eChapters

Abstract

Chitin has been ranked at second position after cellulose as the most abundant natural biopolymer. Chitin has similar chemical structure to that of cellulose with 2-acetamido-2-deoxy-b-d-glucose (NAG) monomers attached via ß (1–>4) linkages. Chitosan is the deacetylated (to varying degrees) form of chitin, which, unlike chitin, is soluble in acidic solutions. Therefore, Chitosan, a copolymer of glucosamine and N-acetyl glucosamine, is amongst the most copious biopolymers on earth and finds wide range of biomedical and industrial applications. It has been approved in 1983 by USDA as a feed additive. Chitin basically is obtained from prawn/crab shells and chemical treatment of chitin produces chitosan. Since supplies of seafood waste are seasonable and variable, so fungi can be used as alternative source for chitosan. The unique physicochemical properties of chitosan provide great potential of its utilization in food industry especially dairy industry such as production of dairy products, dairy waste water treatment, extension of shelf life of dairy products etc. In recent years, exotic synthetic compounds are losing their appeal, thus application of chitinous products in dairy as well as processing aids has received considerable attention. The modified chitosan with greater functional properties has increased application in different dairy foods. This chapter focuses on the fundamental uses of chitosan and their derivatives in a variety of dairy industry applications.

Introduction

The emerging functional foods market presents a considerable challenge to all manufacturers to keep abreast of the use of adequate packaging materials for their products. The interest in functional foods is intrinsically linked to the potential health benefits of their bioactive components. Preserving these bioactive components is, therefore, a crucial factor to providing the anticipated health benefits of functional foods. However, recurring failure in maintaining the quality of functional foods has been reported. Functional foods include a wide variety of products such as prebiotics and probiotics, dried foods (fibers, tea, herbs, etc.), fermented products (yogurts, kefirs, vegetables), and fresh fruits and vegetables. Their bioactive components (minerals, vitamins, fibers, peptides, proteins, w–3 polyunsaturated fats, antioxidants, enzymes, and symbiotics) range from very simple molecules to complex living organisms such as bacteria.

Weaning foods

Introduction

Breast milk is natural and best for the growth and development of newborn babies. Although breast milk is adequate to provide an optimum nutrient till the age of six months but after that it is not sufficient to sustain optimum growth and fulfill their nutritional requirements. Various nutrients are required to supplement milk until child is ready to eat adult meal. This additional food along with the breast milk is referred as “complementary Food”. With adequate amount of complementary feeding breast-feeding continues up to two years of age and beyond so, referred as complementary feeding period.

Appropriate and adequate amount of complementary feeding helps in preventing malnutrition stunting and promoting growth. Introduction of this complementary food is called as weaning.

Weaning is the process of introducing adult food and beverage to the infant to support their growth and development. This is very crucial period in infant’s life. This is a period for diet transition as the nutrition requirements for growth and brain development is quite high. Introduction of various taste and texture promotes biting and chewing skills (Guthrie, 1975). Most six-month age children start eating semisolid foods. Weaning homogenized infant foods play a major role in the nutrition of infants (Martinez, 2004).As infants grow, their nutritional requirements also increase. To keep up this growing demand WHO recommends that infants start eating solid, semi-solid or soft foods at the age of 6 months to ensure sufficient nutrient intake.

Improvements in microscopes enabled scientists to study the ‘invisible’ organisms – that is, those too small to be seen with the naked eye. They were able to show that certain of these microscopic creatures are responsible for the infectious diseases of higher organisms. Most of them are harmless, some are essential for life and some are used in the manufacture of products that are of benefit to humans.

LAB constitutes a group of gram positive bacteria. They are nonsporulating, nonrespiring but aerotolerant cocci or rods, which produce lactic acid as one of the main fermentation products of carbohydrates, they do not have cytochromes. They belong to the phylum Firmicuttes, class Bacilli and order Lactobacillaceae. The group includes several genera such as Lactobacillus, Lactococcus, Bifidobacterium, Pediococcus, Enterobacter, Corynebacterium, Streptococcus, Leuconostoc etc.

1. Introduction

Cleaning and grading are the first and vital post harvest operations undertaken to remove foreign and undesirable materials such as crop seed, chaff, mud, stones, straws, immature grains, dust, husk and even iron and steel particles from grains as well as fruits and vegetables and to separate the products into various fractions. Generally, the hand threshing and the traditional handling used in most developing countries cause a larger percentage of foreign matter with these crops. Thus, more cleaning is required. Cleaning is essentially a separation process, in which some difference in physical properties of the contaminants and the food units is exploited. 

Fruits and vegetables are more perishable and generally have a higher value compared to cereals, making them very important in terms of minimizing waste and improving employability in the food industry. The losses in fruits and vegetables are significant, but through effective post-harvest processing, these losses can be reduced, and surplus produce can be better utilized. This processing involves a variety of techniques that prepare fruits and vegetables for conversion into processed foods. The food preservation and processing industry has evolved from being a luxury to an essential sector, playing a crucial role in conserving and enhancing the utilization of fruits and vegetables. To prevent waste during peak seasons and ensure availability during off-seasons, modern methods of storage and processing are necessary. These techniques allow for both large-scale and small-scale processing, extending the shelf life of produce for better distribution. The ultimate goal of food processing is to apply systematic techniques to preserve, process, package, store, and distribute food in a way that ensures a steady supply of diverse and nutritious food options, thereby improving food intake and nutritional standards, particularly during periods of low availability.
For effective preservation and processing, key prerequisites include cleaning, grading, and sorting the produce based on its maturity level. This ensures that only the highest quality fruits and vegetables are used in the processing chain, maintaining food safety, nutritional value, and consumer acceptability throughout the year.
CLEANING OF AGRICULTURAL COMMODITIES
Blanching is a unit operation used in food processing to remove contaminating materials from food and prepare the surface for further processing. In vegetable processing, blanching serves the additional purpose of cleaning the product. This process involves briefly exposing the food to heat, typically by immersing it in hot water or steam, which helps to remove dirt, enzymes, and microbial contamination. By doing so, blanching not only improves the quality of the food but also prevents microbial growth during storage or delays in processing. This early removal of contaminants ensures that the remaining bulk of food is preserved and remains safe for consumption throughout its shelf life.

29.1 Introduction
Cleaning is achieved using a cleaning agent designed to remove food, dirt, rust stains, minerals, or other residues. It is crucial to choose the appropriate cleaning agent, as not all are suitable for surfaces that come into contact with food. In a food-processing facility, sanitation involves ensuring that utensils and equipment that come into contact with products are kept clean and sterile. Additionally, clothing, air, packaging materials, and non-contact surfaces like floors, walls, and ceilings must be sanitized to prevent product contamination. Employees’ bodies, especially their hands, can also be sources of contamination, so maintaining high personal hygiene and cleanliness standards is essential. Moisture and heat can lead to microbiological contamination of both products and the environment. Moisture on product-contact surfaces and within products creates a medium where microorganisms can thrive and find nutrients, potentially affecting the safety and quality of milk and dairy products.
29.2 Types of Soil
Cleaning involves removing food residues and other types of soil from surfaces like utensils and equipment used in the dairy and food industries.
• In the dairy-processing sector, the equipment must be cleaned of various types of soil including: liquid milk films, air-dried films, heatprecipitated films, heat-hardened films, milk stone, and other foreign materials.
• Soluble soils will dissolve and be carried away in rinse or wash water. For insoluble soil components, chemical detergents may be needed to either dissolve them or soften them to facilitate easier removal.
• Cleaning or sanitizing the product contact surfaces of dairy equipment involves both washing and sterilizing. It’s important to avoid causing undue wear, erosion, or corrosion to these surfaces, as this can reduce their lifespan

There is no single factor as important in the production of fine quality dairy products as absolute and complete cleanliness.

R.B. Barrett

It is not enough to provide milk for man, it must be high quality milk. It would be impossible to provide man with milk and milk products of superior quality if we were unable to remove milk soil and to kill residual microorganisms. Respectively, these are the processes of cleaning and sanitizing.

To successfully provide the atmosphere for proper food safety, the basics must be thoroughly understood. The basics of food safety begin with good understanding of sanitation processes, food-handling procedures that protect from, or eliminate cross contamination problems and specific attention to inspection of and follow up for all processes. Food safety activities need to be programmed into available time of day scheduling just as production requirements do. Whether special personnel or separate shifts handle cleaning responsibilities or you clean as you go on the production line, time must be made available. Safe products leaving the facility must be the watch word of all employees involved with the process.

In order to ensure safe food supply a high level of sanitation should be maintained throughout the food production chain. The word ‘sanitation’ is derived from the Latin word “sanitas” which means “health”. To further apply this word to the food industry, sanitation is the creation and maintenance of hygienic and healthful conditions when processing, preparing and handling food. Sanitation is the application of science to provide wholesome food handled in a hygienic environment by healthy food handlers to prevent contamination by food spoilage microorganisms. Effective sanitation refers to the mechanisms, which accomplish these goals.

Cleaning and sanitisation are the two processes employed in dairy industry to ensure hygiene and product safety. The safety of milk and milk products is a very important aspect and every attempt should be made, during processing, to minimize contamination through handling and processing equipments. The accumulated dried milk solids (milk stones) consist largely of calcium phosphate, milk proteins (precipitated, coagulated and baked on by heat) and insoluble calcium salts from water and washing detergents. The surface can also contain biofilms, which are formed by the incorporation of bacteria into the accumulated inorganic and organic materials that attach to most surfaces. With time and in the presence of nutrients, a biofilm and the bacteria within the biofilm will grow and become strongly attached to the surface. The removal of dairy soil, milk stones as well biofilms is the prime objective of the cleaning process. International Dairy Federation (IDF) defines a clean surface as one which is free from residual film or soil that will not contaminate the food products coming in contact with it.

While cleaning refers to the removal of soil from the surface of the equipment, sanitisation implies destruction of all pathogenic and almost all non-pathogenic organisms. Cleaning and sanitisation are complimentary processes. Either of the processes alone will not achieve the desired result, which is to leave the surface as free as possible from soil and viable organisms. In actual practice cleaning and sanitisation overlap to some extent, as during cleaning a high proportion of bacteria are destroyed and others get removed in the detergent solution. Inadequate or faulty cleaning and sanitisation can have serious consequences, as milk is a prefect nutrient in which bacteria can multiply. A thorough understanding of the cleaning methods is, therefore, necessary for economic production of high quality food products.

Cleaning and sanitizing of dairy plants is essential for providing safe milk products to the consumers as well as for ensuring the good shelf life of these products. It ensures cleanliness, hygiene of the equipments and surroundings and also ensures that the products meet the safety standards. Cleaning of dairy plant consists of broadly of removing the soil from the surface of the equipment by dissolving or suspending the soil in a warm solution of suitable cleaning agents. In the dairy industry, the soil is primarily milk and milk product residues which may be more or less modified by processing treatment. 
Milk and milk product residues are complex mixtures of milk sugar, fat, proteins and mineral salts. Some of these solids are present in emulsion, some are in a colloidal state, and others are in true solution. When milk products are heated in vats or pumped through sanitary pipe lines or over coolers, the metal or glass surfaces become coated with milk remains, which, if allowed to dry, may be difficult to remove.

Cleaning and sanitation are essential for maintaining microbiological safety in ice cream manufacturing, particularly because contamination can occur after pasteurization and freezing does not eliminate all microorganisms. This chapter explains contamination routes, hygienic zoning, cleaning systems, sanitization practices, HACCP principles, and microbiological expectations within an ice cream plant. It examines CIP and COP systems, detergent components, cleaning factors, high-risk equipment and surfaces, and post-pasteurization contamination control. Particular emphasis is placed on preventing biofilms and controlling contamination at filling equipment, tanks, pipelines, feeders, drains, packaging areas, and personnel interfaces. The chapter provides practical sanitation guidance to support food safety, product stability, regulatory compliance, and consumer protection

1. Introduction

To maintain good quality of product & shelf life, it is very important & essential to concentrate on Cleaning & Sanitization process at plant level & to follow the CIP process properly. An attempt is made in the current chapter to present details pertaining to cleaning in fluid milk and milk products manufacturing & processing plants. This chapter will be helpful the students of Food & Dairy Technology for better understanding the process milk plant cleaning & sanitation technology.

Moisture Content
 
Two maximum moisture levels are provided to meet different climatic conditions and marketing practices. Lower values in the first column are suggested for countries with tropical climates or when long-term (more than one crop year) storage is a normal commercial practice. The values in the second column are suggested for more moderate climates or when other short term storage is the normal commercial practice.

Cold plasma technology represents an innovative non-thermal approach for improving food safety while minimizing undesirable changes associated with conventional heat treatments. This chapter introduces the fundamental principles of cold plasma and explains how reactive species generated during plasma treatment can contribute to microbial inactivation and food decontamination. It examines major plasma-generation methods, including dielectric barrier discharge, corona discharge and microwave plasma systems. The chapter highlights the potential of cold plasma for preserving nutritional and sensory characteristics while reducing microbial hazards. It also considers technological challenges such as treatment uniformity, interactions between plasma and food matrices and the need for process optimization and regulatory validation for wider industrial adoption.

Introduction
Similar to the procurement of raw materials in a factory, milk collection is one of the initial and essential steps for a milk processing or marketing company. A successful milk collection system combines efficient route planning, quality control, and effective farmer engagement. By prioritizing technology integration, cold chain management, and regulatory compliance, dairy companies can establish a reliable and sustainable milk procurement system that meets both operational and quality standards.
India dairy sector depends on smallholder individual milk producers, each contributing between one to a few litres of milk per day. Typically, milk production takes place in rural areas, while the demand is concentrated in urban centres. However, rural producers often face significant marketing challenges due to the dispersed nature of milk production, scattered settlements, and inadequate supply infrastructure. Therefore, milk needs to be collected, transported, and marketed from villages to cities to ensure profitable returns for producers. Milk is usually collected from producers at designated collection points in rural areas, which serve a large number of small suppliers. This approach minimizes the need for individual chilling and storage facilities. Collection points should follow the same hygiene standards as dairy processing facilities. Milk should arrive at a chilling station within four hours of milking, especially in warmer climates. There, it must be quickly cooled to below 4°C to preserve its quality. Bulk milk coolers of required capacity are installed for the chilling and storage of milk at low temperature till it is transported to the processing plant.

6.1 Introduction
The majority of milk demand is urban, while production is restricted to rural areas in nearly all developed dairying countries. Consequently, milk must be collected and transported from production sites in the milk-shed areas to processing and distribution points in cities.
The common systems for collection (assembling) of milk are as follows.
1. Through a cooperative organisation. Established by collective or individual dairy societies. Producers are most advantageous when there are no intermediaries involved in profit labelling.
2. by contractors. Producers receive a diminished return.
3. By independent producers. Convenient for individuals who reside in close proximity to dairy processing facilities.
Note: The milk shed is the geographic region from which a city dairy obtains its fluid milk supply. India is currently contemplating the allocation of specific milk silos to individual dairies in order to facilitate their development.

Milk, on reception at the dairy factory is subjected to various unit operations on its way to product manufacture. Processing is applied as a means to convert liquid milk into products or to render the milk (and products) safe from harmful organisms. The basic processing operations to which milk is subjected at processing units have been described in this chapter. The common processing operations employed are depicted in Fig. 4.1. Several of these operations are routine compulsory processes common to all dairies, while certain others are undertaken for specialized purposes in some dairies.

4.1. Filtration and Clarification

At the time of milking various foreign materials such as dirt, feed, manure, dandruff, hair, flies, dust particles, worn out cells, cell debris and many other undesirable substances may find their way into milk. The process of removal of this extraneous matter (solid particles of higher density than that of milk) is called filtration or clarification. This can be achieved either by simple filtration through specially woven filter cloth or continuous process of centrifugal clarification that helps

Introduction

Fermentation is the process in which edible microorganisms invade food substrates and convert them into fermented foods including beverages, using their enzymatic and metabolic processes. These end products will have nontoxic flavors, aroma and texture which enhance the palatability. The word “fermentation” is originated from a Latin word fermentare, defined as “to leaven” (Frias et al., 2016). It is one of the oldest food processing technologies used by humans to preserve perishable food materials for long time, dated back to ancient human civilization (Hutkins, 2008). Globally, more than 5000 varieties of fermented foods are currently in use which includes traditionally fermented dairy products such as Dahi in India to industrial production of wines from fruits (Tamang, 2010) (Table 1 and Figure 1). Biochemically, fermentation is a metabolic process in which energy is derived from organic compounds without the involvement of an exogenous oxidizing agent. Fermentation may result in the production of many by-products such as carbon dioxide, alcohol, organic acids (lactic acid, acetic acid), vitamins, enzymes etc. which are now having more importance in food industries (Caplice and Fitzgerald 1999).

3.1 Introduction
The mammary glands of mammals produce milk, an opaque milky liquid. It is the primary source of nutrition for young mammals before they are capable of digesting other forms of food. The immunoglobulins are transported to the young ones by the early secretion of udder immediately following parturition, which is referred to as colostrum. It has the potential to mitigate the risk of numerous maladies in newborns. The precise composition of fresh milk varies depending on the species, but it contains substantial quantities of calcium, protein, and fat. The mammary glands of mammals produce the opaque white liquid known as milk. Up until they are capable of digesting other types of food, it is the primary source of nutrition for juvenile mammals. Milk serum is defined as milk plasma minus casein micelles, a composition that is similar to that of whey.

The major constituents of milk are
Water is the medium through which the other milk constituents are dissolved or suspended. The majority of the fat in milk is present in the form of small globules, with an average size of 2 to 5 microns (with a range of 0.1 to 22 microns). This is known as milk fat (lipid). Fat is present in an oil-in-water emulsion. Milk fat is composed of numerous fatty acid glyceride esters; when it undergoes hydrolysis, it produces a mixture of glycerol and fatty acids. Proteins from milk: Proteins present in milk: Protein is one of the most intricate organic substances. Proteins are composed of numerous amino acids; some amino acids are essential, while others are not. In order for the body to synthesise proteins, the diet must include the essential amino acids. The preponderance of the proteins in milk are composed of whey proteins, beta-lactoglobulin, and alpha-lactalbumin. Milk is the primary source of casein, a calcium caseinate phosphate compound.