffee arabica robusta - Bing images and Chadha, 2002
  • 43.
  • 44.
    PROCESSING Coffee is processedby two methods • To prepare plantation or parchment coffee Wet method • To obtain cherry coffee Dry method
  • 45.
    WET METHOD  Ripeberries are preferred  Pulped on same day to avoid Fermentation  Mucilage break down  24-36 hours for arabica  More than 72 hours for robusta  Takes longer time in cool weather  They are washed with clean water 3-4 times  The parchment should not stick by hand after washing Natural fermentation Gosh and Venkatachalapathy, 2014
  • 46.
    Treatment with alkali Removalof mucilage by friction
  • 47.
     Soaking inwater for 24 – 42 hours  Improves quality  Sun drying for 7-10 days  Surface drying takes 24-48 hours  Hulling  Polishing  the beans are packed into clean new gunnies Gosh and Venkatachalapathy, 2014
  • 48.
    DRY METHOD Gosh andVenkatachalapathy, 2014
  • 49.
    •Family- Sterculiaceae •Native toSouth America •‘Gift of god’ •Name cocoa derived from plant caucault in Mexico during15th century •Intoduced to India in early 1963 •Large scale cultivation started in 1970s Cocoa (Theobroma cacao) Shanmugavelu et al., 2002
  • 50.
    PROCESSING  The splittingof pods is done within 2-3 days of harvesting  Pods are banged by some hard objects  Opening with knife damages the beans  Pre-fermentation inside the pod is hastened during harvesting and splitting  10-12 pods gives 1 kg wet beans  3 kg of wet beans gives 1 kg of fermented and dried beans Guechi et al., 2010
  • 51.
     Pulp ormucilage covering the bean is removed  Simple process but carried out properly in order to maintain the quality of bean  Flavor compounds and flavor precursors like free amino acids and reducing sugars are formed during fermentation.  The amount of these compounds is a confirmation of the well- fermented process and is responsible for the flavor profile of the finished chocolate Afoakwa et al., 2008 and Lefeber et al., 2012 Fermentation
  • 52.
     Best methodfor small quantity of beans  4-5 trays required at one time  Tray can be 60 cm long and 25 cm wide  10 kg of wet beans required to fill one tray  Top tray covered with leaves  Gets completed in 4-5 days  2-6 kg beans can be fermented  Bamboo baskets of diameter 20 cm and height 15 cm are used for 2 kg of wet beans  Unripe beans not ferment properly  After 24 hours it is covered with gunny bags and applied weight on it  Beans are fermented in 6 days and on seventh day they are taken for drying b. Basket method a. Tray method
  • 53.
    Drying  After fermentationbeans are dried under sun or by artificial means  2-3 cm thin layer for sun drying and time to time stirring  Dried up to 6-8% moisture  To check dryness of beans take beans in hand and crush them the characteristic sound indicates the correctly dried beans Shanmugavelu et al., 2002 and Saltini et al.,2013 Quality and flavor of cocoa products strongly depend on the various stages of cocoa processing
  • 54.
  • 55.
    CASE STUDY 4 storage6 12 18 24 Quality parameters BNTPE F NA TPEF BNTP EF NA TPEF BNTPE F NA TPEF BNTP EF NA TPEF Pod weight 310 505 400 450 400 265 525 350 350 434 300 454 Bean./pod 46 48 49 38 40 50 56 47 45 54 44 54 Bean wet wt./pod 95.62 141. 36 127.1 68.69 36.8 2 88.2 125.27 97.2 91.3 117.6 55.8 117.6 Average bean wt. 2.08 3.0 3.6 1.80 2.2 1.80 2.23 1.6 2.02 2.2 1.3 2.2 % of pods with browning/de cay 4.16 0 0 8.30 0 0 8.30 4.16 0 16.7 8.30 0 Odour 0.1 0 0.1 0.5 0.3 0.1 2.1 0.5 0.3 3.5 1.6 1.2 •The percentage browning/decay of cocoa pods were affected by storage environment and storage days •Beans stored in TPEF did not have any sign of decay throughout the periods of storage.
  • 56.
    •Family – Anacardiaceae •Chromosomeno. 2n = 42 •Native to Brazil •Introduced to Malabar coast of India in 16th century •Grown in tropical and sub- tropical region •Considered as ‘Gold mine of the waste land’ •Cultivated on large scale in Brazil, East Africa and India CASHEW NUT (Anacardium occidentale)
  • 57.
    PROCESSING  Before processingthe nuts should be dried immediately under sun  If the surface is of cement concrete drying for two full day is sufficient  If it is of mud drying for 3-4 days is necessary  Easily broken in the processing Karthic et al., 2014
  • 58.
    CLEANING AND GRADING Raw nuts are cleaned  Graded into three types:- small, medium and large  In most area this grading is not done before processing Karthic et al., 2014
  • 59.
    ROASTING  To makeshell brittle  It was the earliest process  Nuts heated on metal pan in open fire  Due to heat and slight charring the shell become brittle  Not followed in organized sector of industries Open pan roasting
  • 60.
     Fed intorotating hot drum  Ignites the shell portion of nut  Maintains temperature because of oil oozing out of the nuts  The roasted nuts still burning are covered with ash  To absorb the oil  Drum kept rotating for 2-4 minutes  Main disadvantage is loss of CSNL Shanmugavelu et al., 2002 Drum roasting
  • 61.
     Easiest andcommonly used technique  Broken kernel will be 3-4 %  No loss of CSNL  Roasted for 25-30 minutes at 100 lb pressure  Require 12-24 hours of cooling under natural air Steam roasting
  • 62.
    SHELLING  Shelled bylabour  Outer hard skin is removed  Easily removed after roasting PEELING  Extracted kernels have thin outer skin  Brown and pinkish in colour  Removed by hands  Become easier if heat treatment is given for 4 hours in drying chamber
  • 63.
    GRADING W - 180,is the ' King of Cashew ' - They are larger in size and very expensive. W - 210, are popularly known as ' Jumbo ' nuts. W - 240, it is an attractive grade which is reasonably priced.
  • 64.
    W - 320,are the most popular among cashew kernels and highest in terms of availability, worldwide. W - 450, are the smallest and cheapest white whole kernels and hence the favorite among low priced whole grades. www.cashewindia.org
  • 65.
    PACKING  Done intins  The air inside tin is exhausted  Recharged with Co2  Before sealing air tight  Each tin contain 10 kg of kernels Shanmugavelu et al., 2002
  • 66.
    CASE STUDY 5 TestNumber of nuts fed into the shell Completely shelled nut Whole kernels recovered Broken kernels recovered Shelling time (s) 1 50 48 40 10 25 2 50 47 34 16 25 3 50 49 36 14 25 4 50 50 32 18 25 5 50 46 33 17 25 Mean 50 48 35 15 25 •The average shelling efficieny of machine is 95% (higher than the motorised sheller) and whole kernel recovery is 70% (higher than mannual sheller ) •Beneficial for large scale production
  • 67.
    CONCLUSION High value industrialcrops which have great potential for the utilization of waste land The processing plays an important role in plantation crops as they are generally consumed only after processing The quality of plantation crops depends upon the processing methods. The new techniques, methods and improved machineries play an important role in enhancing the quality viz., improved drying method, machineries, optimized storage period etc.
  • 68.

Editor's Notes

  • #3 High value industrial crops # The term ‘Plantation’ means a large-scale agriculture unit Plantation crops are grown in the tropics having great economic importance to provide nutritional security, earn foreign exchange and to ensure livelihood security. because India is blessed with a rich and diverse agro climatic profile. The processing plays an important role in plantation crops as they are
  • #6 Chadha kl 2001 handbook of horticulture indonesia producer Most beautiful and usefull tree in the world all tree parts are usefull to man kind in one way or oyher Important among the all cultivated plants
  • #7 8-10 years for full bearing 60-65 year life span
  • #9 The storage of nuts is beneficial only if the nuts are ripe
  • #11 8 days for sun drying deposition of dirt and dust deteriorate the quality Solar batxh dryer developed by CPCRI takes 3 days for 100 nuts
  • #12 Malaysian direct type takes 34 hours for 200 nuts firing done below the copra bed
  • #13 Partahasarthy 2005 plantation crops 3 days to complete 10h batch per day Developed under phillipine germen project 2500 nuts 2 days
  • #14 Indigenous alcoholic beverages of south asia
  • #16 Proceedings of International Coconut Summit, 7th -11th May, 2007, Kochi, India. Jayasekara and Gunathilake, 2007 “Processing technologies for virgin coconut oil and coconut based Confectionaries and beverages internatinal coconut summit Lsc – 30-50kg/hr
  • #18 Food processing laboratory TNAU accc. To BIS standard of copra grading 70c is best
  • #19 Gupta et al., 2018 Perspectives on areca nut with some global implications: Symposium report transitional research in oral oncology Leprasy mycobacterium laprae nerve skin disease causing discoloration and lamps on skin kr. 457 t india
  • #22 In kr and kallipaku in kerala
  • #24 Annamalai and nair 1982 presented at annual convention of Indian society of agricultural engineers 15-17 feb udaipur Annon 1977 annual report for 1976 CPCRI kasargod India pp.283
  • #25 Shanmuhavelu , peter and kumar pro. tech,. Od spices and plantation crops Bhat 2017 Processing and Value Addition of Arecanut Product Diversification in Plantation Crops
  • #26 Mj francis kerala developed machine
  • #27 In donasia and malaysia highest producer in world 20-25 t ffb 4-5t oil /yr/ha. Ap, kr, assam kerala
  • #28 Kwasi Poku 2002 Small-scale Palm Oil Processing in Africa Food and Agriculture Organization of the United Nations Temp. 1200 C and pressurekg/cm3 BR- 4yr of planting pulp pressing by hydraullic press 75kg/cm3and screw press
  • #29 Davis 1985 enviromental awareness 8(4): 95-106
  • #30 Poor man’s drink venktaswamy(1967)
  • #31  arghya mani 2018 An Array of processed and value added products from palmyrah palm
  • #33 Vengaiah PC, 2013 Jaggery from Palmyrah palm (Borassus flabellifer L.)- Present status and scope Indian Journal of Traditional Knowledge
  • #36 Kangra tea was give geographical indication tag in 2005 China india srilanka kenya
  • #37 In NI April to dec 7-20 days interval Si WHOL YEAR WEEKLY INTERVALS
  • #39 Because of coarse tea leaves
  • #41 Rajju Priya Soni 2015. Tea: Production, Composition, Consumption and its Potential an Antioxidant and Antimicrobial Agent Intl. J. Food. Ferment. Technol.
  • #43 In india it is indtroduced by mohamedan saint settled in mysore bababudan hills near chikmanglure Dr. jacque pena of portugal one cup of coffee overcome kwashiorkor kr, kerala,tn nd ap
  • #45 Arbica sept-oct. Robusta dec. and jan.
  • #47 Wooden
  • #48 Gosh and Venkatachalapathy, 2014 Processing and Drying of Coffee – A Review international Journal of Engineering Research & Technology
  • #51 Flowering from 2nd year of planting 120-370 days to develop a pod from flower harvesting in rainy season
  • #52 Afoakwa et al., 2008 Cocoa fermentation: Chocolate flavour quality Lefeber, T., Papalexandratou, Z., Gobert, W., Camu, N. and De Vuyst, L. (2012) On-farm implementation of a starter culture for improved cocoa bean fermentation and its influence on the flavour of chocolates produced thereof. Food Microbiol 30, 379–392.
  • #53 Guehi, T.S., Dadie, A.T., Koffi, K.P.B., Dabonne, S., Ban-Koffi, L., Kedjebo, K.D., Nemlin, G.J., 2010. Performance of different fermen- tation methods and the effect of their duration on the quality of raw cocoa beans. Int. J. Food Sci. Technol. 45 (12), 2508–2514.
  • #54 Optimizing chocolate production through traceability. A review of the influence of farming practices on cocoa bean quality. Food control 45-60c good quality in sun drying
  • #57 It is hardy drought resistant plant came up in poor soil introduced to india to cover bare hills and for soil conservation kerala tn area
  • #58 3-4 year 30-40years march-april flowering nov.-feb 16-17%ms
  • #59 Iron contamination in the water can interact with polyphenolic materials of testa and the resultant bluish black complex may give patches on white kernel.
  • #63 Decortication
  • #67 Given by jain and kumar 1997 with 70% efficiency motorised sheller Given by ajov 1996 67 mannual sheller
  • #68 Learnt about the product of different plantation crops and their uses in our daily life cashew shelling machine Quality of processed products can be upgraded by appropriate processing