eChapters

10.0. Introduction

Food processing is an important sector in agriculture, the scope of which has increased manifold that can help to prevent wastage of perishable commodities to a great extent. But, at the same time, food processing industries generate a large quantity and variety of food products, provide employment to a large number of people and uplift their economic status. The production, processing and preparation of food, all results in generation of huge quantity of waste material causing health hazards due to environmental pollution. The waste material may be in the form of leaf/ straw, waste during harvesting, food preparation waste, after processing waste, unused material as waste, food processing operation waste etc. The huge wastage of the food material is due to lack of control on such agri-economy practices. So, the disposal of waste material has become a challenge to the processors, as different agencies are pressurizing for an environment friendly treatment of waste material. The utilization of waste for the production of value added products is very important in the management of food processing waste. Different types of food industries wastes are: i) fermentation industry waste, ii) fruit and vegetable industry waste (Table 10.1) iii) Sugar and starch industry waste, iv) diary industry waste, v) meat processing industry waste, vi) coffee industry waste and vii) palm oil industry waste, viii) fish processing industry waste. So, there is great need to find out options which have positive values of food waste. The options having positive values are: i) minimization of the waste generation, ii) development of value added products. Most of fruit and vegetable wastes are a rich source of vital constituents like carbohydrates, proteins, fats, minerals, fibres etc. Mango seed kernel is rich in carbohydrates, fats, proteins, minerals; orange, melon and pumpkin seeds can provide fats and mineral matters. Apricot kernels are rich source of oil (45%) and proteins.

11.0. Introduction

Agricultural marketing is one of the important branches of agricultural economics. Farmers have one commodity or the other in surplus and need to be disposed off or sold to earn some money to satisfy other needs, which otherwise cannot be satisfied on the farm or in the village. Thus, agricultural marketing has two-fold objective i.e. Sale of surplus commodities and buy other commodities to satisfy family needs. In modern commercial agriculture, the surpluses with farmers are steadily rising, so also their family needs are changing with the change in lifestyle. Therefore, agricultural marketing has assumed important place. Traditionally, market is place or building where buying or selling of goods takes place. But, in modern times with fast and long distance communication facilities like telephone, market is no more restricted to a particular place only, but it has become wider and has assumed regional, national or even international status. Buying and selling is finalized on telephones only from distant places. Thus, the concept of market has radically changed.

So, marketing of food/ processed food is an important and vital constituent of modern business management. Knowledge about market is critical for the success of the product in such a highly competitive global market place. Now a day, in such modern time, marketing is itself a highly specialized and distinctive discipline. Based on marketing rules and laws, marketing is sometimes regarded as marketing science. Modern marketing strategies, tools and techniques have attained such complexity that marketing is linked with those of the modern warfare. The results of the marketing wars are witness by Cola wars and other brand bars being fiercely fought in the global market. So, the markets have become virtual battlefield for the brand wars. Markets and technologies are the two powerful forces driving the food processing industry. Further packaging has become a powerful tool in the promotion and marketing of the processed food products.

12.0. Introduction

The benefits of food laws to the consumers and the processing industries depend upon the efficacy with which the laws are implemented. The implementation of laws requires not only a well organized national infrastructure for inspection and quality control, but also requires reliable methods of analysis, that can be used to check the quality standards for improvement of the food product w.r.t. nutrition, safety and sensory attributes. Early and accurate analysis of food product prior to preservation, during preservation or post preservation is a crucial component for quality evaluation and their quality control. Quality control in food industries depends upon three principles viz. i) raw material control, ii) process control and iii) finished product inspection. Once a product has gone through the manufacturing process, little can be done to alter its quality or to overcome the faults. Examination of the finished product at the most represents analysis with respect to standards – to accept or reject. Effective control over the raw material and process minimizes the rejection of the products. The food spoilage can be managed most effectively, if control measures are introduced at an early stage of food preparation/contamination. Reliance on symptom is often not adequate because spoilage may occur before symptom appears. The spoilage of the food may affect sensory, physical, chemical or microbiological attributes. Therefore, now a day, food processors want to analyze their food samples quickly without any delay in shipment for which they have to depend on the different methods for their quality evaluation. The analysis and quality control of food products involve physical, chemical, microbiological and sensory methods. So, widely used standard procedures / methods for evaluation of quality of food prior to preservation, during preservation or post preservation has been given in this chapter for easy implementation.

Milk is a product of biological origin and is a suitable vehicle to accommodate any additive without apparent changes in its look. The quality of milk and its products depends upon quality of raw milk used in their manufacture, processing and handling conditions. It is therefore, necessary to check quality of raw milk to assess its suitability for processing, through various quick tests called “Platform Tests”

Raw milk quality assessment

(A) At collection center: - Milk from various suppliers is generally collected at dairy factory or privately owned collection centers located in marked area of milk sheds. The quantum of supply may vary from 2 – 100 Liters. As each supplier has to be paid in relation to quantity and quality of his produce, it is important to draw samples and ascertain its quality by performing quick tests for the purpose of acceptance or rejection.

Sampling procedures - The sampling procedure differs according to the nature of material and the purpose for which the sample is required. The sample collected for chemical analysis should be representative of the entire batch. Thorough mixing with proper instrument is essential to ensure representative sample. Samples for chemical analysis are to be delivered the same day for testing. If un-avoided, add small amount of preservative (Formaldehyde) to prevent deterioration and bear label to the effect.

Sample from single container – The procedure involved is thorough mixing of contents. If it is small container the contents should be poured from one vessel to another with swirling. In case of can the contents should be mixed with the help of plunger which should be moved up and down and sideways for about 10-15 times. The sample is then drawn with the help of dipper from different levels and collected in clean and dry sample bottles.

Laboratory Tests

Sampling procedures

Samples from number of containers- As soon as the cans are received at the reception dock, remove the lid, mix contents of each can with a plunger and draw equal quantities from each container and mix together. Draw approximately 80 – 100 ml of sample for testing. If the cans are of same diameter, Alternatively, milk from different containers are first poured into a vat and then the sample is drawn by thorough mixing as above..

Samples from storage tank – Before drawing sample from storage tank, switch on the mechanical agitator and allow the contents to mix for 15-20 minutes. Discard first 1.0 L of milk. Transfer 250-500 ml of the mixed milk from the outlet valve into a sample bottle.

Samples from rail / road tankers- Open the lid of the tanker and insert a big plunger through the main hole and move it forward, downward and backward bring the plunger to the surface at each stroke. Continue mixing for 15-20 minutes. Draw proportionate quantities of sample with the help of suitable dipper from different levels. Draw 250-500 ml of well-mixed sample into the sample bottle. The total volume of individual composite sample should not be less than 150 ml.

In the last decade or so, the problem of determining the microbial content and their activities in dairy products has been under close scrutiny. The dairy industries still adopt the dye reduction test because it is cheap, simple and satisfactory. However, other new techniques have been introduced along with some modifications in traditional tests. The microbiological quality must be maintained. To assess the bacterial content and their activities in dairy products, various methods are available for the microbiological testing of milk. The specific tests should be chosen as per the application and other factors like cost etc. On the basis of public health and economic consideration it is necessary to test microbiological quality of milk at a number of points along the chain from producer to consumer which includes - raw milk supply, bulk milk arriving at processors premises, monitoring bulk milk during storage prior to processing and monitoring the procession & the quality control of finished products. The techniques for estimating bacterial numbers in raw material are divided into two categories.

A. Estimation of Calcium

Requirements : Pottasium permanganate solution (0.1N) – Dissolve by heating 33g of potassium permanganate in 1000ml distilled water and allow to stand in coloured bottle for several days. Filter contents through 6mm thick film of asbestos mat on Gooch crucible.

Asbestos mat – Digest asbestos with dilute hydrochloric acid(1:3) for 2-3 days, wash free from acid and digest with 10% sodium hydroxide for few days, wash free from alkali. Digest with dilute Nitric acid(1:3) for several hours and wash. Shake with water into fine pulp and digest with 0.1N potassium permanganate solution that has been acidified with dilute sulphuric acid (1:3), for 1 hour and wash. Use this pulp for layering 6mm film on Gooch crucible.

Dilute hydrochloric acid (1:4), Ammonium hydroxide solution (1:1), Saturated ammonium oxalate solution, Diluted sulphuric acid (1:4)

India has emerged as the largest producer of milk in the World. This has boosted the confidence of producers, planners, dairy entrepreneurs and scientist alike. India has poised to play a major role in global dairy market in coming decade. The rapid growth of science and technology has positive impact on our life style and with strong trend of urbanization several demographic changes are likely to occur. There going to be ever increasing demand on the role of milk and milk products for human health. Accordingly, the demand for higher standards of milk products in terms of hygiene and safety of dairy products is to be followed. The competitiveness for the export of milk products among different dairy industry has increased in recent times due to GATT agreement. The biggest challenge before Indian dairy industry is the quality and safety of milk products indented for human consumption. Legal standards are made to have control over quality of food offered for sale and to safe guard the consumer form health hazards. It is therefore, imperative to determine different parameters that define product quality and safety. The purpose is to ensure production and distribution of products within well defined and accepted standards. This chapter deals with various parameters of product testing in order to maintain requisite prescribed standards.

The growing chemicalization of milk presents a great challenge to the dairy industry. A number of chemical compounds get entry into milk, intentionally or un-intentionally, through their direct or indirect usage for crop, animal; or dairy husbandry practices, as environmental contamination. Several of these contaminants may be naturally present on grazing grass or use as pesticides for green fodder or they may get entry through use of compounded animal feeds. These eventually get excreted into milk as residues and pose problems to food safety. The risk of health hazards arises from veterinary drugs, residual pesticides, heavy metals, detergents and micotoxins etc. It is therefore, become necessary to detect these contaminants in order to make food safe for human consumption.

Detection of Aflatoxin M 1 in Milk

Material requirements : Glass column(30 cm x 1 cm), Silica gel (63-200 µg particle size), volumetric flasks, beakers, micro pipette, HPLC equipment fitted with C 18 column(25 cm x 4.6 mm) and fluorescence detector.

Reagents: Sodium chloride solution (400g in 1000ml water), acetonitrile/water mixture (25:75), sodium sulphsate, chloroform, toluene/acetic acid mixture (9:1), acetonitrile/diethyle ether/hexane mixture (1:3:6), chloroform/acetone mixture (8:2), n-hexane and aflatoxin standard ampule.

Preparation of stock solution : Transfer contents from 2.5ml or 0.5ml ampoule, quantitatively, to 25ml or 50ml volumetric flask respectively. Rinse ampoule with small quantities of chloroform and collect rinsing into flask. Makeup the volume with chloroform, mix well and store at 5º C or below. These solutions will contain 1 µg per ml aflatoxin M1.

Working solution : Transfer 0.5ml of stock solution to a 10ml conical flask. Evaporate contents to dryness using inert gas. Dissolve residue in 10ml of acetonitrile/water mixture. Prepare series of dilutions containing 0.0025, 0.005, 0.01 and 0.025 µg/ml aflatoxin. Similarly treat 5ml of stock solution to give a concentration of 0.5 µg/ml.

Over the past several years, there has been significant change in consumer perception on quality and food safety. Consumers are demanding healthy, nutritious and cost-effective products processed under controlled hygienic conditions. Food safety concern, in recent years, has become dominant and important. The requirement of food safety and quality assurance has never been so demanding as it is now. Globally food safety is being addressed independent of food quality. In anticipation of consumer demands on food safety, food sanitary standards at national and international levels are under constant review. Several inter governmental agencies / organizations are engaged in work related to quality assurance and food safety. Amongst these World Health Organization (WHO) and Codex Alimentarius Commission (CAC) play the major role in protecting public health and defining standards of quality and safety aspects of foods for regional and or world wide usage.

Regulatory Institutions

The quality environment in the Indian food processing sector revolves around compulsory legislation which specify minimum standard and certification system. Legal standards are generally made to have control over the quality of foods offered for sale and to safeguard the consumer from health hazards posed by practice of adulteration. There are basically three types of Indian standards namely

India, one of the largest food producer countries (I in milk production, II in fruit and vegetable production and III in food grain production at world level), possesses the potential of being the biggest with the food and agricultural sector contributing around 26 percent of the Gross Domestic Product (GDP). It is a paradox that people of the country producing such huge quantities of food including fruits, vegetables, milk, cereals grains etc. are still suffering from many nutritional deficiencies in their diet, and even in some places, the stomachs of people remain unfilled for the want of food. The credit of this would predominantly go to the poor postharvest infrastructure as well as knowhow and accessibility to the facilities. All this makes us one among those countries having largest postharvest losses. The reduction of losses occuring during food handling, processing, storage, distribution and use would be an indirect way of increasing the food production and making the country self-sufficient in nutritional requirements.

Physiological Development

Fruits and vegetables can be divided into 3 stages based n their physiological development i.e. growth, maturation and senescence.

Growth: This generally refers to cell division, enlargement and differentiation ultimately giving a particular size, weight and volume to the commodity.

Maturation: It is initiated before the ceasation of growth and lasts till the onset of senescence.

Senescence: The stage when anabolic (synthetic) processes almost terminate and catabolic (degradative) processes are initiated and speeded up causing ageing and finally death of tissues.

Ripening: Stage that begins with the last stages of maturation and lasts till the beginning (first stage) of senescence. Ripening is a very important event in the life of a plant as it transforms a physiologically mature but inedible (or not preferred to be eaten) plant part into an edible, visually and olfactorily attractive and tasty commodity. Ripening marks the completion of developmental phase and is an irrevessible event.

Packaging : Packaging of fruits, vegetables, flowers or any other commodity is chiefly done to assemble the produce in convenient units of different sizes, shapes & types for storage, transportation, marketing and distribution. The size of units may vary depending on the requirement e.g for retail marketing smaller units are preferred and for bulk transportation and storage, large units would be more convenient.

Why do we Require Packaging?

Imagine there is no packaging material and technology available. How we are going to transport apple, mango etc. to distant markets? Definitely as loose. Then how can we weigh or count the fruits being transported or marketed? This would be very difficult. Had there been no packaging the commodity would have suffered great physical, chemical and microbiological losses. It would have been very difficult to handle, manage, transport and market the produce as loose and unpacked. Therefore, the packaging of fresh as well as processed commodities was needed to contain, unitize and protect the produce.

Nature has made such a beautiful system that a fruit does not spoil unless its outer covering is removed and till it is there on the plant. For example banana will not spoil for long time if we do not remove its peel. Similar is the case with apple, guava, mango and many other fruits and vegetables. But as soon as the outer covering is removed the damage begins and the commodity is spoilt very soon.

Preservation is extending shelf life of fresh or processed food by using various methods and prevention or reduction of spoilage. Better the preservation, lesser the spoilage, more the spoilage poorer and inefficient is the preservation.

Therefore, in order to prevent or reduce the spoilage, we have to first identify and understand the causes of spoilage. There are chiefly 3 agencies that cause spoilage in fruits and vegetables i.e. (i) microorganisms, (ii) enzymes & chemical changes and (iii) man, animals, rodents, insects, etc. For effective preservation we have to check the growth and activity of these spoilage causing agencies. So, in order to prevent spoilage and preserve a perishable commodity for long time the following principles and methods are to be followed.

Jam : It is a product prepared by boiling to a suitable consistency, fruit pulp with sufficient quantity of sugar, acid and pectin so as to set and become firm enough to hold the tissues in position. About 45 parts of pulp are used with every 55 parts of sugar. The finished product should not contain less than 68 per cent total soluble solids.

Jelly : Jelly is prepared by boiling the fruit pectin extract with sugar in the presence of appropriate amounts of acid so as to set into a clear gel. A perfect jelly is transparent, devoid of haziness or any suspended material well set, but not too stiff and should have original flavour of the fruit. When cut it should retain its shape and show a smooth cut surface.

Marmalade : It is a fruit jelly like product in which slices of fruit or peel are suspended in the set gel. Mostly they are prepared from citrus fruits like oranges, lemons etc.

Freezing : Freezing is a process where temperature of food (fruits, vegetable etc.) is lowered down considerably below freezing point so that the water present inside the food undergoes change in state from liquid to solid (ice) and gets frozen immediately eg Frozen Pea. Water is immobilized and solutes are concentrated to reduce the water activity.

Principles of preservation : Combination of low temperature, low water activity, and pre-treatments like blanching, dipping in sugar syrup etc. stop (reduce) the growth and activity of microorganisms.

Theory of freezing : Freezing takes place in two main steps

Beverage: It includes all drinks whether they are fermented or unfermented, prepared from fruits or non-fruit, sweetened or unsweetened eg. tea, coffee, coca cola, cider, maaza are all beverages.

Fruit Beverages : Beverage which is prepared partly or fully from fruit juice or pulps with or without additives eg. pure fruit juice, squash, cordial, RTS beverage etc.

Non-fruit Beverage : Beverage which does not contain any fruit part eg. Coca cola, pepsi, sherbet etc.

Unfermented Juice or Pure Fruit Juice: This is the natural juice pressed out of the fruit and practically its composition remains unaltered during preparation and preservation. No additives like sugar, acid, water etc. are added. eg apple juice, orange juice.

Fruit Juice Beverage: This is the fruit juice that has been considerably altered in composition by adding water, sugar, acid, flavour, colours, preservatives etc. before consumption. It may or may not be diluted before it is served as a drink eg. squashes, nectars, appetizers etc.

In a commercial horticultural enterprise, if the product is not marketed properly, safely and beneficially, all the investment, inputs, hard work goes in vain. Basically every commodity that is produced should reach the consumer and marketing is all about how the commodity reaches the consumer. There is no fun of producing any commodity if it does not reach the consumer.

The word market has been derived form Latin word “marcatus” meaning merchandise, where people conduct business. Market therefore refers to place where goods/ commodity and services are bought and sold.

Marketing is a sum total of business activities through which the goods and services are either bought or sold. Cundiff and Still defined marketing as “the business process by which products are matched with markets and through which transfer of ownership are affected.

Why Marketing of Fruits and Vegetables is Complex and Risky as Compared to Other Goods

Before beginning the actual work on the establishment of a Fruit and Vegetable Processing Industry the following points should be considered:

Availability and possibilities of obtaining Funds: Investment of own money or obtaining loans from banks etc.

The scale of industry (Large, Small, Cottage or Home): Has to be decided based on availability of raw material, funds availability, land, labour and other resources.

The location: The processing unit should be located near to the actual production site of raw material so that the transportation costs of high bulk raw materials is reduced. There is no fun or justification of establishing apple processing industry in Lucknow or Bangalore and mango processing industry in Shimla as the related raw materials would have to be transported through long distances.

Site: Site selected in the location should be sunny area free from dampness and sufficient space for waste disposal should be ensured.

With the increasing health consciousness of consumers, there has been an increasing concern over the use of thermal processing methods like blanching, pasteurization, sterilization etc. for enhancing the shelf life of foods as these methods fail to preserve the fresh like nutritional, therapeutical and sensory qualities of the food. With the increased consumer demand for fresh and fresh-like foods, interest in minimal processing of foods is increasing. The trend is also shifting from the traditional heat processing to those technologies that employ no or minimum heat application, thereby retaining the quality to a maximum level. One of the ways to accomplish this is via use of non-thermal processes. Over the past few years a number of non-thermal processes or cold preservation methods have been invented and developed. These methods are being evaluated in pasteurization and sterilization of various foods or in the extension of shelf life of various packaged foods. Some of such novel technologies and the products prepared, have been discussed here under.

1. Extrusion

Extrusion is a size enlargement process wherein small granular food or powdered particles are re-formed into larger pieces with different shapes, textures, colours and flavours from the basic ingredients. In extrusion food is compressed and forced to pass through a fine opening (die). As soon as it comes out of the opening, the outside pressure is very less as compared to the pressure inside the screw of extruder and the food expands instantaneously. If the food is heated the process is called as extrusion cooking. It is a process which combines several unit operations including cooking, mixing, kneading, shearing, compressing, shaping and forming. Extrusion adds a variety to the products by changing shape, size, texture and even some of the minor ingredients of the food and at a reduced cost than most of the other processing methods. Extrusion cooking (not extrusion) is a high temperature short time (HTST) process that reduces microbial contamination and inactivates enzymes.