eChapters

Introduction

Fish and shellfish constitute an important component of global nutrition. Fish protein is an essential source of nutrients for many people, especially in developing countries. Health benefits of fish oil in preventing heart attack and other cardiovascular diseases are well appreciated. Mounting evidences suggest that the benefits of fish consumption are not limited to the well-known effects of fish oil alone. Fish is also a rich source of protein containing all essential amino acids, which is required for the body maintenance and muscular build-up. The protein content in most of the raw finfish meat is in the range of 17 to 22% (g per 100 g), while the cooked portions of some fish such as tuna may have as high as 30% protein. The amino acid score of fish protein compares well with that of whole egg protein, which is considered as a standard protein source. Fish is also rich in the non-protein amino acid - taurine, which has a unique role in neurotransmission. Apart from nutritional properties, fish proteins also possess a number of functional properties such as emulsifying, foaming, gel forming, water binding and fat binding properties, which are important in product formulations. These functional properties are mainly attributed to the major meaning myofibrillar proteins, actin and myosin.

During the processing of fish only the fillets are generally retained while the bulk of product (up to 66%) is discarded. About 30% of the total fish weight remains as waste in the form of skins and bones during preparation of fish fillets. This waste is an excellent raw material for the preparation of high value products including protein foods. The utilization of fish wastes help to eliminate harmful environmental aspects and improve quality in fish processing. Skin and bone are sources of high collagen content. The average quantity of waste generated during fish and shellfish processing operations (based on average annual marine landing data) is indicated in Table 1.

The commercial aquaculture for crustaceans in India has become a huge success due to the introduction of new species, the improved hatchery production of seeds, scientific management of culture practices and the availability of good quality feed and other input. Introduction of new species like Letopenaeus vennamei has resulted in increased yield and productivity. The farming of this species has already been established in coastal Andhra Pradesh, Karnataka and Tamil Nadu and gaining momentum in Kerala and other states.

Similarly, farmers in both coastal and land locked States have gone for large scale farming of Giant Freshwater Prawn (Macrobrachium rosenbergii) popularly called “Scampi” which is having high demand in both domestic and international markets. In order to meet the raw material requirement of large number of processing units established for export and also to meet the domestic demand. The state of Andhra Pradesh accounts for more than 50 per cent of the cultured Scampi production and also in terms of area under culture. During the year 2013-14 the estimated production of L. vannamei was 406018 tons whereas the black tiger export of cultured prawn from the country was to the tune of 41947 tons and that of scampi, it was 1401 tons (MPEDA 2008).

Industrial processing of prawn results in huge quantities of waste in the form of head and shell. Since the exported shrimp products are mainly of peeled items, the shell waste produced is quite high. The head and shell constitute nearly 60% by weight of the whole prawn depending on the species and size. In India its availability is estimated to be 100,000 tonnes annually and it is the single largest fishery waste of the country. Crab shell and squilla are other important raw materials available from marine sector.

11.1 Introduction

Fermented foods are the result of the activity of a few specialized types of micro-organisms among the thousands of species known to mankind. Success of such processes is depended upon the control of environmental conditions ensuring the growth of the desired microbial species and inhibition of others. The fermentation can be broadly defined as the process in which the carbohydrate or like compounds are broken down, under anaerobic or aerobic conditions [171]. The basic role of micro-organisms is to breakdown the organic compounds to get energy for their metabolic activities. From ancient times, people all over the world have developed traditional processes for production of alcoholic beverages (wine) either from natural sugar such as in wine or by degrading the starchy materials (beer). Fruit wines referred to as ‘Soma’ in our ancient scriptures have been part of food of man and were used as medicine, might have originated accidentally (transformation of fruit juice beverages having exhilarating or stimulating properties). Wines are made principally from fruits like grape or extract of other fruits of various types (table wine, sparkling wine, dessert, aperitif or vermouth and pop wines) while the beers are prepared from grains like barley, rice and corn. The principal carbohydrate in grain is starch which can not be fermented directly. This process is brought about by starch splitting enzymes by germinating the grains followed by drying and storage until needed. Distillation of beer produces a variety of liquors (whisky, rum, gin, vodka), while that of wine produces the brandy. Besides, the improvement in the raw material selection, fermentation conditions and techniques, a lot of waste material is generated during fermentation process in the industries. Nevertheless, the food based industries are significant contributors to the economy of the many countries of the world (Fig 1). The global market value of food fermentation based industries is estimated to be around 250 million US dollars. Interestingly, more than 10% of this accounts for alcoholic beverages (Fig 2) with projected increase of US$ 27 billions in 1989 to 40 billions in 1990 [93,123,123,129].

1. INTRODUCTION

Wild fruits are highly nutritious and contain vitamins, carbohydrates, protein and minerals in higher quantity than majority of other common cultivated fruits. They are also a rich source of several bioactive substances, compared to the cultivated fruits. In India,these wild fruit trees grow abundantly across an altitudinal gradient of Himalaya and the majority of them bear fruits during summer. Fruit varieties are consumed by the local inhabitants of the region. At the same time, there are numerous under exploited species of wild fruits having high potential for exploitation viz., Bael (Aegle marmelos CL.), Berberis asiatica DC, Seabuckthorn (Hippophae sp.,) Rubus sp., Prunus armeniaca L., Karonda (Carissa carandas L.) Bitter Almond (Prunus amygdalus Batsch Smith), Feijoa sp. Among the wild fruits, Hippophae sp.was found to be economically efficient, followed by Aegle marmelos, Rubus ellipticus Smith, respectively. Wild apricot (Prunus armeniaca L.), a semi-domesticated and less utilized fruit of the higher Himalaya, provides better economic returns on an annual basis. Attempts have been made to utilize these wild fruits as a source of income, particularly for poor rural inhabitants and unemployed youths of the region by making a variety of edible products such as jam, jelly, juice, squash, sauce, wine etc. Here in this article, production of wine, vermouth and brandy from wild fruits would be focused. But before discussing preparation of wine and brandy in detail, we shall be describing the general process of wine and brandy making first, then the products from the specific wild fruits.

Vacreation: The pasteurization of the milk or cream under reduced pressure by direct steam is called vacreation. This process removes feed and other volatile flavors from cream and to pasteurize it for butter making. This is also called vacuum pasteurization (Plate 623).

Vacuum: The state of negative pressure. It is equal to atmospheric pressure minus absolute pressure.

Vacuum cooling: A technique of cooling vegetable (leafy vegetables, asparagus, brussels sprouts) having a high surface to volume ratio; rapidly and uniformly by boiling off some of their water at 10C and at low pressure (5 mm of Hg) into a sealed container. The produce is cooled by evaporation of water from the tissue surface and is more rapid than hydro cooling (Plate 624).

Vacuum drier: A drier used to dry heat sensitive products where low pressure lowers the temperature, helps to retain natural flavour and minimizes oxidation and browning is called vacuum drier (Plate 625).

Abstract

Drying is an age old practice of food preservation. Removal of moisture from the food materials is usually carried out at atmospheric pressure and elevated temperature. In the presence of oxygen, drying can cause oxidation of some compounds leading to quality deterioration. Drying at higher temperature adds to the losses and can be responsible for enzymatic and non enzymatic browning, loss of aroma, nutrients, antioxidants, pigments etc. On the other hand, drying under sub atmospheric pressure helps in retaining the themosensitive compounds present in natural foods as drying can be accomplished in oxygen free environment. Under vacuum, evaporation of moisture can be possible at lower temperatures.

There is ever increase in the demand for good quality food product with improved quality and shelf life. Over the years, packaging have brought out a revolution in the marketing and distribution of food products including fish. Among the food categories, seafood ranks 3^rd with respect to consumption which explains the importance of fish. Fish is a vital source of food for people. It is the most important single source of high-quality protein, providing approximately 16% of the animal protein consumed by the world’s population (Food and Agriculture Organisation (FAO), United Nations, 1997). By any measure, fishes are amoung the world’s most important natural resources. Annual exploitation from wild populations exceeds 90 million tones, and total annual trade exceeds $ US 55 billion. Additionally, with over 25000 known species, the biodiversity and ecological roles of fish are being increasingly recognized in aquatic conservation, ecosystem management, restoration and aquatic environmental regulation.

Like any other food commodities, fish is one of the highly perishable items which undergoes spoilage if sufficient care is not taken. Various preservation methods have been in place to overcome the spoilage of fish. Chilling and refrigeration is the most preferred preservation method as it helps in preserving fresh like quality. Chilling or icing is reducing the temperature of fish so as to prolong the lag phase of bacteria and helps in reducing the spoilage rate. Fish being one of the most perishable foods, its freshness is rapidly lost even when stored under chilled conditions. Further, consumers demands to have fish in as fresh a state as possible so that the characteristics flavours are retained. Bulk transportation of fresh fish in ice has several limitations like limited extension of shelf life, unnecessary expenditure on freight due to ice, difficulty in handling and maintaining hygienic conditions due to leaching of ice melt water with leaching losses of soluble nutrients and flavouring compounds. Proper packaging will help in improving the keeping quality of fish. Packaging is an important aspect for improving the shelf life and marketability. Packaging enhances the consumer acceptability and hence saleability of the product. Traditionally, food packaging is meant for protection, communication, convenience and containment. The package is used to protect the product from the deteriorative effects of the external environmental conditionals like heat, light, presence or absence of moisture, pressure, microorganisms, and gaseous emissions and so on. Packaging is an integral part of the food processing and plays an important role in preventing or reducing the generation of waste in the supply of food. Packaging assists the preservation of the world’s resources through the prevention of product spoilage and wastage, and by protecting products until they have performed their function. Basic requirements of a package are good marketing properties, reasonable price, technical feasibility, utility for food contact, low environmental stress, and suitability for recycling. Simply packing fish is suitable packaging material will enhance the shelf life of chilled and refrigerated fish to 7 to 15 days depending on fish species. However, in the normal packaging the spoilage process will be accelerated due to presence of O₂ in the normal air packing. Alteration in the package atmosphere will help in overcoming the problem of shelf life, which can be achieved by vacuum packaging or modified atmosphere packaging.

Lanolin, commonly known as Wool grease is primarily a lipid secretion from sebaceous glands of wool bearing animals. The role of Lanolin in nature is to protect wool and skin of animal from climate and the environment. It is an excellent emollient, self-emulsifying and dermatological safe for skin applications. Lanolin is a complex matrix since it is a mixture of high molecularweight esters of fatty acids with fatty alcohols, sterols, tri-terpene alcohols; diesters, long-chain alcohols & diols, long-chain fatty acids and hydroxy acids and is therefore difficult for effective matrix clean-up. Because of its water proofing and antimicrobial properties, lanolin is used mainly in cosmetic and pharmaceutical applications.

Value addition is the most talked about word in food processing industry, particularly in export oriented fish processing industry because of the increased realization of valuable foreign exchange. Value can be added to fish and fishery products according to the requirements of different markets. These products range from live fish and shellfish to ready to serve convenience products. As far as fish processing industry is concerned value addition is one of the possible approaches to raise profitability since this industry is becoming highly competitive and increasingly expensive.

There is great demand for seafood/seafood based products in ready to eat “convenience” form. A number of such diverse products have already invaded the western markets. One factor responsible for such a situation is more and more women getting educated and taking up employment. Reasonably good expendable income, education, awareness and consciousness towards hygiene and health, increased emphasis on leisure pursuits etc. are some of the other reasons.

Marketing of value added products is completely different from the traditional seafood trade. It is dynamic, sensitive, complex and very expensive. Market surveys, packaging and advertising are a few of the very important areas, which ultimately determine the successful movement of a new product. Most of the market channels currently used is not suitable to trade value added products. A new appropriate channel would be the super market chains which want to procure directly from the source of supply. Appearance, packaging and display are all important factors leading to successful marketing of any new value added product. The retail pack must be clean, crisp and clear and make the contents appear attractive to the consumer. The consumer must be given confidence to experiment with a new product launched in the market. Packaging requirements change with product form, target group, market area, species used and so on. The latest packaging must also keep abreast with the latest technology.

Abstract

Mango pulp is high in prebiotic dietary fibers vitamin c, polyphenols, carotenoids, vitamins and dietary minerals. Mint leaves are known for its medicinal aromatic and flavorsome qualities. Mint act as powerful antioxidant, protecting the body against the formation of cancerous cells and is rich source of polyphenolic compounds. Tulsi also have antioxidant, adaptogenic, anti-inflammatory, antibacterial and immune-enhancing properties. Honey is natural sweetener and has antiseptic and antibacterial properties. Medicinally, honey is non irritant promote rapid growth of healthy tissue and is useful in purities value, bed spores, skin and intestinal disorder, etc. Keeping in mind the beneficial effects of these raw materials, attempt was made to prepare value added drink from it, which may have medicinal value and good sensory acceptability with objective to prepare and evaluate the recipe for value added green mango-mint-tulsi beverage and to study the shelf life of the developed value added beverage. The formulation prepared with partial substitution of honey was more acceptable. Throughout the storage period, the squash prepared with honey scored more in flavor, taste, mouth-feel and overall acceptability than without honey. The cost of production without including labour, bottling and other overhead charges came out to be Rs. 34.5/L for squash without honey and Rs. 59.0/L for squash without honey.

1. INTRODUCTION

Food processing industries are engaged in production of different types of processed products and generate various types of wastes. These wastes, whether solid or liquid, on one hand are a direct loss to the producer or manufacturer and on the other hand create environmental pollution, if not disposed properly. Therefore, the processors would always like to minimize these wastes. The generation of wastes not only cause economic losses but would also require additional cost for their management and disposal. As a matter of fact, it is often estimated that proper use of efficient machinery and careful handling during various operations can lead to more than 50% reduction in losses.

In general, the wastes from the food processing industries are either not utilized or primarily utilized as animal feed, fertilizer and in preparation of by-products on a limited extent. Many of the wastes such as cuttings and shreds from the fruit and vegetable processing industry can be used as animal feed. Fruit and vegetables wastes can also be used for extraction of starch, pectin, natural colouring matter, fat, essential oils etc. Wheat and maize bran alongwith palm kernel are used for the production of feed for chickens. Various oils and oleoresins having enormous pharmaceutical properties can be obtained from the spice processing industry.

Fermentation is a cheap and energy efficient means of preserving perishable raw materials. It commonly does not require any sophisticated equipment, neither is the storage of fermented products a big issue. Fermented foods play an important role in providing food security, enhancing livelihoods and improving the nutrition and social well being of millions of people around the world, particularly the marginalised and vulnerable population across the developing countries.

Several products of fruits and vegetables are prepared on commercial and home scale. Products development from fruits and vegetables is the best way to utilize excess produces and save them from post harvest losses..

Value Addition

This is the process of improving the value of a commodity through processing by changing its form, increasing its shelf life or better presentation like packaging. Value addition can be done through the ways.

In monetary terms, value-added’ per unit of the product is the margin between its selling price and cost of production. However, in the dairy and food industry, value addition refers to, extra, features of a product that are beyond the expectations of a consumer at little or no extra cost. In this context, the addition of value to milk can involve monetary value added to a liter of milk by turning it into milk products, enhancing the convenience of quality, shelf life, or health characteristics using processing and packaging interventions.

4.1. Conversion of Milk into Conventional Products

It is an age-old tradition to add value to milk by processing it into milk products. The primary aim was to increase the shelf life of milk that would otherwise be highly perishable. With inadequate facilities to preserve liquid milk fresh in the rural areas’ conversion of milk into a variety of milk products would be an ideal option to effectively preserve the huge quantities of milk procured during the flush season’ In the processing of milk products such as cream, butter, cheese and ghee, by-products such as skim milk, buttermilk, whey, and ghee residue are obtained’ Many of the dairy plants, particularly in India’ are usually confronted with the problem of by-products utilization, especially that of whey and ghee residue in an economical manner. Membrane separation processes have presented new possibilities for the production of newer intermediate products from dairy by-products that can be used for value addition in dairy and food industries.

Abstract

30 lines were selected from 864 germplasm lines for good biscuit making attributes on the basis of low protein content (<10.5%) and low sedimentation value (<40cc). These lines were further screened by actual baking test and alkaline water retention capacity (AWRC) test keeping the standard prescribed for biscuit making qualities viz., low protein content, low sedimentation value, low AWRC and larger diameter with larger spread ratio of biscuit. AWRC had significant negative correlation with biscuit spread ratio. Positive significant correlation was found between biscuit spread ratio and biscuit diameter. On the basis of above findings, it may be recommended that low protein content, low sedimentation value, low AWRC may be used as criteria for better biscuit making i.e. increase biscuit spread ratio and biscuit diameter. So wheat-breeding programme has opened up new opportunities for the end use quality product and wheat based food industry. Hence there is an urgent need for qualitative analysis of desired traits in wheat towards enhanced value addition and thereby an attempted has been made to identify suitable genotypes possessing good biscuit making attributes

Value chain analysis and its management is a strategic planning tool used in analyzing the value chain of a company or sector or a product. Initially, it was used to assess the process of a company or single unit. Then, it was visualized as a holistic and integrated framework in upgrading the activities of companies as a whole with the coordinating efforts of the various units or sub-systems. It is useful in improving the existing system or through introducing a new component in the system.

Value chain

The word ‘value chain’ was first introduced by Michael porter in his book ‘Comparative Advantage’ during 1985. Value chain is defined as “the full range of activities which are required to bring a product or service from conception, through the different phases of production (involving a combination of physical transformation and the input of various producer services), delivery to final customers, and final disposal after use”.

Value chain comprises of full range of activities required to bring a product or service from the stage of conception, production and distribution to consumers (Kaplinsky and Morris, 2001). The study on value chain is intended to achieve comparative advantage through cost minimization and attaining consumer satisfaction. It is the preliminary step in the mapping of market (FAO, 2006).The value chain can be analyzed using Value Chain Analysis (VCA) through either quantitative or qualitative tools or both.

Milk, as secreted in the udder of a healthy animal is practically sterile, but during its transit to the processing plant, becomes heavily contaminated with a variety of micro-organisms. These may be responsible for spoilage of milk or for causing diseases in animals and human beings. It thus becomes imperative that adequate heat treatment is given to milk to destroy these micro-organisms, thus increasing the shelf-life of milk as well as making it safe. Varied heat treatments offer the potential of producing different kinds of processed milk to satisfy the needs of the consumer. To cater to the ever-increasing demand of consumers, several varieties of processed milk are available in the market, some of which are discussed below.

5.1. Pasteurised Milk

Pasteurisation was named after the renowned French scientist Louis Pasteur, who discovered that spoilage organisms could be inactivated in wine by applying heat at temperatures below its boiling point. The process was later applied to milk and remains the most important operation in the processing of milk.

It is the process by which every particle of milk is heated to such temperature-time combinations (usually to 63°C for not less than 30 minutes or to 72°C for not less than 15 seconds) and promptly cooled to 4°C or below so as to destroy any harmful bacteria that may be present without affecting flavour and food value. Pasteurisation does not involve the use of any additives. Apart from making milk safe to drink, pasteurisation increases the length of time it can be kept before it spoils. The nutrient losses due to pasteurisation are so small, that they are considered insignificant.

INTRODUCTION

Vegetables and fruits have many similarities with respect to their composition, methods of cultivation and harvesting, storage properties and processing. In fact many vegetables are considered fruits in the true botanical sense. But the difference between the two is that vegetables are derived from various parts of plants e.g. roots, leaves, stems, buds and so on whereas, fruits are the mature ovaries of plants with their seeds. The edible position of most fruits is the freshly part of the pericap or vessel surrounding the seeds. The other difference between the two is that those plant items that are generally eaten with the main course of a meal are often considered to be vegetables, whereas those that are eaten alone or as a dessert are considered as fruits. This is the distinction made by food processors, certain marketing laws, and the consuming publics.

SYNOPSIS

Food is any substance consumed to provide nutritional support for the body. It is usually of plant or animal or fish origin. Plant foods are the most abundant sources of nutrition on earth. Only plants contain powerful substances called phytochemicals, which protect us from cancer, heart disease, and an array of other serious illnesses.

A dilute solution of acetic acid produced by a two-stage fermentation process in the first stage, fermentable sugars is converted into ethanol by the action of yeasts and in the second stage, bacteria of the genus Acetobacter oxidize the ethanol to acetic acid.

Vinegar is a liquid produced from the fermentation of ethanol in a process that yields its key ingredient, acetic acid. The acetic acid concentration ranges typically from 4 to 8 percent by volume for table vinegar (typically 5%) and higher concentrations for pickling (up to 18%). Natural vinegars also contain smaller amounts of tartaric acid, citric acid, and other acids.

Materials Required

Record book

Procedure

    1.    Follow the instructions given by the teacher and the factory representative.
    2.    Listen carefully to the explanations of the factory representative
    3.    Observe the functioning of various equipments
    4.    Ask queries wherever not understood properly.
    5.    Note down the observations in your record book  

Observations

    1.    Name and address of the factory or processing unit
    2.    Size of the Unit (Large, Small, Cottage, Home)
    3.    FPO Licence No.    
    4.    List of products manufactured    
    5.    Height of the processing plant    
    6.    Information regarding raw material store, finished product storage    
    7.    List of equipments installed in the factory
    8.    Water supply system     
    9.    Waste disposal system    
    10.    Hygiene in the surroundings    
    11.    Any other