QC in Salt (E)

Technical Development Training

Organised ByMicronutrient Initiative India

(M.I) At

Vedaranyam21 January 2015

Presented By

N.AnanthRetd.GM (Technical)

GHCL LimitedChennai

Quality Control In Salt Manufacture

What Is Quality ?

Quality – Meets your need or Expectation.

Quality Monitoring Organizations

• SALT DEPARTMENT

• FOOD SAFETY AND STANDARDS AUTHORITY OF INDIA (FSSAI)

• BUREAU OF INDIAN STANDARDS (BIS)

Nutrition Promoting Organizations

• National Institute of Nutrition (NIN)

• Micronutrient Initiative (MI)

• Global Alliance For Improved Nutrition (GAIN)

• United Nations Children’s Fund (Unicef)

Type Of Salts

• Crystal Iodised Salt ( Unrefined)

• Refined Iodised Salt

• Double Fortified Salt

• Low Sodium Salt

Micronutrition

• Additive mixed with the Food in very small quantities

• Iodine, Iron, Vitamins etc.,

• They are present in milligram Or grams per Kilo of Food Product.

• Iodised Salt- To avoid Goitre, Thyroid deficiencies and deficient Brain growth.

• D.F.Salt – to avoid anemia in addition to the above.

• Low Sodium Salt – Iodised Low Sodium Salt for Iodine supplement and Blood pressure suppression

Micronutrients Fortified Salt

Quality Parameters in Salt• Sodium Chloride• Calcium• Magnesium• Sulphate• Water Insoluble Matter• Moisture• Whiteness• Particle Size distribution• Bulk Density

Quality Control in Salt

• Good Quality Salt – Prevents Wastage of Micronutrients

• Prevents decomposition of Iodine additive and maintains the required dosage.

• Prevents degradation of Iron additive and maintains the required dosage.

Raw Salt Quality and Micronutrients

Quality Aspects of Raw SaltSl.No Quality Parameters Quality Specifications

As per BIS Market Expectations

1 Sodium Chloride 96~97% (Min) 98% (Min)

2 Calcium 3% (Max)

0.18~0.30% 1.8%(Max)

~0.25%

3 Magnesium 0.4௦~0.50% ~0.25%

4 Sulphate 1.20 ~ 1.35% ~1.00%

5 Water Insoluble Matter 1.00% (Max) 0.20% (Max)

6 Moisture 6.00% (Max) 4.00% (Max)

7 Particle Size Less than 4.0 mm Less than 4.0 mm

8 Iodine Content(at Production level) 30 ppm (Min) 30 ppm (Min)

9 Iodine Content(at Retail level) 30 ppm (Min) 30 ppm (Min)

10 Whiteness Index 50

11 Bulk Density 1.0

• Whiteness

• Consistent Iodine Level

• Attractive Packaging without leakers

• Without foreign matters like rust, fibrous and other non salt particles.

Quality Aspects of Salt (Consumer Preference)

Quality Aspects of Edible Fortified Salt

Cause and Effect TableS.No Cause Effect

1 Magnesium Control a) Less Moisture absorption by salt from atmosphereb) Loss of Iodine is lessc) Possibility of Yellow coloration of D.F.Salt is less

2 Calcium Control Lesser possibility of caking of salt

3 Water Insoluble Matter Control Lesser Contamination of Salt by Sand and Clay particles. Possibility of ingress of Heavy metals like Lead, etc. is less.

4 Moisture Control a) Loss of Iodine is lessb) Possibility of Yellow coloration of D.F.Salt is lessc) Freight reduction.

5 Uniform Particle Size Distribution Uniform Distribution of Iodine

6 Higher Bulk density Packaging size lower; freight lower

Stages of Quality Control in the Manufacture of Edible Salt (Iodised)

• Raw Material

• Production

• Packing

Raw materials

• Raw Salt – White, washed and sun-dried salt.

• Potassium Iodate from reliable sources

• Sweet Water (for proper dissolution of Potassium Iodate)

• Salt Pans

• Salt Storage

• Salt Despatch/Handling

Quality Control Stages in the Manufacture of Raw Salt

Quality Control in the Salt PansS.No Quality Parameter Action

1 Calcium Control a) Brine Feed to Crystalliers at not less than 24 degree density.

2 Magnesium Control a) Discharge of Brine from the Crystallisers at density between 28 ~28.5.b) Charge 24 degree density brine immediately without allowing the Crystallisers to dry. Avoid shortage of brine; adjust operations as per the availability of brine.

c) While harvesting the salt , wash the salt int esalt in the 24 degree water charges to the Crystallisers.

d) Harvest only fully grown crystals.


3 Water Insoluble Matter Control a) The Bunds of the Salt Pans should be strong enough to withstand normal rains.

b) Any salt contaminated by bund erosion should be stored and disposed off separately

c) Leave sufficient salt floor while scraping salt.

4 Moisture Control a) Harvest only fully grown crystals.

b) Allow the brine to drain from the harvested salt before transporting to storage.


5 Particle Size Control a) Floor of the Salt Pan should be level without any high or low elevations, so that brine level is uniform in the pan.

b) Brine is to be charge to a depth of about 150 mm ( 6 “ )

c) Salt bed Surface should be dragged frequently.

d) Harvest only fully grown crystals.

6 Higher Bulk Density

Quality Control Aspects in Salt Storage

S.No Quality Parameter Action

1 Water Insoluble Matter and Whiteness Control

a) Storage Floor should have a salt layer and should be clean, with a slight gradient.

b) Take necessary steps to prevent contamination of salt.

2 Magnesium & Moisture Control a) The height of the heap should as small as possible.

b) The salt heap should be washed with 1 or 2 degree Bore well water.

c) Allow sufficient time for the washed water to drain from the heap.

d) Test the heap for the major quality parameters.

Advantages of Integration of Small Pans An Insight

1. Bunds are reduced resulting in increase in effective area of salt cultivation by 5 to 10%; hence increase in salt productivity per acre of overall area.

2. Can afford more width of intermediate salt storage near the pans enabling more area for dewatering of harvested salt.

3. Maintenance of Bunds since the bund area is reduced.


• Use of higher capacity pumps; 3 times the capacity will consume only half the electricity compared 3 pumps of smaller capacity

• In integrated salt works, replacement of 3 pumps with the a single pump of large capacity will reduce the electricity consumption by about half.

•Example: 3 Nos of 10 lit/minute capacity pumps- 0.5 hp x3 = 1.5 hp 1 No of 30 lit/minute capacity pump – 0.75 hp

• Possibility of installing an integrated Salt Washer to further improve the quality.


Quality of SaltAn economic overview – An Example

• Poor quality salt – Loss during washing in a refinery- 26%

• Good quality salt – Loss during washing in a refinery- 18%

• Salt Price Rs.800/MT+Lorry Freight –Rs.700/MT • Cost of Loss - Bad quality salt -Rs.390/MT - Good quality salt – Rs.270/MT• Hence possibility of the refinery customers paying

higher price for Raw Salt.

Quality Control during despatchS.No Quality Parameter Action

1 Water Insoluble Matter a) The Mechanical loader and the truck should be clean wand washed.

b) Salt should be loaded taking care, that the storage floor soil is not mixing with the salt. c) Any salt lumps should be broken and loaded. Contaminated salt lumps should be discarded.

2 Magnesium and Moisture Control a) The old stock should be loaded firstb) The salt heap should be washed with 1 or 2 degree Bore well water.

c) Allow sufficient time for the washed water to drain from the heap.

d) Test the heap for the major quality parameters.

Quality Control in Crushed Iodised Edible Salt

• Salt Crushing:- Before crushing check the salt for any stone or iron

and other foreign particles and remove them.- Magnets may be installed to remove the magnetic

iron particles and the magnets should be cleaned frequently.

• Iodine dosage: - Preparation of Potassium Iodate solution (about 5

kg/litre) (Contd.,)

• (Continued)

• Check level in Iodine solution tank.• Clean the spray nozzle (daily once).• Check for Iodine Content in every batch and

once in 15 minutes for continuous mixing.

Quality Control in Crushed Iodised Edible Salt

Quality Control in Packaging

• Clean the Packing Machine Daily• Clean the pouch sealing device

frequently; check and change the heating element.

• Cleanliness of Packaging section. Remove immediately any spillage.

• Continued

• (Continuation)• Check once in 15 minutes for the - Weight of the salt filled pouch - Leakers - Drop test of the filled pouches .

• Check the quantity of filled pouches in outer bags – once for every 20 bags.

• Check the stitching machine – every morning before start up; clean the machine at the end of the day.

• Do not stack the filled bags more than 10 bags heights.


• Quality of Packing labour or personnel• Should be clean.• Should not be sick.• Should wear clean clothes.• Should wear the head cover Finger nails should be short and clean. Should not wear metallic and glass rings and bangles. Should not spit. Hand and Legs should be washed after using rest rooms. Footwear need to be clean (or) they should be removed and

kept outside.


• Others1. Storage Tanks and vessels should be always closed.

2. Contamination by oil, grease, fasteners, gaskets and tools should be avoided.

3. Dogs and other animals should not be allowed to loiter in the packing and storing areas.

4. Packaging Area should be protected from the entry of Flying and Crawling Insects.

5. Windows should be provided with mesh and the doors with curtains.


Quality Control

A Mindset

A Few Snippets

• Improvement in Quality -> Improvement in Business

• Improvement in Quality -> Market support• Improvement in Quality -> A progressive

mindset – A forward path to Success.

Thanks

Micronutrient Initiative India(M.I)

The Participants

QC in Salt (E)

Documents

Transcript of QC in Salt (E)