Sustainable Fruit & Vegetable Processing in India. Smita Lele… · Sustainable Fruit & Vegetable...
Transcript of Sustainable Fruit & Vegetable Processing in India. Smita Lele… · Sustainable Fruit & Vegetable...
Sustainable Fruit &
Vegetable Processing in
IndiaProf. S. S. Lele
Registrar & Professor of Biochemical Engineering,
Institute of Chemical Technology, Mumbai
Institute of Chemical Technology (ICT)
NIRF Rank II• ICT (formerly UDCT), is a premier chemical
technology research institute located in Mumbai, Maharashtra, India.
• Focused on training and research in various branches of chemical engineering and chemical technology.
• A glorious history of 78 years,
• Produced many industrialists, academics, bureaucrats, Padma awardees, secretaries to government departments, directors of CSIR labs
• Over 500 first generation entrepreneurs.
• Dept. of Food Engineering & Technology dedicated to relevant research and offering courses – B.Tech, M.Tech and Ph.D
Food transition
Basic Necessity
Sense of security
Cultural identity
Fashion and Status Symbol
Health and well being
Food Processing in India
• India - one of the top three producers of fruits
and vegetables
Food Processing - we appear in the bottom three !
• Agriculture Based Economy.
• Small Land holdings
• Growing sector – Urbanization, rising demands,
consumer awareness
Source: MOFPI, India
Why processed vegetable are not popular in Indian
Market ?
• Viability of fresh fruits and vegetable
• Cheap domestic labor
• Psychological barriers against processed foods
• Diversity in cooking style and taste
• Cost consciousness rather than quality consciousness
• Limited purchasing capacity of masses
• Marked difference in taxation of unpacked Vs. packed vegetables by the governing bodies
• Ready to serve Vs. Ready to cook.
State wise F & V production
Source : Indian Horticulture Database, 2013
Major F & V grown in Maharashtra
• Leading state for production of grapes.
- 80% of the Grapes exports from India.
• Largest producer of Alphonso Mangoes.
Highlights the top fruits
and vegetable produced in the state.
(Onion, Tomato, Brinjal, Cauliflower, Bhindi)
Source: Ministry of Food Processing Industries
Challenges
Increasing population
Urbanization
Environmental pollution
Reduction in cultivable land
Reduction in water for irrigation
Post harvest losses
Use of conventional methods for cultivation
Lesser income to farmers
Need of the hour
• Simple processing technologies
• Multiple product range
• Multi-Processing Equipment (Tray Driers, Retorts )capable of handling different raw materials
• Small scale plants with capacities of a few tonne of products per month.
• One such plant may be supporting produce from few hundred acres farming for seasonal vegetables
Value added
products
from waste
RTE/RTC
products
Minimal
processed
vegetables
Farmer: Good
price for
producer
Local
Employment
Consumer:
Healthy and safe
food
Processors
Inclusive Growth
Farmers
Processor
Consumers
Society
Growth without exploiting other partner
SSL Group Philosophy
Affordable
Convenient
Tasty
Healthy
.
Sustainability challenges for small scale F& V
industries
• Raw material
o Intermittent and irregular supply throughout the year (high in season, otherwise none)
o Fluctuating market prices
o Effect of weather & climatic conditions on availability & supply
• Technologies suitable for low value low bulk and low scale commodities ???
• Taxation policies
. Sustainability ----
• Packaging
o One of the major costs in a food processing Industry
o Variety of choices in product range and pack size/product quantity with regulatory aspects- nutritional
facts/label (consumer demand)
o Different packaging material for different types of products. (Technological demand)
• Working Capital intensive
This makes fruit and vegetable processing industry‟s “working capital intensive”
compared to other FMCG manufacturers.
Price rather than Quality conscious
Consumer
Where do you put your food waste ?
The wealth can be generated from
the food waste , which contain
many useful bimolecule , which
can be used in pharmaceutical
and neutraceutical application
Wholistic approach for vegetable processing
Value Addition by Waste Utilisation
• Biomolecules can be extracted from medicinal plants and from
food source
• Neutraceuticals can be manufactured using food source
• Food source may be fruits or vegetable itself and/or waste i.e.,
skin, seeds, leaves, roots etc.
Case Study :
Complete
processing of ash
gourd (Kohala)
Gourds
• Belonging to family Cucurbitaceae.
• Family consists of about 700 species and 100 genera.
• Share 5 to 6 % of the total vegetable produce in India.
• Consumed in various forms
• Most are part of traditional Indian medicinal and food systems
• Rich in vitamins, minerals and are also very good source of soluble fibre
• This indicates the huge potential in nutraceutical and value added product
industries
Ash
go
urd
• Large climbing or trailing herb
• Cultivated throughout India and in other South East Asian countries
• Used in a variety of foods, the most common being petha
• Used in Ayurvedic medicines such as Kooshmanda Rasayanam
• The fruit has a tough, waxy skin hence the name wax gourd
• Has a shelf life of one year (if uncut) due to this waxy skin
Extension of shelf life
• Un cut ash gourd has a shelf life of one year
• If cut it deteriorates in two days due to various physiological or biochemical
activities
• Biochemical activities are due to the various indigenous enzymes present in
the fruit itself or those produced by the normal microbial flora.
3rd week test
3rd week control
Process Flow sheet for complete utilization of ash gourd
Fruit & Vegetable Processing
• Perishable items (Almost 40-50% post
harvest losses)
• Adopting various methods of
preservations.
• Many are underutilised in spite of
being Flavourful, Nutritious &
Therapeutic
• Limited availability of fresh produce
(Seasonal, Wild)
• Big industrialists do not venture
Drumstick
Colocasia
Jamun
Jackfruit
Kokum
Tropical Fruit wine tech transfer 2016 @
Sawarde Valley Food Foundation
• Worked for the past 2 decades in developing Holistic or „Wholistic‟ Technologies to process underutilised fruits & vegetables.
• wholistic: complete utilisation of the raw material - seeds, peels, every edible part
• Cauliflower leaves for calcium,
• White pumpkin (Kohala) peels - source of edible wax for fruit coating - increase shelf life of say strawberries
• Cookies from jackfruit seeds or mango kernel
• Makes small scale processing more cost effectiveFarmer-processor-Consumer---Win-Win-Win situation !!
Mango/ Jamun /kokum/ jackfruit
Tech transfer Justsip /Justeat
• With Support from –
• The Department of Science and Technology (DST) and
• Rajiv Gandhi Science & Technology Commission (RGSTC)
• The Technologies developed & transferred for following
• Dehydrated Vegetable Powder mixes (Just Sip™)
• Retorted Ready to Eat (RTE) curries (Just Eat™)
• Tropical Fruit wines (100L Demo plant, Hedgewar trust, Sawantwadi) now transferred to Sahydry Soc. Sawarde, Chiplun
100% Natural, No preservatives, Nutritious
5 --Just Sip : Nutritional Facts
Just Sip Palak
=+
Just Sip Tomato
50 gm fresh palak
+
20 gm carrot
+
20 gm dudhi
+
50 gm tomato
+
5 gm beet
+
5 gm seasonal vegetable
Total 150 gm fresh mixed vegetables
Green, Orange, Red – Natural antioxidants
ANTIAGING
FULL OF VIGOUR
Just sip, a comparison with available products in the market
Per 100gm
JUST SIP
PALAK
KNORR VEG
SOUP
MAGGI
MIX VEG
CHING"S
MIX VEG Comments
energy (Kcal) 319.62 360 318 14.4 High
protein (gm) 12.29 10 9 0.3 V.High
carbohydrate(gm) 64.57 61 56.3 3.3
fat (gm) 1.413 8.2 6.3 0
saturated fat (gm) 0.41 3.8 3.1 0
trans fat 0 0.8 0.1 0 NIL
cholesterol (mg) 0 0.001 6 0 NIL
vitamin A (IU) 2111.4 traces traces 63.6 V.V.High
vitamin C (mg) 12.71 traces traces 0.7 V.V.High
Calcium (mg) 54.51 - - 80.3
Iron (mg) 10.25 - - -
Sodium (mg) 4250 5370 - -
total dietary fibre 13.11 - - - V. high
Just sip, a comparison with available products in the market
100gm
JUST SIP
TOMATO
KNORR THICK
TOMATO SOUP
MAGGI
TOMATO
SOUP MIX
CHING"S
TOMATO
SOUP MIX Comments
energy(Kcal) 330.91 330 307 26 High
protein (gm) 8.78 8 9 0.3
carbo.(gm) 71.31 65 60.8 6.3
fat (gm) 1.16 4 3.2 4 Low
Sat. fat (gm) 0.23 1.3 1.4 0 V.Low
trans fat 0 1 0.1 0 Nil
Chole. (mg) 0 0.001 6 0 Nil
Vit.A (IU) 3116.2 1490.6 - 41.1µg V.V.High
Vit.C (mg) 15.47 29 - 0.8 Ok
Ca (mg) 32.66 - 12.9 12.9 High
Iron (mg) 5.68 - - -
Sodium (mg) 4460 4400 - -
dietary fibre 12.85 - - - High
Why Just sip and Just eat products are good ?
NO PRESERVATIVES, NO CHEMICALS, NO MSG
• Products having shelf life 12 to 18 months @ Rs. 90 - 120 for 300 g
• Processing vegetables from 200 acres of farmland
• 100% natural, nutritionally rich products with a homely appeal
• Products rich in protein, fiber, minerals & vitamins.
• GREEN Technology with zero waste and zero pollution.
Trilok Food India, Satara
• SSI- Partnership Firm with a Plant set up on half-an-acre of land with a built-up area of 5,000sq ft.
• Under PPP model with financial Assistance Received from Department of Science and Technology (DST), Ministry of Science and Technology, Govt. of India for the project submitted by Prof. Smita S. Lele, ICT, Mumbai.
• Products (Just Sip, Just Eat and Big Meal) are manufactured in state of art new Facility as per guidelines of Food Safety & standards Act of India ( FSSAI) under the technical guidance of Prof.Smita Lele.
• Sister concerns:
• Trilok Marketing (Marketing Food distribution/Retail network forBranded FMCG products)
• Trilok Foods (FMCG Food retail store in Satara)
Gaurang Kotnis ,
young food technologist,
budding entrepreneur
owner of TFI
Dr. Anil Kakodkar,
Prof S. S. Lele, and Prof G.D. Yadav, Vice
Chancellor, ICT at the Trilok Food India
inauguration event. (Nov-2014)
Major Equipment at TFI
• Two lines
• General purpose F & V processing -- Major
equip –Tray Dryer
• Retort processing line -160kg capacity Retort,
Lab scale Retort, Pressure sealing machine
To Sum up…
• Sub-contract system with 50 local farmers for supply of raw material sourced from 200 acres of farmland at Satara
• Expected to give benefits to over 200 farmers / tribal in Konkan
• Innovative, authentic food products developed with a traditional touch
• Multi purpose machinery and multi product plant to process few tons per day
• Sustainable Wholistic processing using unused fruits (eg juicy jackfruit) and waste (edible wax)
• Modular design to be repeated across state and nation leading to generation of wealth from waste to reduce post harvest losses