CASSAVA PROCESSING TECHNOLOGY

DISCLAIMER

This presentation is made possible by the generous support of the American people through the United States Agency for International Development (USAID). The contents are the responsibility of Texas

A&M University and Bogor Agricultural University as the USAID Tropical Plant Curriculum Project partners and do not necessarily

reflect the views of USAID or the United States Government.

Introduction

• In Indonesia, cassava is the 2nd agricultural food product after rice

• Important basic material for many food products and industries.

• Weakness : low protein and vitamin content and also unbalanced nutritional composition. Some varieties contain HCN.

• Cassava is important source of energy in Indonesia.

Cassava Composition (100 g)

COMPONENT CONTENT Calories Water Phosphorus Carbohydrates Calcium Vitamin C Proteins Irons Fats Vitamin B1 Eatable part

146,00 kcal 62,50 g

40,00 mg 34,00 g

33,00 mg 30,00 mg

1,20 g 0,70 mg 0,30 g

0,06 mg 75,00 %

FRESH CASSAVA TECHNOLOGY • Cassava is a perishable commodity: cassavas should be

moved rapidly from field to processing site and also need rapid handling in the processing.

• Main problem : sensitive invested by mold and microbes, such as Rhizopus sp., Aspergillus sp., Mucor sp., Bacillus Polimexa and yeast. This infection is prevented by smearing the stem directly after it is harvested with some organic acids (propionic acid, benzoic acid or its mineral salts); although this way is sound unpractical.

• The effort to lengthen the shelf life of fresh cassavas : – In the storage, layered with green leaves (cassava leaves,

soursop leaves and mango leaves). – Store the fresh cassava in the soil that had been added with

straws. This made the cassavas could persist for weeks.

Materials: Cassava (fresh) Tools: Bucket Sack Knife Mat Processing: • Separate the cassava from its stem, peel and wash clean; • Cut the cassava which is too long; • Put it in the sun for 1 – 2 days. • Put it again in the sun until dry, and then put it in the sack. It is called gaplek when it’s dry; • Store in a dry place, not in a wet or humid place. Application: Gaplek may be cooked (steamed) with addition of palm

sugar and rasped coconut. The characteristic of fine gaplek are :

• Can be made become round or long (± 3 cm), flour, or pellet (± 2 cm length and maximum diameter = 1 cm); • In dry condition, gaplek is white, not moldy, and no peel left; • The packaging should use a strong, clean, and good

sack.

GAPLEK

Gaplek Processing

Tapioca Flour • 2 two groups :refine tapioca and rough tapioca. Refine

tapioca is made by grinding the rough tapioca. • Tapioca quality depends on several factors, they are:

– The flour color; good tapioca color is white. – Water content; the flour should be really dried until its water

content is low. – The amount of fiber and dirt; try to reduce the fiber and dirt in the

flour. That’s why, use the under 1 year cassava because it still only has a few fiber but a lot of starch content.

– Viscosity level; try to make the tapioca adhesiveness is always high. Avoid the excess of water in production process.

• Processed tapioca as glucose syrup and dextrin is needed in many industries, such as cotton candy industry, canned fruits, ice creams, drinks and fermentation industries. Tapioca is also used as thickener, filler, and emulsifier in food industries, such as in the puddings, soups, infant foods, ice creams, and meat sausages processing, pharmacy industry, etc.

• Tapioca waste is used for feeding poultry.

Tapioca Processing procedures: • Peel, wash, and rasp the fresh cassava; • Add water, squeeze and strain with filtering

cloth; • Store the filtrate for 1 night to get the starch; • Then waste the water on the sludge and drain

the sludge; • Put in the sun until dry; • Pound and sift. • 1 g/l of Alum or aluminum sulfate or 1 mg/l of

chlorine can be added to make the precipitation runs faster, while 0.1 % of natrium bisulphide (Na2SO4) is added to improve its color.

Cassava Flour

• The cassava used should be good and old, so that the flour produced has good quality. Cassava under 6 months has very high water content, the flour substances are few.

• Processing procedures: 1. Cassava was peeled, washed, then

dried it in the sun; 2. Put the dried cassava in the pounder,

and then pound; 3. Sift with fine sifter; 4. Pound the rest of sifting and then sift

again until it’s fine; 5. Put the flour in the sun. The drying

process is done inside the room with heating tool, like stove, if it is raining.

Cassava flour processing

• Tiwul is a kind of traditional food made from cassava. Tiwul is very well known, especially in Java, since long ago. tiwul is usually used as rice substitution.

• Traditionally tiwul processing is very simple. The steps are (1) cassava is peeled; (2) peeled cassava is cut become rectangular shape; (3) it is put in the sun until dry (called gaplek); (4) gaplek is pounded become flour; (5) flour is put on the winnowing tray and splashed with water, and then swayed until it is formed tiny grain (called tiwul); (6) tiwul is steamed to produce tiwul that is ready to eat.

• Traditionally made tiwul has lower capacity and low quality in its hygiene and nutrients content. There are many improvements needed in the processing to lift up the status of tiwul from traditional become high quality food product.

Tiwul : Traditional Process

Tiwul : Improvement Process • Cassava has to have good quality, because high quality products

are come from good raw materials quality. Peeled cassava is then dipped in the dipping tank to be washed. Washed cassava is cut uniformly with cutting tool (knife), so that it could produce dried cassava which has equal drying degree after drying process. Dried cassava is milled with hammer mill to produce cassava flour. Tiwul is made from this flour. Adding water to the flour will produce rice like grains. The process is done by using special design graining machine. The grains are dried due to lengthen its shelf life. Dried tiwul is ready to package.

• Nutrification processes that can be done to tiwul are vitamins or minerals addition. It can be done in the graining step by adding the water with nutritional substances, vitamins or minerals. Adding certain nutrient into tiwul will improve its status. From here, tiwul is expected to be more loved by the people because of its quality, hygiene, and its nutritional value, also its availability.

CASSAVA CHIPS

• Cassava chips are snacks that made from thin slices of cassava tubers and fried with some spices or only salt. Cassava is peeled, washed clean, and sliced thin (using cutting tool or slicer). The cassava slices are dipped into Natrium bisulphide solution 2000 ppm, or into salt solution. Then, it is fried in hot oil. After it is drained, the cassava chips can be directly packaged.

• To make crispy cassava chips: one kg of cassavas are peeled, washed, and sliced thin. Then these slices are dipped into betel lime for one night. The day after, it is washed, and dipped into baking soda solution (1 of spoon baking soda every 3 liters of water) for 2.5 hours. Then drained, added spices you like, and fried until it is cooked.

ENYEK-ENYEK (SIMULATED CASSAVA CHIPS)

• Enyek-enyek (cassava crackers) are traditional dried food snacks from cassava with spices addition, such as red peppers and scallions. The enyek-enyek processing include peeling, washing, rasping, spices adding, steaming, drying, cutting, frying, and packaging.

• Compared to ordinary chips, simulated chips have some benefits, such as : – Simulated chips can be molded in various different

shapes and sizes you like. – The shape and size of simulated chips can be

homogeneous. – Easier in spices and flavors application. – The yields are high.

Enyek-enyek Processing Materials • cassavas, refined salt, garlic, red peppers, red onions, coriander, refined sugar, and

oil. Washing, Dipping, and Peeling • Washing is done only for dirty cassavas, by passing the cassavas into clean water.

Then they are dipped for 30 minutes in the dipping tanks. They are peeled after they clean.

Cassava Rasping • Cassavas are rasped with grater or rasper. It may used home rasper or industry

rasper. Rasping tool for industrial scale is a tool with jagged cylindrical stainless steel that has 30 cm of diameter.

Cassava and spices mixing • Rasped cassavas are added spices, such as red peppers, scallions, salt, etc. Fresh

red peppers are smashed with mixer, while the scallions are chopped soft with knife. After the spices addition, they are stirred evenly.

Steaming • Mashed raw cassava dough after being mixed with spices, and then molded become

thin slices with plastic layered rolling machine and steamed for 5 – 10 minutes.

First Drying • Enyek-enyek is dried in a dying cabinet by hanging on the cabinet shelf in a row. This

drying process is done with 800C hot air for 3 – 4 hours. Cutting • Enyek-enyek cutting uses special cutting tool. Dried enyek-enyek are stacked in 10 –

12 layers to be flatted at their ends, and then cut 3 x 3 cm2 or rounded enyek-enyek cut with punching machine.

The next drying • Cut enyek-enyek is dried with drying machine which produces 800C hot air. This

takes about 30 minutes.

Frying • After the drying finished, then it is fried with deep frying method (use a lot of oil until

all products submerge). The frying temperature is 180 0C for 3 – 5 seconds. Sorting • The sorting is done for choosing the good/full enyek-enyek (do not fracture). It can be

done using a sifting machine. Packaging • Packaging is the final step of enyek-enyek production, where enyek-enyek is

wrapped with plastics. The best kind of plastics used to wrap enyek-enyek is PP/POP. PP/POP are plastics with poly propylene as the first layer and oriented poly propylene as the second layer. Then enyek-enyek is put in a box and it is ready to market.

PEARL TAPIOCA

• Pearl tapioca is a grainy dry product which has white and transparent color, made from tapioca flour, rounded, and then gelatinized by frying it without oil or thermally processed with water vapor, and dried.

• Produced a lot in Malaysia, Thailand and Japan. In Indonesia, it is produced in pearl sago, especially in Maluku and Sulawesi.

• Wrapped in 1 ons to 1/4 kg plastics and usually used for pudding and sekoteng.

PEARL TAPIOCA • Pearl tapioca processing steps are: wetting, smoothing

(sifting), graining, sifting, gelatinizing, and drying. At first, tapioca flour is mixed with water until it is wet but does not sticky.

• The wetting process is done by mixing 1 kg of tapioca and 600 – 700 ml of water, until wet tapioca doesn’t have water and sticks each other if it is hold. The wet flour is then crumbled and sieved with crude sifter (diameter = 1 mm) and put in the graining tool. Graining tool can be a rotary cylindrical machine. In a small scale, bucket, winnowing tray or tools that can rotate and have cylindrical shapes are also can be used.

• To get the same size and shape, tapioca grains are sifted with appropriate size sifter. The diameter of tapioca granules that usually liked are 2 – 3 mm. Then they are gelatinized by frying it without oil for 3 – 5 minutes until 90 – 95% gelatinized. After that, put them in the sun or dried with oven 60 – 70o C for 2 – 3 hours.

MODIFIED STARCH • Natural starches, such as tapioca, corn and sago starch,

and other starches, have some obstacles in their used as raw materials in food or non-food industries. They need a very long time to cook (need high energy), and also the pastes are hard and opaque (not transparent). Besides, they have sticky characteristics and can not endure acid treatment.

• In the other side, industries want the starches have good viscous stability in high or low temperature, can hold mechanical treatments, and have viscous ability which can endure acid condition and high temperature.

• The desirable modified starch characteristics are: have higher brightness (whiter), lower retrogradation degree, lower viscosity level, clearer gel, softer gel texture, lower stretching ability, easily broken starch granules, higher time and temperature of gelatinization, and lower time and temperature of granules to break.

MODIFIED STARCH

• Natural starches can be modified due to have the characteristics above. This modification means as molecular structure modification that can be done chemically, physically, or enzymatic.

• Recently, methods that often used in modifying starches are acid, enzymatic, oxidation, and cross binding modifications. Each modification methods produce different characteristics of starch.

MODIFIED STARCH

• Modification with acid will produce thinner starches when they are dissolved, more soluble, and have lower molecular weight.

• Enzymatic modification, usually a-amylase, produce higher viscous stability of starches both in high or low temperatures and have better gelling ability.

• Oxidation will produce clearer starches with lower stretching and viscous ability.

• Cross binding modification produce high viscosity starches that have higher ability to endure mechanical treatment.

MODIFIED STARCH

Acid Modification • Chloride acid is used in acid modification.

At first, the starches are mixed with chloride acid liquors at 370C and heated, then added with ethanol 80% and centrifuged to separate modified starches from the solution. The starches sludge are washed with water until free from chloride ions and dried until 10% water content.

MODIFIED STARCH

Enzymatic Modification • Enzymatic modification use a-amylase.

Starch liquor is heated 370C and added with phosphate buffer pH 6.9 and a-amylase, let them reacted. Then the mixture is heated, added with ethanol 80%, and centrifuged. After that, separate the sludge, wash and dry until reach 10% water content.

MODIFIED STARCH Cross Binding Modification • Cross binding modification is done by making the starch

to react with other compounds which can form cross binding at certain pH and temperature.

• The compounds are ephichlorohydrin, trimeta phosphate, diepokside, etc.

• The starch produced is usually more viscous than natural starch.

• Simply the cross binding modification is done as: starch is mixed with water until the mixture become thick; arrange its pH become 9.0 by using sodium hydroxide; added with cross binding compound, like POCI, followed by neutralization with chloride acid; separate the starch from its liquid part by centrifugation; the sludge is washed with water until free from chloride ions, and then dried (with 500C oven or sun drying); grind after it is dry.

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