Jain Spice Plant- Innovation

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Jain Spice Plant- Innovation DRYING- INTRODUCTION Drying is one of the oldest and a widely utilized unit operation for preservation of food products.

1 Jain Spice Plant- Innovation DRYING- INTRODUCTION Drying is one of the oldest and a widely utilized unit operation for preservation of food products. Sun drying is the most preferred even today also, as it is simple & cheap. Over a period many advanced drying techniques came but still Most of the Spices grown in India are still sundried. Traditionally the spices like Chili, Turmeric and Ginger are sun dried in India since long. The sun drying process is uncontrolled and purely depends on the environmental condition and so the drying time is lengthy and varies from place to place. for any Drying process the total drying time is very important and critical as we are exposing food to atmosphere and so short drying time is best as against lengthy to minimize Microbial contamination. Disadvantages Sun Drying Damage to the product by rodents, birds and animals Degradation through exposure to direct irradiation of the sun and to rain, storm and dew Contamination by dirt, dust, wind-blown debris and environmental pollution Insect infestation Growth of microorganisms Additional losses during storage due to insufficient or non-uniform drying Losses can be estimated at more than 30% and it could be reduced to a great extent by improved methods of drying J a i n S p i c e P l a n t 1

2 DEHYDRATION PROCESS Further PRODUCT SPECIFIC INNOVATION by Jain s. Jain Farm fresh foods Limited entered in to Spice processing with an innovative dehydration technology and started its commercial production from Jan Company had built in-house three stage continuous belt tunnel Dryer for dehydration of Chili, Turmeric and Ginger. The process involves vigorous hot water washing/cleaning, Inspection and cutting of fresh spices before loading to Dryer. The dryer uses hot air as medium for dryer and this hot air is passed through product bed from both top as well as bottom side. Dryer has 3 zones and those are again divided in to different compartment to control drying process very closely and precisely. The capacity of dryer is 70 Mt/Day on fresh input basis and the drying time required is max 5H Process Time Traditional Vs Jain Spice Name Traditional Process Time Jain Innovative Process Time Sr. (Max) No 1 Chili Sun Drying 15 Days Mechanical Dehydration 6 Hrs. 2 Turmeric Boiling and then Sun 15 Days Mechanical Dehydration 6 Hrs. Drying 3 Ginger Sun Drying 15 Days Mechanical Dehydration 6 Hrs. Process in Brief used to dehydrate Fresh Chili, Turmeric and Ginger Fresh Chili, Turmeric and Ginger Pre-cleaning and Inspection Two Stage Hot water washing Cutting Dehydration Dehydrated Product J a i n S p i c e P l a n t 2

3 Jains Innovative Processes (Difference with reference to Traditional Process) A) Chili Drying Jains Traditional J a i n S p i c e P l a n t 3

4 B) Jains Processes - Turmeric Drying Jains Innovative Process Traditional Process J a i n S p i c e P l a n t 4

Foreign Bodies risk Better retention of Volatile Oil, Curcumin. Better Yield Traceability- Trace back till Farm No dye contamination from ink as procuring RM from Farmer.

5 Advantages of Drying Processes Developed by JAIN s. Vigorous washing arrangement to remove all contaminants from Farm. Hot Water Blanching Fully integrated process so less manpower and no human intervention Hot water washing along with fast drying better microbial results No Aflatoxins, Pathogens and Foreign Bodies risk Better retention of Volatile Oil, Curcumin. Better Yield Traceability- Trace back till Farm No dye contamination from ink as procuring RM from Farmer. Disadvantages of Traditional Processing- No Control on Drying Lengthy Drying Process Difficult to reduce Moisture below 12% Lot of Manual handling Source of Aflatoxins, Pathogens and Foreign Bodies Infestation, Insect Contamination - J a i n S p i c e P l a n t 5

6 Jain Process Advantages over Traditional Process Guaranteed Aflatoxin Free product Delivering low micro product No risk of Pathogen No infestation less manpower fully automated and mechanical so less manual intervention Better Yield Improved product Quality ( Color, VO, ) Production with Quality Results A) Dehydrated Turmeric Flakes Production (Consistent Absence of Aflatoxin) Turmeric Production Details Date Varity Dryer Lot Feed to Dryer Dehy. Turmeric Flakes Analytical Results TSS Moisture Curcumin Mold Aflatoxin Salmonella No Kg Kg Brix % % cfu/gm ppb cfu/25g Salem 8TUD BLQ (<2.0 ppb) ND Gattu 8TUD BLQ (<2.0 ppb) ND Salem 8TUD BLQ (<2.0 ppb) ND pratibha 8TUD BLQ (<2.0 ppb) ND Salem 8TUD BLQ (<2.0 ppb) ND Salem 8TUD BLQ (<2.0 ppb) ND Krishna 8TUD BLQ (<2.0 ppb) ND Salem 8TUD BLQ (<2.0 ppb) ND Salem 8TUD <10 BLQ (<2.0 ppb) ND Salem 8TUD BLQ (<2.0 ppb) ND Salem 8TUD BLQ (<2.0 ppb) ND Pratibha 8TUD BLQ (<2.0 ppb) ND Rajapuri 8TUD BLQ (<2.0 ppb) ND Salem 8TUD BLQ (<2.0 ppb) ND Salem 8TUD BLQ (<2.0 ppb) ND Salem 8TUD BLQ (<2.0 ppb) ND Salem 8TUD BLQ (<2.0 ppb) ND pratibha 8TUD BLQ (<2.0 ppb) ND Results: 1. No Aflatoxin observed 2. Mold content is max 400 cfu/g 3. Curcumin observed in between 2 to 4.8 % J a i n S p i c e P l a n t 6

7 B) Dehydrated Chili Production & Quality Results Production Details Analytical Results Date Varity TSS Dryer Lot no. Feed to Dryer Dehydrated Chili Moisture Color Mold Aflatoxins (TOTAL) Salmonella Pungenc y as Capsaici n Brix Kg Kg % ASTA cfu/gm ppb cfu/25g SHU 23-Jan-18 Bio indica RCD BLQ (<2.0 ppb ND Jan-18 VNR RCD BLQ (<2.0 ppb) ND Jan RCD BLQ (<2.0 ppb) ND Jan-18 Wonder RCD BLQ (<2.0 ppb) ND Feb-18 Wonder 8.1 8RCD BLQ (<2.0 ppb ND May-18 Wonder 9 8RCD BLQ (<2.0 ppb) ND Oct RCD <100 BLQ (<2.0 ppb ND Oct RCD <10 BLQ (<2.0 ppb) ND Oct RCD BLQ (<2.0 ppb ND Oct RCD BLQ (<2.0 ppb) ND Oct-18 Rasgulla 10 8RCD BLQ (<2.0 ppb ND Oct-18 Rasgulla RCD BLQ (<2.0 ppb) NO Oct-18 Rasgulla RCD BLQ (<2.0 ppb ND Oct-18 KRISHNA RCD BLQ (<2.0 ppb) ND Oct-18 Rasgulla RCD BLQ (<2.0 ppb ND Oct-18 KRISHNA RCD BLQ (<2.0 ppb) ND Oct-18 Saniya RCD BLQ (<2.0 ppb) ND Oct-18 Saniya 8.2 8RCD BLQ (<2.0 ppb) ND Nov-18 Saniya 8.1 8RCD BLQ (<2.0 ppb) ND Nov-18 Saniya 8.9 8RCD BLQ (<2.0 ppb) ND Dec-18 Krishna 9.2 8RCD BLQ (<2.0 ppb) ND Dec-18 Krishna 9 8RCD BLQ (<2.0 ppb) ND Results: 1. Aflatoxin is absent in all of the dehydrated Chili 2. Mold content is also low so the process is taking care of Microbiology also 3. Moisture of Product is below 8% and the color of product is also good J a i n S p i c e P l a n t 7

8 C) Dehydrated Ginger: Production and Quality Results Mfg. Date Ginger Production Details Feed to Dryer Dehy. Ginger Flakes Dryer Lot TSS Moisture AIA Volatile Oil Analytical Results Yeast/gm Mold/gm E.coli Salmonella Kg Kg No Brix % % % cfu/g cfu/g cfu/g cfu/25g 1/7/ GID <10 30 ND ND 1/18/ GID < ND ND 2/5/ GID < ND ND 5/2/ GID < ND ND 7/1/ GID < ND ND 7/6/ GID <10 20 ND ND 7/20/ GID < ND ND 7/22/ GID < ND ND 8/11/ GID < ND ND 8/13/ GID <10 <10 ND ND 8/16/ GID < ND ND 9/7/ GID < ND ND GID < ND ND GID < ND ND GID ND ND GID <10 30 ND ND 11/18/ GID <10 70 ND ND 12/7/ GID <10 50 ND ND 12/14/ GID <10 40 ND ND 12/17/ GID <10 60 ND ND 12/27/ GID <10 30 ND ND Results: 1. Maximum Mold count observed 1500 cfu/gm 2. On an average VO Content found 2.8%, which is much better as against we found in traditional sun drying. *** J a i n S p i c e P l a n t 8

Drying of agricultural products using forced convection indirect solar dryer

International Refereed Journal of Engineering and Science (IRJES) ISSN (Online) 2319-183X, (Print) 2319-1821 Volume 6, Issue 8 (August 2017), PP.47-54 Drying of agricultural products using forced convection