Jain Spice Plant- Innovation

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

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 2017. 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

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

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

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

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 19.02.2018 Salem 8TUD1001 77327 11943 8 6.09 4.23 30 BLQ (<2.0 ppb) ND 20.02.18 Gattu 8TUD1002 7048 1500 5.2 2.37 4.89 20 BLQ (<2.0 ppb) ND 26.02.2018 Salem 8TUD1003 161355 28282 4.2 5 2.64 60 BLQ (<2.0 ppb) ND 04.03.2018 pratibha 8TUD1004 16293 3590 5.4 8.57 3.87 110 BLQ (<2.0 ppb) ND 10.03.2018 Salem 8TUD1005 187152 30896 5.8 8.04 3.15 120 BLQ (<2.0 ppb) ND 11.03.2018 Salem 8TUD1006 120410 20283 4.5 8.54 2.71 30 BLQ (<2.0 ppb) ND 15.03.2018 Krishna 8TUD1007 14990 2560 4.6 7.45 2.32 10 BLQ (<2.0 ppb) ND 16.03.2018 Salem 8TUD1008 259369 44750 5.4 5.18 3.56 180 BLQ (<2.0 ppb) ND 25.03.2018 Salem 8TUD1009 156148 29980 5.6 5.75 3.49 <10 BLQ (<2.0 ppb) ND 01.04.2018 Salem 8TUD1010 197838 35807 6.2 4.35 3.41 70 BLQ (<2.0 ppb) ND 08.04.2018 Salem 8TUD1011 136822 25395 5.6 8.2 3.44 20 BLQ (<2.0 ppb) ND 09.04.2018 Pratibha 8TUD1012 32933 7069 5.4 7.6 2.74 50 BLQ (<2.0 ppb) ND 14.04.2018 Rajapuri 8TUD1013 14125 2525 5.8 4.52 3.09 100 BLQ (<2.0 ppb) ND 14.04.2018 Salem 8TUD1014 112842 18735 5.5 6.15 1.77 30 BLQ (<2.0 ppb) ND 24.04.2018 Salem 8TUD1015 121617 20064 5.8 8.23 2.54 20 BLQ (<2.0 ppb) ND 04.05.18 Salem 8TUD1016 10737 1900 5.5 7.32 2.98 60 BLQ (<2.0 ppb) ND 07.05.18 Salem 8TUD1017 26064 2515 5.6 6.32 2.31 250 BLQ (<2.0 ppb) ND 09.05.18 pratibha 8TUD1018 35223 2600 5.6 4.25 2.36 400 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

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 11.2 8RCD1003 17997 2514 7.65 39.05 40 BLQ (<2.0 ppb ND 18735 25-Jan-18 VNR 10.6 8RCD1004 12675 2530 8.89 41.89 180 BLQ (<2.0 ppb) ND 56450 27-Jan-18 341 9.6 8RCD1005 6874 1351 5.23 102.62 30 BLQ (<2.0 ppb) ND 36657 29-Jan-18 Wonder 11.6 8RCD1006 47877 6755 4.02 106.66 100 BLQ (<2.0 ppb) ND 3452 11-Feb-18 Wonder 8.1 8RCD1007 14803 2545 4.55 114.14 100 BLQ (<2.0 ppb ND 4904 5-May-18 Wonder 9 8RCD1008 3202 125 6.54 53.89 100 BLQ (<2.0 ppb) ND 11587 8-Oct-18 720 9.1 8RCD1011 4066 600 6.75 113.69 <100 BLQ (<2.0 ppb ND 15597 8-Oct-18 720 9.1 8RCD1012 2121 330 4.12 163.98 <10 BLQ (<2.0 ppb) ND 12468 16-Oct-18 720 8.5 8RCD1013 10969 1570 1.61 86.13 70 BLQ (<2.0 ppb ND 8458 19-Oct-18 720 10.1 8RCD1014 12932 1800 0.85 89.05 50 BLQ (<2.0 ppb) ND 9159 19-Oct-18 Rasgulla 10 8RCD1015 8924 1070 4.08 80.59 210 BLQ (<2.0 ppb ND 5966 20-Oct-18 Rasgulla 10.4 8RCD1016 681 150 4.5 85 150 BLQ (<2.0 ppb) NO 2403 24-Oct-18 Rasgulla 10.3 8RCD1017 10087 1170 1.85 103.44 50 BLQ (<2.0 ppb ND 5769 25-Oct-18 KRISHNA 10.1 8RCD1018 6390 1030 11.84 90.38 210 BLQ (<2.0 ppb) ND 2709 28-Oct-18 Rasgulla 10.4 8RCD1019 8681 1080 4.33 100.28 160 BLQ (<2.0 ppb ND 8497 28-Oct-18 KRISHNA 10.2 8RCD1020 17095 2790 4.43 151.54 170 BLQ (<2.0 ppb) ND 10244 30-Oct-18 Saniya 10.5 8RCD1021 10969 1990 2.12 134 400 BLQ (<2.0 ppb) ND 11342 31-Oct-18 Saniya 8.2 8RCD1022 25443 4050 5.6 138.18 40 BLQ (<2.0 ppb) ND 13068 2-Nov-18 Saniya 8.1 8RCD1023 4053 690 2.94 135.64 150 BLQ (<2.0 ppb) ND 8883 3-Nov-18 Saniya 8.9 8RCD1024 8127 1465 2.06 119.13 130 BLQ (<2.0 ppb) ND 9248 10-Dec-18 Krishna 9.2 8RCD1025 11579 1890 5.54 124.32 180 BLQ (<2.0 ppb) ND 10598 10-Dec-18 Krishna 9 8RCD1203 8971 1100 3.46 158.23 60 BLQ (<2.0 ppb) ND 19604 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

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 1/7/2018 21658 1050 8GID1001 4.6 0 0.62 2.8 <10 30 ND ND 1/18/2018 26666 2720 8GID1002 4.5 6.58 0.31 2.16 <10 240 ND ND 2/5/2018 23133 1345 8GID1003 4.6 8.6 0.12 1.99 <10 170 ND ND 5/2/2018 4570 1410 8GID1005 5.5 7.51 0.21 3.5 <10 130 ND ND 7/1/2018 5931 1084 8GID1006 8.3 9.61 0.14 1.52 <10 330 ND ND 7/6/2018 4852 955 8GID1007 2.5 2.47 0.14 1.98 <10 20 ND ND 7/20/2018 6947 188 8GID1012 2.1 5.34 1.05 4.44 <10 160 ND ND 7/22/2018 13460 627 8GID1014 2.2 7.54 1.26 5.84 <100 1500 ND ND 8/11/2018 15716 950 8GID1016 2.8 2.92 0.3 3.24 <10 310 ND ND 8/13/2018 16310 1155 8GID1017 3 4.05 0.2 3.6 <10 <10 ND ND 8/16/2018 16125 1035 8GID1018 2.8 7.1 0.01 3.8 <10 150 ND ND 9/7/2018 51537 2780 8GID1022 3.6 2.41 0.19 3.43 <10 120 ND ND 10.09.2018 51484 4200 8GID1024 3.5 1.98 0.19 2.98 <10 320 ND ND 14.09.2018 59776 4560 8GID1025 3.7 4.86 0.16 2.37 <10 100 ND ND 18.09.2018 18870 1490 8GID1026 3.2 5.22 0.2 2.45 ND ND 09.10.2018 15108 1225 8GID1030 2.8 7.95 0.22 1.12 <10 30 ND ND 11/18/2018 4294 1155 8GID1031 2.8 7.6 0.52 1.6 <10 70 ND ND 12/7/2018 14503 1200 8GID1034 5.3 3.8 0.34 2.31 <10 50 ND ND 12/14/2018 35720 4392 8GID1035 3.8 5.66 0.69 1.83 <10 40 ND ND 12/17/2018 13415 1340 8GID1036 2.8 4.47 1.1 2.66 <10 60 ND ND 12/27/2018 8417 300 8GID1037 3.8 4.35 2.83 <10 30 ND ND 3.7 4.9 0.4 2.8 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