Training Report

1. Induction Report
VISHNU MOHAN M

2. Oleoresin
Essential Oil
TasteAroma
Oleoresin
Spice

3. Oleoresin
Benefits of Oleoresin
• Consistency in product quality
• Shelf Life improved
• Storage area required is minimized
• Cost Benefit (Low Labor cost & Overheads, Low Dosage)
• Dosage
• Availability (Full year availability)
• Product Consistency (No Variation in quality due to yield)
Fixed Oil
• Doesn't evaporate
• Has higher FFA
• Low refractive Index
• Optically Inactive
Volatile Oil
• Evaporates under certain temperature
• Can be recovered easily under distillation
• High refractive Index
• Optically Active

4. Advance Extraction Technology
- Super Critical Carbon Dioxide Extraction Co2
- Used to achieve higher concentration percentage and flavor
and aroma
- Spinning Cone Column
- Used for Products which has lower percentage of aroma
or flavor like fruits
- Centritherm
- Used for concentration of heat sensitive products, low
temp extraction, keeps the aroma, flavor & active
ingredients in tact
- Basic Steam Distillation
- Used for Extraction of oil, can achieve different grades
with various fraction
- Solvent extraction facilities
- Majority of products are used with solvent extraction
- Mechanical Extraction (Non Solvent)
- Mostly products marketed under straights brand are
processed through mechanical extraction

5. Extraction Process
- Continuous Extraction
- Key Highlights
- Process cycle time is 24 hrs
- High Yield
- Lot of Moving Parts, Prone to breakdown
- Batch Extraction
- Key Highlights
- Process Cycle time is 72 Hrs
- High Yield
- Minimum Moving Parts
- Low Power Consumption
- Co2 Extraction
- Key Highlights
- Process Cycle time is 2 Hrs
- Low Yield but Rich Texture and higher quantity of active ingredients
- Compact Process

6. Black Pepper Process
- Key Process Steps for Black Pepper Extraction
• Sieving Process
• DE stoning
• Moisturizing the black pepper
• Flaking
• Oil Distillation
• Extraction
• DE colorization by addition of active Charcoal
• Desolvantization of Micella
• Normal
• Vacuum
• Aeration
• Crystallization of concentrated Micella for Piperine Extraction
• ANF
• Pulverizing
• Blending
• Packing
Important Temperatures & Pressure
- Solvent vaporizing temp - 77.1° C
- Evaporation Temperature for
concentration - 95° C
- Normal Distillation – 95° C
- Pressure in Vacuum Distillation is
0.85 Bar
Solvents used is Ethyl Acetate & Hexene

7. Turmeric Process
- Key Process Steps for Turmeric Extraction
• Cleaning
• Moisturizing
• Grinding & Flaking
• Quality Check
• Extraction & Filtration
• Evaporation
• Desolvantization
• 1st Stage Purification
• 2nd Stage Purification
• Magnetic separation
• Homogenizing
• Blending
• Filling & Packaging
• Packing
Important Temperatures & Pressure
- Solvent vaporizing temp - 77.1° C
- Evaporation Temperature for
concentration - 100° C
- Normal Distillation – 100° C
- Pressure in Vacuum Distillation is
0.85 Bar
Solvents used is Ethyl Acetate & Hexene

8. Chili Color & Capsaicin
Extraction Process
• After extraction of Oleoresin, Liquid Liquid Extraction method
is used to separate color & Flavor
• Oleoresin is pumped to a extractor which is coupled with a
rotating screw
• 10% aqueous solvent (Methanol
5% water) is added to oleoresin
There is contact time which
Carries separation of Color at the
Bottom and capsaicin at the top with
Solvent and then capsaicin is
desolvantized

9. Centritherm Extraction
• Highlights
• Keeps the active ingredients intact
• Can achieve higher concentration
• Low temperature evaporation can be achieved
• Centrifugal design
• Used for fruit, tea, coffee & Vegetable extracts etc
• Also used for heat sensitive spices or active ingredients
• No effect on color, flavor and active ingredients
• Used for solvent removal
• Low product loss and effective product handling
• Can handle highly viscous fluid

10. Raw Material
Spices Weight in
Tons
Source Avg Prices
In Rs/Kg
Chili 14000-
18000
Andhra (Guntur),Karnataka & MP 50-90
110-140
Pepper 4500 Vietnam, Sri Lanka, Indonesia, Madagascar,
India
300-550
Turmeric 14000 Kerala, Karnataka, Maharashtra, Andhra,
Tamil Nadu, North East, Burma, Cambodia,
Indonesia, Nigeria, Ethiopia
100-230
Ginger 2500 Karnataka, Nigeria, Burma, China, Kerala 60-170
Nutmeg 500-700 India, Sri Lanka 120-290
Cardamom 500-700 Russia, Bulgaria, India 600-1400
Paprika 500 China 60-80
Celery 1000-1200 Punjab 70-80
Mustard 50-100 Ukraine, Canada 35-60

11. Raw Material
Spices / Properties
Black
Pepper
Indonesia
Black
Pepper
Vietnam
Black Pepper
Madagascar
Light
Black Pepper
Madagascar
Bold
Black
Pepper
Srilanka
Black
Pepper
White
Indian
Turmeric
Finger
Polished
ethiopia
Turmeric
Finger
Gundlupet
Indian
(TG)
Turmeric
Finger
Indonesia
Turmeric
Finger
Indonesia
Sliced
Turmeric
Burma
New Malai
Moisture % 0-12 0-12 0-14 0-14 0-15 0-12 0-11 0-11 0-11 0-11 0-12
Yield % 8-10 7-9 9-11 9-11 9.4-12.5 7-10 8.8-10 6.5-9 7.5-10 7.5-10 10.2-12.5
Oil v/w 2.5-4.2 1.5-2.5 4-6 4-6 4-6 2-3
Active Ingredient 47-50 45.5-55 48-52 48-52 49-55 48.5-55 2.6-4.5 2.6-4.5 3.5-5.5 4.1-6 4.1-6
Season Aug-Oct Feb-Jun Feb-Jun Feb-Jun Aug-Oct Dec-Apr Feb-Apr Feb-Apr Aug-Dec Aug-Dec Aug-Dec
Color Unit - cu 4500-5000 5200-6500 5200-6500 5000-6500 4100-5500

12. Raw Material
Spices / Properties
Ginger
Dried
Sliced
Nigeria
Ginger
Dried
Rajkumary
Ginger
Dried
Shimoga
Ginger
Dried
Chinese
Cassia
Indonesia
Nutmeg
Indonesia Cardamom
Coriander
Russian
Cumin
Indian
Cinnamon
Madagascar
Horsnorms
Laurel Leaf
Turkey
Moisture % 0-12 0-11 0-12 0-12 0-8 0-11 0-12 0-8 0-11 0-10 0-12
Yield % 6-7.3 4.5-5.7 6-7.5 6-7.3 3.5-5.5 20.5-28 5-7 11-16 11-17 7.5-12 3.3-5
Oil v/w 1.9-2.5 1.6-2.3 1.6-2.6 1.9-2.5 63-75 3.6-12 1.5-2 1.5-4
Active Ingredient 6-9 10-15
Season Dec-Jan Jan-March Apr-Jun Jan-Feb Jan-Dec Feb-May Aug-Jan Jan-Dec Feb-March Jan-Dec Jan-Mar
Color Unit - cu

13. Raw Material
Spices / Properties
Caraway
Seed India
Clove Buds
Sri lanka
Yellow
Mustard
Piper
Longrum
Indian
Ashwagandha
Indian
Thyme
Tyrkey
Dill Seed
Indian
Moisture % 0-11 0-11 0-12 0-12 0-12 0-12 0-12
Yield % 16-20 17.2-20 25-35 4-8 12-20 2-3 5-8
Oil v/w 12-15 0.35-0.8 0.07-0.45 1-2
Active Ingredient 15-18
Season Feb-Mar Jan-Dec Mar-May Jan-Mar Jan-Mar Aug-Sep Feb-Mar
Color Unit - cu

14. Seasons for Spices
MATERIAL
HARVEST
SEASON
JAN FEB MAR APR MAY JUN JUL AUG SEP OCT NOV DEC
VANILLA BEANS CURED - MADAGASCAR * *
VANILLA BEANS CURED A GRADE - INDIAN * * * * *
VANILLA BEANS CURED A GRADE - T * *
BLACK PEPPER - NEDUMANGADU * * * *
BLACK PEPPER - WAYANADU * * * *
BLACK PEPPER - SRILANKA * * * * * *
BLACK PEPPER - INDONESIA * * *
BLACK PEPPER - VIETNAM * * * * *
BLACK PEPPER - MADAGASCAR * * *
WHITE PEPPER LIGHT - IMPORTED * * * * *
GREEN PEPPER * *
PINK PEPPER - GRADE II *
TURMERIC FINGER - ALLEPPY * * * * *
TURMERIC - KOCHA * * * * * *
TURMERIC - T.P * * * * * *
TURMERIC - GREEN *
TURMERIC - T.G. * * *
TURMERIC - VITHAKAL - ERODE * *
TURMERIC - LAKADONG * * *
TURMERIC - BARSI KOCHA * * * * * *
TURMERIC DESI CADAPPA POLISHED * * *
TURMERIC - VIETNAM * * * *

15. Seasons for Spices
TURMERIC - INDONESIA * * * * *
TURMERIC - MYANMAR-M * * * * *
TURMERIC - CAMBODIA * * *
TURMERIC FINGER MYANMAR - MALAI * * * * *
TURMERIC UNPOLISHED - INDONESIA * * * * *
TURMERIC - INDONESIA - MOTHER * *
CARDAMOM * * * * * *
BLACK CARDAMOM * * * *
CELERY SEEDS * * *
BLACK PEPPER MG 1 * * * *
BLACK PEPPER PINHEAD * * * * *
CHILLI 273 STMLS AF/PF * * *
CHILLI TOMATO AF/PF * * *
GINGER DRIED WHOLE - RAJAKUMARY * *
GINGER DRIED WHOLE - SHIMOGA * * *
GINGER GREEN - LOCAL *
GINGER DRIED - FOR CO2 * *
GINGER DRIED SLICED - NIGERIAN * *
GINGER DRIED - CHINESE * * *
GINGER DRIED WHOLE - ETHIOPIA * * *
GINGER DRIED WHOLE - BURMA * * *
CASSIA - IMPORTED * * * * * * * * * * * *

16. Seasons for Spices
CLOVE BUDS - SRILANKA * * *
CLOVE BUDS - MADAGASGAR * * *
CLOVE BUDS -LOCAL * *
MACE - LOCAL * *
MACE ORDINARY - IMPORTED * * * *
NUTMEG - LOCAL * * * *
NUTMEG LOCAL WITHOUT SHELL - BEST QUALIT * * *
NUTMEG BWP WITH SHELL - SRILANKA * * * *
NUTMEG BWP WITH SHELL - INDONESIA * * * *
NUTMEG - PAPUA * * * *
GUGGUL * *
DATES WITHOUT SEED * * * * * * *
ALMOND * * * * * * * * * * * *
ONION FRESH * *
ONION (SAVALA) FRESH * *
CLOVE SPLIT * * *
CORIANDER FRESH LEAVES * *
SPINACH FRESH LEAVES * * * * * * * * * * * *
CURRY LEAVES FRESH * *
HADJOD FRESH * * * *
BOSWELLIA SERRATA * * *
GREEN TEA LEAVES - DRIED * * * * * * * * * * * *
MUSTARD SEEDS - SANGAM * * *
MUSTARD YELLOW - INDIAN * * *
MUSTARD DALL * * *

17. Seasons for Spices
MUSTARD SEEDS FORGE - CANADIAN * * * *
MUSTARD YELLOW - CANADIAN * * * *
MUSTARD SEED CUTLUS - CANADIAN * * * *
BLACK PEPPER TGEB * * * * *
BLACK PEPPER TGSEB * * * * *
BLACK PEPPER UNGARBLED-RAJAKUMARI
BLACK PEPPER PINHEADS-BOLD * *
TURMERIC BIT POLISHED-SALEM * *
CORIANDER CLEAN * * *
CUMIN SEEDS CLEAN * *
FENNEL SEED SMALL * *
CUMIN * *
FENNEL * *
FENUGREEK BOLD * * *
CHILLI BYADGI * * * *
CHILLI - TOMATO BEST * * *
CHILLI - WONDERHOT * *
CHILLI - JWALA LAYER * * *
CHILLI - S4 MEDIUM BEST- GUNTUR * * * *
CHILLI - TEJA RED * * * *
CHILLI (GREEN) - DRIED * * *
CHILLI - NAMDHARI * * * *
CHILLI GREEN (FRESH) * * *
CHILLI 334 STMLS-AF/PF * * * *
RED CHILLI MUNDU STMS -AF/PF * * *

18. Seasons for Spices
CHILLI END5 STMLSAF/PFASTF * * * *
CHILLI 273 WSTM AF/PF * * * *
CHILLI DD WSTM AF/PF * * * *
CHILLI 341STMLS AF/PF * * *
ROSEMARY MOROCCAN * *
SAGE TURKISH * *
SAGE DALMATION * *
OREGANO GROUND - TURKISH * *
OREGANO LEAVES - GIVAUDAN QUALITY * *
BASIL - INDIAN * *
GYMNEMA SYLVESTRIS LEAVES * *
HORSERADISH DEHYDRATED FLAKES - CHINESE * *
TEA * * * * * * * * * * * *
COFFEE POWDER - PURE * *
VALERIAN ROOTS *
ACORUS CALAMUS ROOTS (VAYAMBU) * *
ASHWAGANDHA ROOTS-EXTRACTION GRADE * *
GALANGAL ROOT * *
LICORICE ROOTS * *
BACOPA MONNIERI * *
DECALEPIS HAMILTONI (MAGALI) * *
GARDENIA GUMMIFERA (DIKAMALLI) * *
CHAMOMILE DRIED FLOWERS - FAIRTRADE * *
BLACK CARROT FRESH *

19. Seasons for Spices
BAY LEAF * * * * * * * * * * * *
ROSEMARY FRESH LEAVES *
ROSEMARY LEAVES - DRIED *
PATCHOULI FRESH LEAVES * *
MINT FRESH LEAVES * * * * * * * * * * * *
ONION SMALL * * * *
PIMENTO * *

20. Quality measures maintained
• Raw Material Sampling Method root+1
• Raw Material is approved according to specifications
• Lab Sample Processing of Spices up to Miscella
• Piperine, Cur cumin Content is checked in HPLC (High
Performance liquid chromatography)
• Sample is stored for every new product as well as
existing/invoiced product up to 3 years
• Certification can be provided to customers like (FSSC 22000,
HALAL-JUM, HALAL-MUI, KOSHER, FSSAI, BRC, ISO etc)
• Audit is conducted by these certifying authorities periodically
• Quality customer interface for comprehensive clarifications to
customer’s QC or any quality related concerns
• Specifications are very important before closing the order, lack
or insufficient specification might cause rework or free supply.
• Product configuration can be fine tuned with the help of QC

21. Microbiology Test
• Microbiological Parameters Analyzed
• Total Plate count / Standard Plate count
• Total yeast and mould count
• Pathogenic Bacteria
• E.Coli
• Salmonella
• Bacillus Cereus
• S.Aureus
• C.Perfringens
• Pseudomonas
• Enterobacteria
• Coliforms
• Method Followed
Bacteriological Analytical Manual (BAM) US Safety
Challenges with BAM is reporting is under a range which is not acceptable to customers.
• Customers requirement’s are
Indian Standard Method
ISO Method

22. Microbiology Test
Bacterial effect on Product
Plate count and total yeast count can affect shelf life, odour, taste, appearance. it
can cause some decease in long term when a persons immunity is low
Pathogenic bacteria can cause deceases after consumption.
Growth of the bacteria
If the moisture content in the product is slightly higher chances of bacterial
growth are higher
Some bacteria’s like spores can survive higher temperatures, they can deactivate
at higher temp and grow in normal temp. In some QC tests they can’t be detected.
Other treatment methods
ETO Treatment (Ethylene Oxide Gas)

23. Finance & Costing
• A sample is send to Spice board, where Yield is calculated.
• If the yield is not achieved by the company in production, the agreed
quantity declared by Spice board needs to be exported.
• Under Merchant trade if the domestic trader or company wants to
export the material CT-1 form & Shipping bill with license number
needs to provided to Synthite, where import duty can be claimed by
Synthite
• E.g. – 100 Kg of Pepper Oleoresin needs to be sold
• Yield on pepper is 13%
• 769 Kg of Raw Material is required
• Per Kg Cost of Raw Material 550 INR
• Total Cost of Raw Material – 423000
• Import Duty – 3,34,000
• Interest – 18%
• For EOU Import Duty waiver CT-3 is required and ARE-3 Issued by
Supplier
Import Duty Raw Material
78.98% Pepper
70% Chili
36.136% Turmeric
30.9% Ginger
36% Most of the
spices

24. Planning
Sales Order
In FG Stock
Assign to Order
QC Clearance
Delivery
Creation
PGI & Dispatch
In Semi finished
FG Stock
Blending as per
PO
Mixing &
Blending Area
QC Clearance
Assigned to
Sales order
Delivery
Creation
PGI & Dispatch
Need to Make
Resource
Planner
PO to RM
If not in stock
then
Procurement
Production
Semi FG
FG
Assign to Order
QC Clearance
Delivery
Creation / PGI /
Dispatch
Order
Confirmation
Material Planner

25. Testing-
Equipment’s used for Testing
UV Spectrometer
Used to determine color value, Active Ingredient content
UV light is passed through the sample with different wavelength’s suitable for
particular product
Programs can be preset for different products
less accurate than HPCL
Test is performed with various intervals
GAS Chromatography
Test Provides detailed analysis about composition and volatile oil
Two phases are used Stationary and Mobile
200°c is the standard temperature maintained in the equipment input product is
passed through the inlet
Machine has circular column inside made of silica & coated with steel is the
stationary phase
Gases used are Hydrogen, Oxygen, Nitrogen with 300 Bar Pressure
Input product is converted into gaseous form & fed in the machine which is the
mobile phase.

26. Testing
High Pressure Liquid Chromatography (HPLC)
• HPLC has Stationary and Mobile phase
• Product is separated physically
• More accurate than UV method
• Different Columns are used for different products
• Pressure varies for different products
• Waste is collected after detector determines active Ingredients
• Detector has nanometer to which is used for measurement

27. Additives
• Polysorbate (Monebat) – 80 Water soluble
• Propylene glycol Water Soluble
• Sun Flower Oil Oil Soluble
• Atsurf Oil Soluble
• Datum ester Oil & Water Soluble
• Sorbitol Water & Oil Soluble
• Tri Acetine Water & Oil Soluble
• Key Properties of Additives
• Water or Oil Solubility
• Disposability
• Can maintain product structure like visual appearance
• Viscosity

28. Blending Principle
Loss in handling / Product loss
Products which has heavy density difference might
settle at the bottom of the vessel, In such cases it can not be recovered
completely
Specification
Emulsifier or additive is added to manage the specification i.e.
to achieve 40/20 Oleoresin of piperine & Oil blend, 50% piperine semi finished
good is available, 20% extra additives needs to be added or 80 gms of oleoresin
needs to used to achieve 40% Piperine content and accordingly the oil
percentage.
Shelf Life
Addition of additives will reduce the shelf life of oleoresin in majority of
the products shelf life of oleoresin is 12 months & 24 months for essential oil
Sequence of Blending
Incorrect sequence will distort the appearance of the product, the
product might not blend well with the users products due to density variation of
additives

29. Active Ingredients
Sr No Products Active Components
1 Turmeric Curcumin, Demethoxy Curcumin, Bis
Demethoxy Curcumin
2 Pepper Alpha & Beta Piperine, D-Limonene,
Sabinene, Beta Caryophellene
3 Capsicum Capsaicin, Dilhydro Capsaicin, Nor Dilhydro
Capsaicin
4 Ginger Gingerols, Shogoals, Alpha & Beta
Zingiberene
5 Cinnamon, Casia Courmarin, Cinnamic Aldehyde
6 Cardamom Cineol, Terpenyl Acetate
7 Nutmeg Myristicin, Safrole, Alpha & Beta Pinen
8 Celery D-Limonene, Selinene
9 Vanilla Vanillin
10 Clove Euginol, Euginol Acetate
11 Mustard Allyl ISO Thiocyanate, Butyl ISO Thiocyanate

30. Spice Equivalency
Sr No Products Kg
1 OR Black Pepper 20
2 OR Green Pepper 100
3 OR Ginger 40
4 OR Cardamom 50
5 Oil Celery 100
6 OR Chili 2.5% Capsaicin 25
7 OR Chili 10% Capsaicin 100
8 OR Turmeric C-14 60
9 OR Nutmeg 200
10 Oil Garlic 700
11 OR Fennel 20

31. Applications Area
Sauces
Tomato Sauce
Green Chili Sauce
Mayonnaise Sauce
Bakery & Confectionary
Fruit Cake
Icing for cakes
Flavors for cakes
Biscuits & Cookies
Cream Biscuits
Breads
Snacks & Savories
Namkeens
Extruded Snacks
Potato Chips
Pickle
Beverages
Fruit Beverages
Carbonated Beverages
Flavored Drinking water
Tea Flavoring
Herbal Tea
Dairy
Flavored Milk
Buttermilk
Ice Creams
Perfumery & Fragrances

32. Understand Requirement in
market
• What is the customer application like Masala Tea, Color required for ice
cream, Sauce, Seasoning, Dairy, Soup, Noodles, Personal care,
Neutraceutical, Beverages, Perfumes etc
• Oleoresin with what percentage of oil is required with specific gravity
• Format required, Beadlets, Granules
• Amount of active ingredients required
• What kind of appearance is required
• Water Soluble or Oil Soluble not applicable for sauce, seasoning
• Quantity required accordingly packaging can be decided
• Encapsulated product requirement of oil or oleoresin
• What kind of tests are required e.g. Microbiology
• What kind of certification required HALAL, FSSAI Etc
• Which process is preferred Co2 or solvent extraction
• Specific additives needs to be added
• Any other specific requirement

33. Team Building in industry
• Making the team aware of the responsibilities
• Have a positive language of communication with customers &
internally
• Trust the team & back them to exceed the target
• Issues can be escalated to HOD with the help of Data or reference
• Minimize rework due to lack of Incorrect or insufficient input
• Consistent feedback from HOD monthly
• Review the Order Booking & backlog according to the forecast &
target
• Focus on maximum reach & engage with customer on consistent
basis
• Understand the market feedback and fine-tune strategies for various
products & involve sales & application and sales team.
• Focus on creating new sales avenues
• As a leader consistently work hard
• Try to replicate best sales practices
• Weekly meeting

34. THANK YOU
VISHNU MOHAN M