CHAPTER I INTRODUCTION

The alarming public health issues have made the scientists and researchers to search knowledge and new wisdom to curtail the problems of non- communicable diseases (NCDS) in the recent past. The threat to humanity due to environmental hazards and issues awakened the Agricultural Scientists, Nutritionists and Food Scientists to combat Obesity, Diabetes mellitus, cardiovascular disorders and cancers all over the globe to work on Green technology and Green concepts in all areas of natural and basic sciences to curtail the incidences of mortality and morbidity due to risk factors associated with Public Health issues as stated above.

Food processing in India is an emerging area of science hence it is essential to safeguard food from spoilage. It could help millions of humans who are unfed every day. The industrial revolution brought many technologies together and provided new possibilities for a healthy society. Since there are more people to be fed, more and more factories are to be built for mass production of goods in huge number of growing towns and cities for an extended population (Singh et al ., 2013). The traditional food technology methods have been identified with some modifications to safeguard the preparatory process. Indian traditional foods have their own medicinal values (Rais et al ., 2013 ). When compared with the modern food processing technique, traditional food needs lot of energy, manpower and long time for its process and added preservatives to improve its shelf life.

India is the largest consumer and the second largest producer of sugar in the world.

Sugar industry is the second largest organized industrial sector in our country. In most parts of the world, sugar is an important part of the human diet, making food more palatable and providing food energy. After cereals and vegetable oils, sugar derived from sugar cane and 26

beet provided more kilocalories per capita per day on an average, than other food groups.

Sugar beet ( Beta vulgaris ), Family Amaranthaceae, the tuberous root contains a high proportion of sucrose. Sugarcane (Saccharum spp.), family Poaceae, is cultivated in tropical and sub-tropical regions for sucrose that is found in its stems. An unbleached and unrefined sweetener made from sugar cane resembling brown sugar, containing more minerals, golden or brown in color is Panela.

The multi- dimensional approach to public health and natural resources viability in specific regions of human habitation and its contribution to good health is the focus to take up this research on the topic “Innovative Processing method of palm sugar through Traditional

Technology Transfer” – to bring out the ease in preparing “Palm Sugar” a natural resource from ‘Sap’ obtained from palm trees of Ramnad District. The Researcher is a resident of

Ramanathapuram, taken this research work to support the local palm products producers families working in the coastal regions of Ramanathapuram District.

The Ramanathapuram District has more than one crore palm trees all around the district. But the maximum use to tap Sap during seasons starting from February to July end every year is minimal. It is an “untapped Potential” of this district resource not much development and research in processing Sap for Palm sugar production is done. Hence the study was taken to explore the transfer of traditional technology used in producing “palm candy” to “palm sugar” directly and this is the focused objective in designing the equipment to produce palm sugar as an organic product as it was not cultivated by farmers or agriculturists. It is a wild tree grown densely in a natural way. The products of palm tree is highly valuable and eco- friendly. The entire tree is useful to human race. This natural resource to be safe guarded and tapped for human living as a food source keeping all these factors into consideration the study has been taken to help the rural folk involved in palm

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products activities in particular, to initiate the production of palm sugar as a cottage industry in Ramanathapuram District.

Palm trees usually thrive in tropical and sub-tropical regions. In fact, there is an area designated as Palm Belt of the world, which extends up to 45 ° on both sides of the equator.

This belt involves three continents covering 13 countries in Africa, ten in Asia and five in

South America. In India, Palmyrah palm ( Borassus flabellifer Lin ) is traditionally used for obtaining various edible and non-edible products. According to the census taken in India in

1995, about 8.59 crores of palmyrah trees present in India and out of which 5.19 crores of palmyrah trees present in Tamil Nadu. Palm trees thrive on non-agricultural lands, on the banks of streams, rivers and canals, on undulating hill slopes and sandy lands which are normally unfit for cultivation. (Central Palm Gur & Palm Products Institute, 2001).

The Palmyra is one of the most valuable and important trees in India. It is not indigenous to this country but is extensively cultivated as it readily propagates itself in regions where it is abundant; it is also found growing wild. The uses of various parts of the tree are innumerable. ( Sandhya et al.,2003). The Palm Products Industry is also one of the major cottage industries under the Village Industries Sector in the State. Tamil Nadu is the pioneer in development of Palm Products Industry in India. Palmyra is declared as the "State

Tree" of Tamil Nadu. The State earns foreign exchange by exporting Palm products. The palm tree is present everywhere. Palm trees can last more than 100 years. Palm trees easily germinate and grow, both in domestic and wild environment.

The Tamil Nadu Palm Products Development Board is functioning since 1995 and is engaged in the introduction of modern concepts to promote research for the development of

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palm products industry and for the better utilization of palm products with the social objective of uplifting the economic condition of rural palm gur artisans.

Most of the palms in forest show highly restricted distribution to ecological niches, except Calamus , Genera Livistona , Hyphaene , Borassus , Nypa , Salaca and Ptychoraphis which represent single species each in our flora. About 24 species belonging to nine genera are endemic, including 14 species of Calamus. Most of our present palm species are indicated by the past history, in which Calamus is possible exception. Most of the Palmyra flora is present in Andaman–Nicobar islands and the rest of the bio-geographical regions of distribution of the palms are subjected to extensive habitat loss. Anthropogenic factors like continued deforestation, change in land use, unscrupulous extraction of wild source, etc. are the major reason of habitat loss and poses serious threat to our natural palm populations.

(Tamilnadu palm development Board, 2003 )

Edible items that could be made from the fruit of palm trees include sap, jaggery, sugar, syrup, candy, palm fruit jam, chocolates, confectioneries, sherbet as well as non edible items like palm fiber and palm leaf products, baskets are produced and marketed

(www.tn.gov.in). Palm leaves are traditionally used for making cigarette wrappings. The leaves which are similar as the coconut leaves are used for thatch, for weaving baskets, band matting and roofing. The midribs of leaflets are used for making durability brooms, fishing tools; outer parts of stem used for flooring, furnishing and hand grips of tools; its roots are useful for medicine and fishing tools; palm sap can be used for indigestion, rashes and pulmonary irritation

Palm sap is a nutritional drink, which is very popular during the flowering season.

The sap season begins in January, when the palm trees starts budding. In this period, juice is

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obtained only from the male palm trees. The female palm trees start giving sap in the last week of March or in the first week of April. At this time output from the male palms is on the downturn and it keeps tapering down till the end of April. Then the female palms alone give sap till the end of the sap season, which generally lasts till the first-half of June. Sap is condensed into palm candy and used with hot and cold drinks like paanagam . Fresh palm sap is boiled shortly to collect palm candy and palm sugar. If this is not done, within few hours the ‘sweet toddy’ ferments into a sour and potent brew called toddy, which is not fit to drink the next day.

The white palm sap, at initial stages (when collected) does not ferment (non- alcoholic) and tastes very sweet. As the time passes the sap gets fermented, intoxicates and tastes sour. The fermented liquid is known as 'Palm Wine' or Kallu (Tamil). As the palm sap gets fermented very quickly, people apply lime on the surface of the pot as a preservative.

The lime prevents quick fermentation . (National Research and Development Corporation,

2005)

Toddy is a sweetish, heavy, milky white, vigorously effervescent alcoholic beverage, possess fermentive odour, contains nutrients and becomes turbid. Fresh toddy has pH 5.5 which on 24 hours storage reduced to pH 4.1.

Palm sugar

Crystalline sugar made from Sap with or without clarification is known as Palm candy. Sugar produced from the nectar of the palmyra or sugar palm tree. Farmers tap the palm flower spikes to release the juice, which is kettle-boiled until it thickens into a golden sugar. Palm sugar found to contain insufficient organic acids like fumaric, malic, oxalic, sucinic acids and tartaric acid. Asian palms provide significant quantities of food, beverage,

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fiber, rattan, construction material and other products (Sushil et al ., 2013). Asia is endowed with world’s largest palm biodiversity and it is utilized to prepare commercial products, most of the palm related products were established by local farmers. Chocolates, toffees and confectionery items are made from Palm Sugar.

Palm Candy

Palm gur, palm candy has also its importance among the products of sap. It is being produced and used since procuring sweet sap from palmyra has been known. It has got its various uses in Ayurvedic medicinal preparations. Palm Sap is being fully utilized and converted as a value added product of Palm Candy by traditional method (45 days; low yield) which has been modified by a research conducted by Anna University (25 days; high yield).

The technical know-how of the improved method in the production of palm candy has been provided to the palm gur artisans. ( Tamilnadu palm products Development board, 2000)

Palm Jaggery

Jaggery is the most important product made out of pathaneer. It is made directly by concentrating the pathaneer to a thick consistency. Pathaneer is concentrated without deliming and the product is generally light brown (almost yellow) in colour. The product from Thailand is rather soft, unlike the products from India and Sri Lanka. Jaggery has an intense, earthy and salty taste and reminiscent of chocolates in its taste, darker and richer in color with cooling effect. And it does not contain deleterious bone meal content, meant for whitening sugar; make use in the preparation of delicacies like payasams and neyyai appams and thus it is very popular in Tamil Nadu in the name of “Karuppatti vellam” or “Pana vellam”.

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Treacle

Pathaneer when concentrated by heating to about 1/6 th of its original volume forms thick dark syrup called treacle. The temperature should not be raised beyond 107 °C. The syrup with a brix of 65 % is ready to be removed from the flame, cooled and bottled. In Sri

Lanka it is marketed in 750 ml bottles. Treacle become dark with a disagreeable product if caramelized (i.e. upon uncontrolled temperature) which can be avoided by concentration under optimal temperature, giving a golden syrup.

Crystal Sugar Making

The initial process of sugar making is practically the same as that of gur. In this case, juice is de-limed, filtered and boiled. The juice is poured into the crystallizer at 110 °C. Palm sugar is a natural sweetener made from the sap of palm trees. It is sold in the form of rounded cakes, cylinders, and blocks or in large plastic or glass jars. Powdered palm sugar is completely natural, a healthy sweetener, devoid of chemical additives and a viable alternative for white sugar.

Sap, sweet sap of the palm otherwise called as sweet toddy or palm nectar, becomes popular because of its high nutritive value as it contains a number of minerals and salts and is high in protein. It is a natural and non alcoholic beverage, an instant thirst quencher, sweet, oyster white, translucent, delicious taste, agreeable flavor and contains acids like ascorbic acid, nicotinic acid and riboflavin. The chemical percentage composition of sap varies, depending on various factors viz., place, type of palm, mode and season of its collection.

It is obtained by slicing the spathes of the palmyra, coconut and sago palms and scraping the tender most part, just below the crown. It requires neither mechanical crushing, as in the case of cane, nor leaching like that of beet-root. This palm nectar is widely consumed in India, Sri Lanka, Africa, Malaysia, Indonesia, Thailand and Myanmar.

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(Siddharameswara Swamy et al., 2013 ). Palm sugar like flavoring (PSLF) with low pH shows a significant effect, highest anti-oxidant activity on the Maillard reaction.

Panangkalkandu, a sugar in brown colour, when taken with water, will be a very good medication for throat problems and gastric abnormalities. Palm candy mixed with hot water will cure cough instantly (Sapjah naveen, 2008). Palm candy has medicinal uses such as deforming, diuretic and anti inflammatory agent in treatment of inflammation of urethra and respiratory tract (Mayer, 1995). The sap is given as a tonic to asthma and anaemia patients.

Jaggery is given for anaemia, for diseases characterized by a marked loss of potassium. Palm candy is used in coughs and pulmonary infections, wheezing and as a laxative for children

(Suresh Babu et al , 2005).

The variations on the quality of sap may be due to genetic and metabolic characteristics of the tree, environmental factors, collection time, microbial load, personal hygiene. Microorganisms seem to be the main effect on quality of palm sap because they can use sugar through the inversion reaction and produce organic acids ( Ziadi et al ., 2014).

Barh et al., 2005 , reported that In West Bengal fresh sap exudation was collected at morning between 4 to 6 a.m, from inflorescence of Borassus flavbelifer and Cocos nucifera and from phloem cutting of Phoenix sylvestris in a sterilized 250 ml conical flask. Collected sap were brought to laboratory in aseptic, sterile and air tight thermos and then filtered with

Whatman filter paper. Analysis was performed within two hours for fresh sap and after 24 hours fermented sap.

Tapping is an art, percentage of obtained of sap yields depend on the skills of the tapper (Khieu et al., 1996). Palm trees have to be climbed for tapping as their inflorescences are located at the summit of their trunk which is often over 10 meters high. Various methods are used to climb the tree and six methods are recorded (Kovoor et al., 1983 ), by using

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ankle-loops, aerial ropeways between trees, hoop-belt, riveted bamboo, mobile 4-9 meter long ladders and fixed ones on the upper part of the trunks, notches in the trunk etc.

There are many techniques for tapping palms viz., i) destructive (incision of stem apex of felled palm) and is preferred in Ghana; ii) non destructive (excision of male inflorescence), e.g. in eastern Nigeria (upon economic considerations). The excision of the terminal bud of standing trees is harmful since tapped palms never resume vigorous growth.

Tapped stems die unless tapping is stopped before the apical meristem is totally destroyed

(Cunningham, 1990 ). The most advanced method of tapping is that applied to the inflorescence spadix which guarantees a high yield for long periods without affecting the well-being of the tree.

Mostly, tapped palm trees provide sap which is very rich in sugar (10 to 20 % according to species and individual variation). The yields are highly variable according to the species and its management. When the trees are managed properly, the main tapped palm species ( Arenga pinnata , Borassus flabellifer, Cocos nucifera and Nypa fruticans ) can reach yields of about 20 tonnes of sugar per hectare (Van Die, 1994). Compared to sugarcane production (5-15 tonnes of sugar/ha/year), the B orassus flabellifer tree can reach 18 tons/hectare/year under rain-fed conditions (Khieu, 1996) and the coconut tree 19 tons/hectare/year (Jeganathan, 2001 ). Elaeis guineensis produces much less sugar (1.2 tonne per hectare, Udom, 2000 ) and also there are good prospects for obtaining much higher yields in a production system oriented towards sugar production.

Sap is highly susceptible to natural fermentation at ambient temperature within few hours of extraction from palms. Once fermented, it transforms to toddy with 4 % alcohol.

Using several technologies developed by various research institutes, sap can be processed and preserved in its natural form to retain the vitamins, sugar, and other nutrients beneficial to 34

health. To preserve and extend the shelf life of sap, heat preservation techniques such as pasteurization is used. A special filtration technique to enhance the shelf life of sap was developed by the National Chemical Laboratory in Pune, India. (Central Food Technological

Research Institute in Mysore, 2001).

Palm sugar syrup produced by a vacuum evaporator retained desired quality attributes in syrup better than palm sugar syrup produced by heating with an open pan. The results obtained from the different treatments suggest that non-enzymatic browning of palm sugar syrup during storage could be reduced. This could be done by using vacuum evaporator for the production of palm sugar syrup and storing at low temperatures ( Naknean et al ., 2013 ).

Arenga palm sugar block can be transformed successfully into arenga palm sugar granule by dry granulation method ( Iskandar et al., 2014).

Concentration by vacuum evaporation lowers reducing sugar content such as fructose and glucose, substrates of Maillard’s reaction, than the traditional open pan process, whereas it retains the sucrose concentration. It could thus be outlined that vacuum evaporation is a more reliable technique for palm sugar syrup production as it minimizes the loss of quality through the degradation of products due to the process of heating. It can also be drawn from the results that heating temperature is the main factor affecting the quality of palm sugar syrup ( Naknean et al., 2009).

Ho et al., 2008 , explained the traditional method used for the production of palm sugar lead to products of inconsistent quality with Maillard compounds of variable proportion due to the high standard deviation of variables in addition to the quality of age and raw material.

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Production of palm sugar syrup by traditional method uses both high temperature and long duration. Non-enzymatic browning reaction and inversion reaction can take place during heating process which might affect the properties of palm sugar syrup (Naknean et al.,

2009). Some major limitations of this traditional method include the inconsistent quality of raw palm sap and non-standardized processing methods which lead to inconsistent quality of the resulting palm sugar.

A large variation in the physical, chemical and microbiological qualities of palm sugar concentrate produced by traditional method is identified. Literatures quote as samples with low total soluble solids, contained high total acidity but low pH, low transmittance value are assured for change of qualities. The palm sap during harvesting – before processing, if contaminated, its sugar would be used by micro-organisms and resulting in higher acid content, which synergist with heat and increases the concentration of reducing sugar, becomes a media for the growth of osmophillic yeast leading to microbial contamination and poor storage conditions. In order to improve quality of palm sugar concentrate, suitable temperature and time during evaporating process are also of importance.

The loss of quality of palm sugar syrup due to non enzymatic browning reaction increased with increases in storage temperature and time ( Naknean et al., 2013 ). The temperature of 70, 80 and 90 °C give different effect on crystallinity but tend to similar effect on morphology of granule and microstructure. The dry granulation has the same effect on functional group comparing with wet granulation and the former at 80 °C is recommended to produce quality palm granule ( Iskandar et al., 2014 ).

The factors of time and temperature have an influence on the quality of palm sap.

High concentration of Maillard reaction products, caramelisation products and phenolic content results in increase in antioxidant activity and in the intensity of brown colour, sweet 36

taste, thickness and viscosity of palm sugar syrup. In addition, good practices such as hygiene, sanitary facilities and equipment could greatly contribute to extend this product’s shelf-life ( Naknean et al., 2011 ).

Paulas et al., 2003, reported that the daily Borassus flabellifer sap yields average between 6 and 10 liters per tree but can be as low as 1 liter or as high as 20 liters per tree and this can be explained by genetic and environmental factors. Nypa fruticans produces more inflorescences (and potentially more sap) when the stands are kept thinned of old leaves.

In the Philippines, Quimbo (2001) was developed a new, highly profitable method of tapping which increases the sap yield from less than 60,000 liters per hectare to more than

100,000 by wider spacing between trees.

The impact of manuring trees on sap yields is reported to be great. A hybrid between a tall variety (Typica) and a dwarf one (Pumila) was found to be the best. It is likely that yield improvement research will produce varieties that will yield more than 100 liters of sap per palm and more than 14,800 liters per hectare per annum.

Proper timing of harvest reduces incidence and severity of cracking or splitting of products, excessive dehydration, insect infestation and attack by micro-organisms (Kadar and Hussein 2009) . Moisture should be 20-26 %, with equilibrium relative humidity (ERH) of not more than 65 % ensure resistance to microbiological factors such as mold, yeast and bacteria. Transportation under refrigeration (0-2 C and 90-95 % RH) to maintain their quality; Hydro cooling can be used to effect disinfection of water and removal of excess surface moisture before packing in the shipping containers. But forced air cooling can be a better choice than hydro cooling; inspected for quality, fumigated in completely sealed chambers; shaker for preliminary washing; hot air blast is applied to remove excess water.

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Quality loss resulting from pathological and physiological deterioration increases with increasing moisture content and storage temperature ( Yahia et al., 2004 ). Storing at low temperatures is the most important way of maintaining quality; as it minimizes the loss of color, flavor and textural quality and also delays development of sugar spotting, incidence of molds and yeasts and insect infestation and prevents development of syrupiness. In order to reduce moisture loss and improve shelf-life, packaging in moisture-barrier plastic bags or use of plastic liner in the box is helpful.

Since quality is supremely important in food, deterioration has to be controlled during production and storage. Non-enzymatic browning may cause unacceptable nutritional and sensory effects in some stored food products and may be a limiting factor in the shelf-life of products. Our aim to optimize or design a suitable method to reduce the quality loss of palm sugar product; concentration by vacuum evaporation is an improvement method for palm sugar production as this may minimize the loss of quality and degradation due to the heating process.

During the past five decades though sugarcane production has increased around three- folds, the sugar recovery has not shown any upward trend. It has always been hovering around 10 percent. Therefore, the Indian sugar industry presently faces a tough competition in the international market. The cost of sugar production in India is about 30 % higher than the international market price. As production of Palm sugar requires limited know-how, technological barrier to enter the market are relatively low.

Opportunities exist for organic palm sugar in Germany as it is the largest and growing

European market for organic food. From 2006-12, sales of organic food have tripled mainly coming from imports. In addition, industry sources have indicated that the consumers have

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the impression that the organic sugar is brown. Sugar is the third largest category in the fair trade market as measured by the Fair Trade Organization (FTO).

Focus of the present study

Authentic food ingredients have a reputation of being healthier and safer than synthetic ingredients. In addition, the synthetic sweeteners are losing momentum as research increasingly confirms that they are unhealthy.

The opportunities for sugar palm tree for its palm sugar are still opened widely. The demand for the commodity never decreases and so far the demand cannot be fulfilled. The palm sugar that comes from the sap of the sugar palm tree is preferred by consumer and thus the palm sugar industry is the alternative to improve the people welfare as the process can be done in a simple way and with small capital (Banten, 2005 ).

Agro industry is one of industrial branches that relate closely and directly with agriculture. Agro industry as one of the important sub systems in the agro business has potentials to support high economic growth because the market share and value added are high enough. Agricultural sector has important role in the national economy. The agricultural sector is able to survive and able to grow positively and able to absorb labors hence it alleviate the risk of economic growth decrease wholly (Djoni and Sukandar et al., 2013 ).

Tamilnadu palm development board (2003 ) reported that six lacks artisans, both men and women, are currently engaged in the Palm Products Industry in the State both directly and indirectly. This includes 30,000 Scheduled Caste artisans who are directly engaged in activities related to the Palm Products Industry such as tapping of Sap, manufacturing of Palm Jaggery. In the existing process of preparing Panaga kalkandu impurities like thread, sand, dust etc., are present in this product. Considering the deleterious

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effect of consuming this type of palm sugar, a necessity has arisen to develop a process for preparing palm sugar without using any materials that are not permitted in Food Laws.

The challenges that the scientists, researchers, extension workers and farmers face in this millennium is to find appropriate and improved ways of utilizing the earth's resources.

Alternate uses of palm sugar particularly in ethnic foods for enhancing their nutritive value and exploiting the export potential of these products with value addition need an in-depth study.

In any industrial production particularly in agro-industries the raw material should be consistent in quality to maintain uniform quality standard in the end product. No study seems to have been taken to map the variations in the palm sap quality among palm trees, the taping period and the related preservation techniques for the sap collected from various farms prior to the preparation of palm sugar. Taking into consideration of these aspects, this study is under taken.

Due to increasing competition from the fast growing urban economy, poorly paid activities such as palm sugar collection and processing are under severe economic pressure.

In the end this may lead to an abandoning of palm sugar production and to the extinction of the palm tree from the farm system. Despite the difficulties involved in sap collection and sugar production, palm sugar has continued to be a preferred as the source of sweetness in local communities.

Since quality is supremely important in food, thermal deterioration has to be controlled during processing and storage. Nonenzymatic browning including Maillard reaction and caramelisation may cause unacceptable nutritional and sensory effects in sugar based food products and may be a limiting factor in the shelf life of products. Rangarajan

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(2000) stated about the usage of superphosphate in food industry, mainly in palm products industry for adjusting pH which resulted in many health effects. Therefore, the study of the processing method and storage temperature that influence on non enzymatic browning reactions are very important.

Ramanathapuram District in Tamilnadu is an arid and backward area with thick unemployment population. The cultivation of palmyra trees is common in this area. Hence this area has been selected for this study.

The crystal palm sugar is an innovative product from the sugar palm sap processing.

The crystal palm sugar is more practical and ready to be consumed, the water content is lower so the storability is longer and the crystal palm sugar is packaged into practical package while the solid palm sugar difficult to store, and more hygiene. The crystal palm sugar is suggested by the health expert because it has low calorie content when compared with the granulated sugar.

Contamination of the products may be expected by sources like presence of micro- organisms in raw material or finished product, during harvesting in open condition or if stored in traditional earth jars (may be with high load of osmophillic yeast count) which is not a good practice in sanitary. The best criterion sets to prevent this contamination should depends on individual production factors such as personal hygiene, sanitary facilities, heating temperature, heating time and storage conditions. High temperature destroys a substantial amount of micro-organisms (Phaichamnan et al., 2010).

Hence, we plan to focus on designing an efficient machine along with standardization of the biochemical and physiological parameters for better and quick extraction of palm sugar. Physico-chemical properties and nutraceuticals of the collected saps are decided to be determined to highlight its quality. Comparison of estimated sugars and minerals in palm 41

sugar prepared by the conventional and innovative method is planned to be done in the present study. Suitable temperature and humidity are also to be incorporated in our present work to account for standardization for bulk storage of palm sugar with following objectives.

OBJECTIVES

1. To assess of physico-chemical and Nutrient properties of Sap collected from

different locations.

2. To conduct a survey on the existing conventional processing methods of

production of palm jaggery and candy.

3. To designing and fabricate an equipment for production of palm sugar.

4. To study the physiochemical and nutritional properties of palm sugar prepared by

using innovative process.

5. To determine the phytochemical composition and Antioxidant activity of palm

sugar prepared by using innovative process.

6. To study the Shelf life analysis of palm sugar assessed by different packaging

materials.

7. To study the Antimicrobial activity of palm sugar prepared by using innovative

process.

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CHAPTER II

METHDOLOGY

The research design pertaining to the study “Innovative Processing Methods of

Palm Sugar Production and its functional properties” is presented under the following headings.

PHASE I

1.1.Selection of Area and Samples.

1.1.1 Collection of Information from Palm Sap Tappers.

1.1.2 Collection of Palm sap.

1.2.Determination of Physiochemical properties and nutrient composition of the collected palm sap.

PHASE II

2.1. Understanding the conventional methods used for Palm sugar and Palm candy production in and around Tamilnadu.

2.1.2. Disadvantages observed in the conventional method of palm candy and palm sugar production.

2.1.3 Experimental procedure for preparation of palm sugar using innovative process.

PHASE III

3.1. Evaluation of Physiochemical properties of standard and palm sugar produce under innovative process

3.2. Estimation of Nutrient content of standard and experimental palm sugar

3.3. Determination of phytochemical composition and Antioxidant activity of standard and experimental palm sugar.

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PHASE IV

4.1. Assessment of Shelf life using different packaging materials of palm sugar prepared by using innovative process.

4.1.1. Study of Storage conditions of Palm Sugar using in different packaging materials.

4.1.2. Determinate of Shelf life analysis of Palm Sugar prepared by using innovative process.

PHASE V

5.1. Analysis of Antimicrobial activity of standard and experimental palm sugar

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PHASE I

1.1 SELECTION OF AREA AND SAMP LES

The growth of palm trees will ever be more appreciable in Ramanathapuram district because of the availability of more number of dry lands in it, which in turn were more suitable for the cultivation and growth of these palm trees. The hamlets of Ramanathapuram namely, Kilakarai, Narippayur, Kannirajapuram and Vembar, hosts the highest palmyrah cultivation. Hence the investigator focused the above mentioned areas in Ramanathapuram district for sap collection. Moreover, from literature reviews the percentages of availability of sap in these areas were comparatively higher than that seen elsewhere in Tamil Nadu.

The total Palmyrah Palm Production of the Tamilnadu in the year 2010-2011 was

74475 metric tonnes, out of which, 67876 metric tonnes from cultivated area of 368 acres

(BBSAW – 2009). Ramanathapuram is a district with more number of dry lands with large number of Palmyra cultivation.

The population of Palmyrah palm tree is found to be tremendously high in the

Eastern coastal line comprising from Kilakarai to Thiruchendur and the occupation of most of the inhabitants of this area is reported to be palm tapping, which in turn leads to easy and ready availability of manpower for all processes like sap collection and palm products processing.

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Figure-1. Coastline of Tamilnadu-Ramanathapuram

1.1.1Collection of Information from Palm Sap Tappers

The selected four villages namely Kilakarai, Narippayur, Kannirajapuram and

Vembar had a total of 1600 palm sap tappers. Twenty five palm sap tappers from each of the selected four villages (100 numbers) were randomly selected for collecting the information on palm sap and palm products production. Care was taken to select the palm sap tappers who were continuously involved and did the production of palm jaggery and palm candy. The information namely socioeconomic status, method of palm sap collection, economics involved in palm sap and palm jaggery production was collected using a specially designed interview schedule. According to Kothari (2011) interview method of collecting data involves presentation of oral –verbal stimuli and reply in terms of oral- verbal responses.

This information was collected in order to understand usefulness of the developed innovative processing over the traditional processing technology. The Schedule used is presented in Appendix I.

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1.1.2.Collection of Palm sap

The selected four villages namely Kilakarai, Narippayur, Kannirajapuram and

Vembar the sap was collected from the selected palm tappers. The sap for the study was collectedfrom march to june 2013. Only during these months there is high production of quality palm sap. Thus this period was selected. The saps from the four villages were collected for three consecutive days from the same sap tappers of the selected villages. The method of sap collection from the palmyrah tree is detailed below.

Farmers climbed the Palmyra palm tree mostly twice a day in the morning and evening with the help of a rope. Both male and female inflorescence is tenderized by gentle massaging with a massaging horn and was then sliced with a sharp tapping knife. The slices were less than a millimeter in thickness and the slicing opened up the channels for the sap to flow. Cutting the older leaves of the tree at the growing point of palm exposed the tender part at the tip of the stem, which was then punctured and the juice was oozed up from a shallow depression into a mouth of a fresh sterilized earthen pot hung below. The palm sap was transferred in 12 hours from mud pots into hages vessels of stainless steel, plastic or

Aluminium vessels.

The mud pots were then coated with lime and kept for further collection of palm sap, after incision the spike on alternate days twice in the first and third week of every month till the end of tapping season. During the course of the day, flow of sap decreases as the freshly incised area turns brown, covered up by tannins. Hence in about 12 hours time, tapping has to be repeated by incision to increase the flow of palm sap.

The collected palm sap was filtered through a fine muslin cloth or a fine cotton cloth to give a clear sap. The samples were stored immediately in sterilized bottles in ice box (0-8

°C) and transported to the laboratory for analysis the physico-chemical and nutritional properties on the same day. Fermentation might be observed if temperature is altered above, 47

resulting in the formation of alcohol an undesirable product. Every time during the process it becomes necessary to confirm the palm sap is not fermented. The collection of palm sap is given in Figure II .

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FIGURE -2. COLLECTION OF PALM SAP

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1.1.2. DETERMINATION OF PHYSIOCHEMICAL PROPERTIES AND NUTRIENT

COMPOSITION OF THE COLLECTED PALM SAP

The collected palm saps from the four villages were subjected to physiochemical

analysis of properties namely moisture, pH, Acidity, Colour, Brix, viscosity and Boiling

point. The proximate composition namely Carbohydrate, Protein, fat and Calories, Vitamins,

minerals and reducing, non-reducing sugars were analysed. The methods followed for

analysis is presented in T able I . The procedures adapted are given in Appendix II

Table -1 Methods used for Analysis of physical properties in Palm Sap and Sugar

S.No Physical Parameters Method Reference 1. Moisture Oven method Willits (1951)

2. pH Digital pH meter Arnold Orville Beckman (1934)

3. Colour Hunter colour lab IS : 3025 (Part 4) (1983) Reader

4. Tittrable acidity Nephrometer IS 3025{ Part 22} (1983)

5. °Brix Refracto meter IS 3025{ Part 16} (1983)

6. Boiling point AACC (1987) Thiele tube 7. Viscosity Rapid visco analyser AACC (1987) (RVA) 8. Glucose, Sucrose, Fructose, Maltose HPLC AOAC ,14.075-14.079, (1984).

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Table 2 Nutritional Properties of Palm sap and Sugar

S.No Nutrients /100ml of Neera Method of analysis References 1. Protein Kjeldal method AOAC, 976.05,( 2012) 2 Fat Shoxlet method AOAC, 920.39, (2012)

3 Carbohydrate UV Spectrophotometer Sadasivam, et, al., (2005)

5. Fat soluble vitamins AOAC (1998), (carotene, Cholecalciferol, HPLC -5968-2970E Alpha Tocopherol, Vitamin K) Water soluble vitamins (Niacin, Pyridoxine, Thiamine, Riboflavin) 6. Minerals Atomic spectroscopy - AOAC (2012) Calcium, Iron, Sodium, ICP-OES Potassium, Magnesium, Phosphorous, Zinc. 7. Flavonoids U.V spectrophotometer Da Silva, Pezzini & Soares, (2015) 8. Antioxidants activity U.V spectrophotometer Sharma & Kumar, (2011) DPPH method (BHT standard)

9. Antimicrobial Activity Kirby- Bauer Disc Bauer, Kirby Sherris, Turck. Diffusion method (1966)

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Phase II

2.1 UNDERSTANDING CONVENTIONAL METHODS FOR PALM SUGAR, PALM

CANDY PRODUCTION IN AND AROUND TAMILNADU

In order to understand the conventional methods followed for palm sugar and palm candy preparation. Four units suggested by the Khadi and Village Industries Commission were contacted and the method of production was observed and the products was collected for testing the physical and chemical hazards. The following were observed in the four units for understanding the conventional method of production 1. Materials used 2. pH monitoring

3. Clarification materials used 4. Crystallization methods 5.The type of vessels used 6.

Standardization of production 7. Time duration of production 8. Microbial load of the product 9. Fermentation process.

2.1.1 Traditional methods of palm candy preparation

In connection with the survey on existing method of palm candy preparation, the investigator surveyed Tiruchendur, Uthangudi in Thoothukudi District, Marthandam in

Kanyakumari district and Narippaiyur, Sayalkudi in Ramnad District and Central Palm Gur unit in Chennai, affiliated with Government of India. In these areas villagers engaged in palm products like Palm Jaggery and preparation of palm candy by conventional method along with other products using ‘palm sap’ (pathaneer). Palmgur Co-operative Federation provides the technological support in the processing and production of palm sap and its associated by- products such as jaggery, sugar and candy.

The physical and chemical hazards were scrutinized from the collected samples of palm sap in the selected units given in table-3. The physical hazards such as stone, sand, thread, mud and stick might lead to a severe contamination and finally to a poor quality product. The physical hazards may be due to the preparation of palm sugar being done in 52

open and using uncleaned vessels, ii) No efforts undertaken for maintaining a clean and sterilized utensils or premises; iii) No standardization targets either for raw materials or for finished products of palm sugar; iv) No care for purification of finished products and v) Long duration usually 40 days required for preparation. The chemical hazards due to addition of clarifying agents like commercial superphosphate, might cause some neurological problems; all these might lead to an adverse effect in the quality of the product.

Table-3. Identification of physical/Chemical hazards in Palm sap

S. No Potential Type of hazards Residues hazards in palm sap (%)

1 Physical Mud 2 Sand 5 Thread 3 Stone 2 2 Chemical Superphosphate 9 3 Microbial load Bacteria/yeasts ++

Traditionally, palm sap is manually collected from each inflorescence of the Palmyra palm tree. Palm sugar concentrate was produced by evaporating the palm sap in a large opened pan (approximately 60-100 liters/pan) and heated using the twigs and palm leaves as fuel till the required consistency (deep brown colour) was obtained.

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FLOW CHART FOR PALM CANDY PREPARATION – NARIPPAIURE – SAYALKUDI

Collection of Neera (Pot Coated With Lime)

Adding Super Phosphate Solution

Boiling (Above 100 ºC)

Transfer into Crystal Box

Poured In Sand (For 40 Days)

Crystal Formation

Storage (Traditionally In Sacks)

2.2 DISADVANTAGES OBSERVED IN THE CONVENTIONAL METHOD OF

PALM CANDY AND SUGAR PRODUCTION

The following observations are recorded on seeing the various methods involved in palm sugar production, which lead to design and fabricates equipment for production of palm sugar using a new process. The disadvantages observed in terms of clarification and process involved in preparation of palm sugar using conventional method.

2.3 EXPERIMENTAL PROCEDURES FOR PREPARATION OF PALM SUGAR

USING INNOVATIVE PROCESS

Experiment I: Modification In Clarification Method

In this study of palm sugar preparation, three types of plant materials were selected as a natural clarifier instead of synthetic materials to adjust the pH for clarification and crystallization. Usage of organic extracts in the preparation of palm sugar pave a healthy track for the future generation in consuming such high and pure quality products. The stem of selected plants like Ladies finger , Malai Poovarasu and Hibiscus Rosasinensis were collected from Ramanathapuram district. The stem part of the plants were cut into small pieces, dried,

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powdered and macerated with glacial acetic acid as solvent for 24 hrs. The plant extracts were then concentrated by evaporation and used.

PLATE I : TRADITIONAL METHOD OF PALM CANDY PREPARATION

Clarification of Neera

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This natural clarifier overtakes the property of commercial superphosphate in the preparation of Neera, as the latter may cause neurological disorders as they are synthetic based when compared to the former. The Sap collected from palmyra trees from four different locations namely, Kilakarai, Narippaiure, Kannirajapuram and Vembar in

Ramanathapuram district, were analysed for their nutritional and functional properties presented in Table 4.On the basis of the analyzed results, the sample of Neera obtained from

Narippayur village was found to be good quality, nutritious and the best for crystal formation.

Table -4 Types of Clarifier used in the process of Palm sugar preparation

Sl. Clarifier Method of preparation Quantity of Final pH No. (Sap – 50 litres) plant extracts adjusted to neutrality 1. Synthetic super phosphate Conventional 5 g 6.5

Innovative process

2. Vineger Conventional 6 ml 5.7

Innovative process

3. Hibiscus Rosasinensis Conventional 10 g 7.2

Innovative process

4. Malai Poovarasu Conventional 10 g 6.6

Innovative process

5. Lady’s Finger Conventional 10 g 7.8

Innovative process

Hibiscus Rosasinensis extract used as a clarifier in all methods for preparation.

Clarifiers in different concentrations were used for understanding the best natural clarifiers to be used for production of palm sugar using innovative process. The resultant palm syrup was heated up to 106 °C -108 °C for an invariable boiling time ranging

56

from 20-60 minutes depending upon the samples and finally the syrup was cooled for 10 minutes. The Preparation of Palm sugar using the natural clarifier have been compared to the existing palm sugar (being prepared by using calcium hydroxide) in various aspects like pH, cleanser, temperature and duration for crystal formation.

PLATE II EXPERIMENTAL PROCEDURES DEVELOPED FOR PALM SUGAR

(A). MALAI POOVARASU AND ITS ACETIC ACID EXTRACT

(B). LADIES FINGER AND ITS ACETIC ACID EXTRACT

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Conventional method of palm sugar production

Conventional method of palm sugar production consists of a large iron vessel used for heat treatment. Palm sap was collected, filtered and finally poured into the large vessel capacity of 15-20 liters. Wood materials or any tree debris were used as fuel for heating up the iron vessel, ground plan was shown in Fig. 2. Using a long stirrer made up of iron and agitation was given manually. Stirring was done till the water content present in sap evaporated and finaly formation of the syrup. The final product will be used for palm sugar manufacturing.

Fig. 3 Vessel heating system

Disadvantages of conventional method

Air pollution was created during burning lots of fire wood and other types of fuel; Smoke creates respiratory problem and ophthalmic problems among the workers; temperature cannot be maintained throughout the process. The procedure was carried at open environment, interference of dusts and other debris can be found which make the risk of reducing the product quality.

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2. Modification of conventional boiling method over electric boiling system (Direct contact of electric coil)

Palm sap tapped from tree was filtered and fed into the system. The system consists of

20 liters capacity food grade material 304 and inbuilt electrical coil which provides direct contact with sap and transfers the heat.

Disadvantages of Electric boiling system

Excess of time required for heating up the raw material; No sedimentation was formed after conducting thermal energy directly to the sap; an unpleasant odour was produced during the process and owing to the of electric coil with the palm sap, some part of syrup got burnt

(blackening) which will reduce the quality.

3. Modification of conventional boiling method over Steam heating system

The boiler is essentially a closed vessel inside which water is stored. Thermal energy was generated using electric coil in a furnace and heat was produced. This thermal energy comes in contact with water vessel where the thermal energy transfer to the water and consequently steam is produced in the boiler. Then this steam is piped to the container containing palm sap.

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Fig. 4 Steam heating system

It includes with thermal efficiency, combustion efficiency & fuel to steam efficiency.

Steam boiler efficiency depends upon the size of boiler used. A typical efficiency of steam boiler is 80% to 88%. Actually some losses occurred due to incomplete combustion, radiating loss occurs from steam boiler surrounding wall, defective combustion gas etc.

Disadvantages of Boiler heating system

Inadequate of thermal energy which led to improper formation of sugar from palm sap; not compact in construction; not economical; size is a difficulty for transportation and construction; long time required for rising steam at desired pressure, as there is a need for plenty of water in such boilers; as the water and steam are in same vessel the very high pressure of steam is not possible and the steam received from boiler.

4. Modification of conventional boiling method over Thermic fluid system

Thermal fluid heating is a type of indirect heating in which a liquid phase heat transfer medium is heated and circulated to one or more heat energy users within a closed loop system. Thermal oil, glycol, and water are common heat transfer mediums.

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Fig. 5 Thermic fluid heater

Heat Transfer fluids

Thermic fluid heaters are popular in industry and are fast replacing steam boilers in certain applications because of the following advantages :-

Exemption from Indian Boiler Regulations act and related formalities.

No need for water treatment.

No problem of scale deposition on heat transfer tubes.

Safety from explosion hazards due to low operating pressures.

Heating medium being a liquid, higher efficiency of heat utilisation can be achieved.

Among the process – Thermic fluid system was highly promising thus fabrication of equipment was carried out.

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Inventing innovative method for efficient production of palm sugar

Fig. 6 Flow chart displays developing of innovative method of palm sugar production

Experiment II: Modification of Conventional Chula Boiling Method to Electric Boiler

Method:

This Palm sugar extractor was designed with help of technical consultancy from expert as it is not available in market. This extractor was designed for standardizing the process and to maintain maintaining uniform quality. Thermostatically controlled heating pan of food grade stainless steel was used for concentrating the sap. Food grade materials and plant extracts instead of chemical clarifiers were used for adjusting the pH, clarification and crystallization. For the evaporation of moisture in the syrup different drying methods were tried out and the one that was found most efficient has been standardized and utilized.

Traditionally, palm sap was manually collected from each inflorescence of the

Palmyra palm tree. Palm sugar concentrate was produced by evaporating the palm sap by using wood fired stove and the process ends up by observing the intensity of brown colour, thickness and viscosity of the product. Overheating process would alter its unique flavour and

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colour. The total soluble solids with sugar in the finished product should be at least 65 0 Brix or above for food safety purpose.

PLATE III PALM SUGAR DEVELOPED BY USING PALM SUGAR EXTRACTOR

Cooling Rotator

CENTRIFUGE METHOD OF SUGAR COLLECTION

DRYING PROCESS OF PALM SUGAR

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The Equipment design has applied in three steps: 1. Boiler 2. Chiller 3.Centrifuge

1. Boiler: Boiler is basically a closed vessel in which water or fluid is heated until the liquid is converted into vapor at required pressure. Mostly, Boiler is operated in vacuum to achieve the desired temperature at a short duration of time. In this process, a cylindrical shell boiler is used.

The early proponent of the cylindrical form is a British engineer John Blakey, who proposed his design in 1774. Another early advocate is the American engineer, Oliver Evans, who rightly recognized that the cylindrical form is the best, in the view of mechanical resistance. Normally these boilers are capable of working under 40-50 psi. Here, a cylindrical boiler made of Stainless Steel (SS-316), is used.

Table 5 Stainless Steel (SS-316) Composition

S.No Element Standard (Max) 1. Carbon 0.08 2. Phosphorus 0.045 3. Silicon 0.75 4. Nickel 10.00 - 14.00 5. Nitrogen 0.10 6. Manganese 2.00 7. Sulfur 0.030 8. Chromium 16.00 - 18.00 9. Molybdenum 2.00 - 3.00 10. UTS 579 MPa at ambience 11. Thermal conductivity 16.2 W/mK at 100 °C

The boiler is cylindrical in shape and it is made up of stainless steel 304. The stainless steel is used to prevent melting, but copper will melt at this temperature so copper is

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not used in this boiler. Elements are vertically mounted in the top of the boiler. The elements in the boilers are easily removable. Some of the elements are illustrated below.

1) Temperature controlling sensor (RTD)

2) Electrical heaters (4)

3) Steam outlet

4) Safety valve

5) Thermic fluid

6) High temperature insulation (Ceramic wool)

7) Motor (pump on, pump off the palm sugar water)

Shell and tube type boilers have adequate steam space above the normal liquid level of the shell. Shell boilers have dryness fraction up to 98%. It means the moisture content present in the steam is 2 %. This results in higher heat content of steam thus shorter batch timings and higher productivity and product quality. Mainly the boiler contains three shells.

Shell Layers

Shell 1:

The innermost shell contains temperature controlling sensor inside the palm water that undergoes heating. The temperature will be controlled by the sensor named RTD. Resistance temperature detectors are temperature sensors that contains resistor that changes the resistance value as its temperature changes. If the sensor detects temperature more than 50-60 degree Celsius in this process, it will automatically stop heating. RTDs have been used because of its high accuracy, low drift and for its stability.

The first layer forms the wall for the container holding the Palm nectar. The tank is made up of Stainless Steel (SS-316). Palm nectar is boiled inside the shell. The processing

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liquid is taken in this 45 liter capacity tank. Shell 1 transfers heat from the heating source to the dispensation fluid. The working temperature inside the shell is about 150 °C.

Shell 2:

This forms the second layer of the boiler, which contains the heating elements. The heat energy is generated using a heating coil, which converts electric energy to thermal energy. Four heating coils of 1kw (1000 Watts) is used. This heating coil can reach up to 800

°C at 100 bar pressure. Electrical energy is a form of energy that occurs as a result of either stored (potential) or moving (kinetic energy) charged particles.

The faster the atoms or molecules move, the more heat or thermal energy they have.

The heat energy produced by the heating coil needs to be transferred to the processing fluid.

But direct transfer of heat is not possible, as it will spoil the palm nectar. So in order to provide equal and gradual heat transfer from the coil to the palm nectar, a thermal fluid is used.

Food grade oil acts as a thermic (thermal) fluid, a heat carrier, which is heated up in the heater and circulated through the user equipment. In future further improvements can be done. There it transfers heat for the process through a heat exchanger and the fluid is then returned to the heater. Electrical heaters are inserted separately in a tube which is of 1.15 inch diameter in the second shell for heating the thermic fluid. The flow of thermic fluid at the user end is controlled mostly by a pneumatically operated control valve, based on the operating temperature. The heater operates on low or high fire depending on the return oil temperature, which varies with the system load. There is a small tube containing a thermic fluid for passing on the heat indirectly to the sample just as to prevent the blackening and thus improvising the quality of food grade palm products.

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Shell 3:

Exactly the third shell is made up of ceramic wool; therefore the heat will be maintained in the first two shells. The heat loss will be reduced because of the ceramic wool.

The capacity of the ceramic wool is up to 500 degree Celsius. So instead of glass wool ceramic wool has been used. If we use other wool dust will mix with the palm water.

In order to avoid heat loss from the thermal fluid and to increase the thermal efficiency, an insulation layer around the thermic fluid is kept. The insulation material used here is glass wool. Glass wool insulation is one of the most widely used forms of insulations world-wide because of its thermal and acoustic properties, light weight, high tensile strength and exceptional resilience and with service temperatures ranging up to 250 °C.

Glass wool is formed into products with various thickness and densities. It comes in the form of rolls and slabs with or without Aluminum foil. Types of facings were aluminum foil, black glass tissue and glass cloth. Density 12 Kg/m 3 to 100 Kg/ m 3; Thickness 12 mm to

100 mm. Glass wool is suitable for the temperature ranging from -195 °C to +230 °C. For special applications it can be used up to 450 °C. Aluminum foil facing is suitable for temperatures up to 120 °C. Glass wool is chemically inert, rot proof and odorless.

Application does not cause or accelerate corrosion.

Glass wool is an insulating material made from fibers of glass arranged using a binder into a texture similar to wool. The process traps many small pockets of air between the glass, and these small air pockets result in high thermal insulation properties. Glass wool is produced in rolls or in slabs, with different thermal and mechanical properties. It may also be produced as a material that can be sprayed or applied in place, on the surface to be insulated.

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Shell 4:

Finally, a closing cover is used to enclose the entire boiler, thermic fluid, heating coils and insulation layer using a stainless steel wall. Stainless Steel (SS-316) is used to in this wall.

Stirrer:

Here a stirrer is connected to a motor running at constant speed. This entire setup is mounted on the boiler. The electrical control panel box is fixed at the side of this palm sugar machine.

2. Chiller

A chiller is a machine that removes heat from a liquid via a vapor- compression or absorption refrigeration cycle. This liquid can then be circulated through a heat exchanger to cool air. As a necessary by product, refrigeration creates waste heat that must be exhausted to ambient or, for greater efficiency, recovered for heating purposes.

Concerns in design and selection of chillers include performance, efficiency, maintenance, and product life cycle environmental impact. Here, a cylindrical container which is coiled around with a copper tube is used as chiller. R12 also known as Freon-12 is used as refrigerant for the chiller.

The construction consists of a stainless steel container with a capacity of 10 liters.

This container receives the semi-solid solution from the boiler output. This container is coiled around with a copper tube with a thickness of 1mm (OD=12mm). The refrigerant is circulated with the help of a 1HP compressor, which can be cooled with the help of radiators or air fins. Similar to the boiler section, a stirrer connected to a motor is mounted on top of

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the chiller. This helps to provide uniform cooling to the entire semi-solid solution. This has to be cooled uniformly with continuous stirring, to avoid build-up of crystals.

Figure 7 Inside deign of Chiller

R12 can be prepared by reacting carbon tetrachloride with hydrogen fluoride in the presence of a catalytic amount of antimony pentachloride. This reaction can also produce trichlorofluoromethane (CCl 3F), chlorotrifluoromethane (CClF 3)and tetrafluorometh ane (CF 4).

CCl 4 + 2HF → CCl 2F2 + 2HCl

The elements and the explanation about the cooing process is given below

1) Copper windings around the vessel

2) Compressor that contains the Freon gas

3) Expansion valve

The cooling effect in this cooler has been achieved by condensation and vaporization of the Freon gas, the principle is same as the working principle of a refrigerator.

The vessel that contains palm liquid will be wounded by copper wire. So that it will act as a heat exchanger. There is a compressor that contains the Freon gas. The Freon gas will be passed through the metal pipe. The insulated compartment of the cooler contains an

69

expansion valve and a heat exchange coil. In this process the Freon is vaporized by absorbing the heat inside the palm liquid.

In the cooler the electrically run compressor does work Freon gas by increasing the pressure of the gas instantly the temperature of the gas will increases. This gas enters the coil.

Heat flow from the high temperature gas to the lower temperature surrounding the coil. This heat loss causes the high pressure gas to condense to liquid, as motion of the Freon molecules decreases and intermolecular attraction are formed.

3. Centrifuge

A centrifuge is a piece of equipment that puts an object in rotation around a fixed axis (spins it in a circle), applying a potentially strong force perpendicular to the axis of spin

(outward). The construction is made up of a stainless steel cylinder inside which a mess is kept. This mess is connected to a motor mounted under the centrifuge cylinder. This motor is capable of rotating at very high speeds of range 3000 rpm. The mess in which the solution is poured is a cylindrical section with filter holes of order of 0.01mm to 0.5mm.

Figure 8 Inside view of Centrifuge

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The centrifugal force can separate a mixture consists of two substances with different density by continuous rotation. Normally this has been used to separate any mixtures with having different density. This process has been used here to separate the palm sugar crystals and its molasses. The main components in this process are:

1) Container

2) Induction motor

3) Controller

The container will be filled with the palm sugar with molasses. The principle of spin motor and centrifugal force is used in such a way that with the suitable speed of centrifuge suppresses the loss of crystal sugar in the molasses.

Especially the induction motor which is having nonlinear characteristic whose value varies with the operating condition, so it changes the load automatically the speed also changes. The speed cannot be maintained uniformly because of masscults will be different quality.

The controller has been used to adjust the speed that can maintain the motor speed despite varying load changes. This results in giving the quality crystal palm sugar within a short span of time.

The production process commences with the manual harvest of palm nectar, which is then boiled above 100 °C at the start and gradually increased to a temperature of about 120-

150 ° ďC. A stirrer is mounted on the boiler head, whose purpose is to supervise uniform heating of the processing fluid by continuously stirring the solution. The moisture content in the nectar begins to vaporize, which is then condensed and collected in a collecting tank. The sugar paste formed is collected and allowed to cool.

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The palm sap that has been extracted from the palm is diluted. So that the pH level of the palm water will be neutral. The boiler is then filled with the extracted palm nectar, by pumping it via an inlet valve. The heating coil is given power, which creates a thermal heat of about 800 ° ďC at 100 bar pressure. This is transferred to the processing fluid with the help of a thermic fluid. A stirrer mechanism is introduced and mounted on the top part of the boiler, for uniform heating of the nectar. The palm nectar is heated in a boiler with thermic fluid to 50-

60 degree Celsius at which the nectar begins to boil with a simultaneous separation of calcium from palm toddy water.

During this process the water will be separated from the palm water in the form of steam. In the top of the boiler there are two valves; Steam valve will collect the steam in a separate container. The steam water that has been collected can be used as a byproduct

(hospital cleanser). Another valve is used to collect the palm water. Using mesh filter (a high density cloth), the calcium in the palm water is completely separated. Again after the separation of palm water from calcium it is refilled in the boiler and heated for 110 degree

Celsius.

After that, heat is gradually increased and water molecules are vaporized. These vapours are collected through an outlet valve, where it expands, condenses and then removed as water, leaving a semi-solid solution. The palm nectar reaches a maximum temperature of

120-150 ° ďC. The entire process takes only one and half to two hours to complete. The paste like solution obtained is then collected.

The semi-solid solution from the boiler is collected in the chiller’s container. The temperature of this solution is about 120-150 °C. Now the cooling has to be faster, but without contamination. So we go for forced convection, using a thin copper tube which is coiled around the cylinder from top to bottom. Through this copper tube a refrigerant solution 72

(mostly R12 or Freon-12), is circulated continuously with the help of the air compressor. As

R12 absorbs the heat from the hot solution and circulates back it cools down by relieving heat to the atmosphere via radiator or air fins. A stirrer is used continuously in motion to avoid settling of the solution for preventing crystallization of solution and also for faster cooling.

As the cooling takes place temperatures drop down from 120-150 °C to 20-25 ° ďC. The solution is not allowed to go below 20 ° ďC as it may causes solidification of the solution. This is monitored using micro controllers which closely watches over the temperature and automatically cuts off the coolant supply when the desired temperature is reached. Mostly this process takes about half an hour to complete.

The semi-solid solution from the chiller will still have some moisture content in it.

This moisture needs to be removed in order to get fine crystallized sugar. Centrifugal force is used at this stage to separate palm sugar crystals and molasses or mother liquor. The solution is poured into the centrifuge’s mess and is rotated at very high speeds of 3000 rpm. With the help of centrifugal force and sedimentation principle the denser sugar content and water are separated. Water is removed and is collected in the cylinder outside the mess as it passes through the small pores in the mess. After this process crystal palm sugar will be separated from this mother liquor.

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PHASE III

3.1 EVALUATION OF PHYSIOCHEMICAL PROPERTIES OF STANDARD AND

PALM SUGAR PRODUCED UNDER INNOVATIVE PROCESS

The selected palm sugar sample from the Narippaiure production unit and sample prepared by our innovative process were subjected to physiochemical analysis of properties namely moisture, pH, Acidity, Colour, Brix, viscosity and Boiling point. The methods followed for analysis is presented in T able I & II . The procedures adapted are given in

Appendix II

The Standard used for comparison is the palm candy that is available in the powdered form and sold as palm sugar.

3.2 DETERMINATION OF NUTRIENT CONTENT OF STANDARD AND PALM

SUGAR DEVELOPED UNDER INNOVATIVE PROCESS

Nutritional properties of standard and developed palm sugar were studied by using standard procedure. In order to estimate the proximate composition (protein, fat, CHO, calories), Sugars (Glucose, sucrose, fructose, maltose) and micro nutrients such as Vitamins

(B carotene, Vitamin B1, B2, B6, Vitamin C) minerals (Calcium, Iron, Sodium, Potassium,

Magnesium, Phosphorous, Zinc) . ( Methods- Refer table II ) The standard procedures are given in Appendix II.

3.3. DETERMINATION OF PHYTOCHEMICAL COMPOSITION AND

ANTIOXIDANT ACTIVITY OF STANDARD AND EXPERIMENTAL PALM

SUGAR

DPPH Radical-Scavenging Activity

The DPPH assay method is based on reduction of 2, 2-diphenyl-1-picryl hydrzyl radical (DPPH) ,a stable free radical. The effect of phenolic compounds on the DPPH radical was used for determination of antioxidant activity of the extracts. When DPPH reacts with an 74

antioxidant compound, it can donate hydrogen, it is also reduced and the colour changes from deep violet to light yellow.

DPPH (0.1mm) radical solution in 95% ethanol was prepared. DPPH stock solution

(1ml) was added to various concentrations (0.01-1 mg/ml in 60% ethanol) .The control was prepared as above without any extract. The reaction mixture was allowed to stand in dark for

30 min at room temperature and the discoloration of DPPH was measured against blank at

517.

The inhibition ratio (percent) was calculated according to the following equation:

% Scavenging = [absorbance of control - absorbance of sample)/absorbance of control] X

100

The actual decrease in absorption induced by the tested compounds was compared with the positive control. The IC 50 value was calculated using the dose inhibition curve.

PHASE IV

4.1. DETERMINATE OF SHELF LIFE USING DIFFERENT PACKAGING

MATERIALS OF PALM SUGAR

4.1.1. Storage of Palm Sugar using different packaging materials:

Different packaging materials were used to pack the standard and developed palm sugar and palm sugar. To find out the proper packaging material this enables the complete protection. Four different packaging materials were used namely, 150 gauge High Density

Polyethylene (HDPE) · 80 gauge Low Density Polyethylene (LDPE) · Aluminium foil,

Laminated Aluminium Pouches. About 1.5 kg of palm candy and about 1.5 kg of palm sugar were packed by using above packing materials as 60 packs and sealed.

After packaging to observe the physical changes occurring in the product during the storage period, the palm candy was stored at room temperature, refrigeration temperature and three different relative humidity conditions. These packs were kept 90 days in different 75

temperatures and sensory attributes of sugar namely appearance, texture, colour, taste and odour were evaluated. . Palm Sugar was stored at room temperature. After six months to observe the physical changes in the palm Sugar. Finally the standard palm Sugar and compare to prepare palm Sugar is prepared through innovative process.

PLATE IV VACCUM PACKING

4.2. ANALYSIS ON ANTIMICROBIAL ACTIVITY OF STANDARD AND

EXPERIMENTAL SUGAR

To find the possibility of developed palm sugar and standard sugar the inhibitory activity of the sugar for bacteria and fungi was carried out. Antibacterial analysis was conducted using standard Ethanol.

Antibacterial tests were evaluated by measuring the zone of inhibition against the test microorganisms namely S higella flexneri, Escherichia coli, Pseudomonas aeruginosa . These micoorganism were tested as they were commonly found in sugar. Ethanol was used as solvent for extraction. Nalidixic acid (30mg) disc was used as reference antibacterial agent.

The tests were carried out in triplicates. The detailed procedure is given in Appendix _

The search for antimicrobials from natural sources has received much attention and efforts have been put in to identify compounds that can act as suitable antimicrobials agent to 76

replace synthetic ones. Phytochemicals derived from plant products serve as a prototype to develop less toxic and more effective medicines in controlling the growth of microorganism.

(Kelmanson JE et, al., 2000 )

PLATE V ANTIMICROBIAL ACTIVITY OF EXPERIMENTAL PALM SUGAR

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The minimal inhibitory concentration:

The minimal inhibitory concentration (MIC) was estimated using the broth dilution method (1991, vander bergle) for the above microorganisms. Dilutions of extract from 0.075 to 2.0mg /ml were used. Test bacterial culture was used at the concentration of 10 5 Colony forming units for 2mg/ml preparation. The lowest sugars extract concentration that prevented visible bacterial growth after 24 hours of incubation at 37 0 c was taken as minimal inhibitory concentration values and experiments were triplicated.

Determination of Total bacterial count in standard and palm sugar prepared by using innovative process

About 1 g of the sample was serially diluted in sterile distilled water up to 10 -8 dilutions. A suitable dilution of this sample was spread plated on the nutrient agar plates. The plates were incubated at 37 oC and the number of the colonies was counted after 24 hours of incubation.

DATA ANALYSIS

Statisticalanalysis All data were expressed as Mean±SD. Statistical analysis was performed b y Oneway ANOVA using Origin version 6.0 software andp<0.05 was considered as statistical ly significant. Formula is presented in Appendix IV

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CHAPTER III

RESULTS AND DISCUSSION

The results of the study pertaining to “Innovative Processing Methods of Palm Sugar

Production and its functional properties ” are presented under the following heads:

4.1 Phase I

4.1.1 Socio economic status of palm sap Tappers

4.1.2 Physiochemical properties of selected palm sap samples

4.1.2.1 Physical properties of selected palm sap samples

4.1.2.2 Proximate composition of selected palm sap samples

4.1.2.3 Mineral sand vitamins composition of selected palm sap samples

4.1.2.4 Composition of sugar present in the palm sap samples

4.2 Phase II

4.2.1 Materials used for fabrication of the palm sugar extractors 4.2.2Advantages Observed in different Innovative Process against conventional Method for Production of palm sugar 4.2.3 Construction of the palm sugar extractor involving the innovative process 4.3 Phase III

4.3.2 Comparison of Physico chemical Characteristics of the Palm Sugar produced by conventional and Innovative Process

4.3.3 Comparison of the Nutrient content , flavonoids and antioxidant property of the palm sugar produced by conventional and Innovative Process

PHASE IV

4.3 Shelf life analysis of palm sugar prepared by innovative process PHASE V 5.1 Antimicrobial study on standard and palm sugar prepared by innovative process

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PHASE I

4.1.1 SOCIO-ECONOMIC STATUS OF PALM SAP TAPPERS

Our research work of palm sap (Neera) collection from palmyrah trees has been planned to be originating coastal line locations of Ramanathapuram district namely,

Kilakarai, Narippaiure, Kannirajapuram and Vembar in Ramanathapuram district. Hence, the quality of palm sugar can be assuredly expected if and only if the palm sap is obtained from seashore palm trees as they usually show an increased Brix value owing to the presence of more sugar contents compared to those located in the interior part of the District. Moreover, one can find numerous palmyra tree grown villages, tremendous number of palmyrah trees population and more number of tappers being found prevalently in these areas of seashore locations of Gulf of Mannar. The inhabitants of these locations, have their occupation as”

Palm Neera tapping” during the season and do fishing during the off seasons. Since large number of tappers can be hired for palm Neera collection, one can be so sure about in the minimization of cost of production of palm sugar.

The tappers in these areas usually depend upon the Palmyra market association for their economical support even before the season commences. Their economic conditions are poor and also lack in knowledge of processing techniques, preservation methods and storage process etc., they are unable to carry out direct marketing of palm gur and palm candy products. The agents fix a very high value for the low-income people’s products and were very much greedy enough to sell at a hiked margin. Owing to all the above aspects, the price of palm gur and candy available in the market is found to be very high compared to that of white sugar.

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Table-6 Socioeconomic Status of Palm sap Tappers

S.No Particulars Number of respondent Percentage (%) n=50 I Age Distribution

1 20-40 22 44

2 40-60 25 50

3 60-80 3 6

II Sex

Male 35 70

Female 15 30

III Level of Education

Primary 2 4

Secondary 20 40

Higher secondary 10 10

Graduate 3 6

Illiterate 15 30

IV Types of Occupation

Fishing/ Neera Tapper 26 52

Daily wages 14 28

Working in shops 10 20

V Family Income / month

Low income (<4500) 13 26

Middle income (4500 – 7500) 28 56

High income (>7500) 9 18

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The socio-economic status of palm sap tappers indicates that 50 % of the tappers were engaged persons for tapping occupation were found to be in the age group of 40-

60range and to the next level of tapping profession, the age group lie in the range 20-40 as they frame 44 percentage of the total community of that area. People fewer than60 or above

80 in age were not generally seen in such occupations as the former class don’t prefer this and the latter one are not young and energetic to undergo such works.

Of all the classes of consideration for employed status, the fishing /Sap tapping category of people (52 %) dominates the other two, the daily labour (28 %) and working in shops (20 %). This because during the non-palm juice season (August -December), the self- employing palm worker family groups can find a surplus percentage of profits by processing of edible products like palm Nongu, palm fruit and palm tubers etc., and non-edible products like palm fibre and palm leaf articles meant for manufacturing plates, mat or baskets etc., which in turn could even be exported. Apart from this, every family gets benefitted by having a business share with the processing units; indulging their family women and heirs in processing, preservation, packing and marketing and all such sorts of palmyrah works so as to empower and sustain their livelihoods throughout the year. The percentage of people under labor categorieswas less (34 %) as they are paid less amount for Neera tapping ( Rathiha et al., 2009).

A sum of Rs. 400-450 per day (middle income group) has been fixed as pay for Neera tappers (almost 56 % of total respondent) as the nature of tapping work is very hard and heavy task demanding; also to attract the professional tappers and to make them not to quit and alleviate such professions as they are a boon to the workers in the sector. This fix of high pay has become possible by some of the schemes announced by Government as for disbursal of working capital to jaggery manufacturers and loans to members of various societies 82

manufacturing palm products. If the tappers were charged with less pay like Rs. 200 or

250/day, (low income) then on analysis, it was confirmed as only very less percentage (only

6 %) of such daily income were seen in tapping process and also that no tappers were usually paid with high income group (Rs. 500/ day) as it covers only 18 %.

Palm sugar is known in Indonesia as the sweetener for food and beverage that can be used as the substitute for granulated sugar. The sugar palm can be shaped become solid palm sugar and crystal palm sugar. The solid palm sugar is obtained by cooking the sugar palm sap up to be thickened like taffy, then pour it into mould. Crystal palm sugar, the cooking is longer, up to the sugar become crystal, then be dried or put in oven up to the water content under three percentage.

Palm Neera was collected from different spikes of the same tree and at randomly selected trees in the same Farm to find out the variations in the properties. The palm products producers in Narippaiure were largely involved in the production of palm gur and palm candy.

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4.1.2 PHYSIOCHEMICAL PROPERTIES OF SELECTED NEERA SAMPLES

Table-7

Parameters Fresh Neera Ash (gm) 0Brix (%) Viscosity Titratable Boiling Point °C -1) samples pH (Normal 6.7 to Acidity (gl 7.2)

KS1 11.50±2.00 0.17±0.05 16.2±3.00 0.69±0.45 1.00±0.14 107.80±5.22 NS2 10.92±1.24 0.21±0.05 17.5±3.04 1.04±0.04 0.38±0.38 109.00±5.57 KS3 10.80±1.96 0.23±0.06 15.4±2.02 0.89±0.44 1.17±0.50 109.80±1.79 VS4 10.50±1.00 0.14±0.03 14.2±2.06 0.55±0.59 0.69±0.52 109.00±2.24

Mean ± standard deviation (n= 5)

KS1-Kilakkarai sample; NS2-Narippayur sample; KS3-Kanirajapuram sample; VS4-Vembar sample

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The Physio-chemical properties of Neeraare presented in Table-7. The nominal colour and appearance of the quality of Neera was as pale white compared to oyster white or that of creamy yellow which in turn refers to an undesirable sap that is turbid with a fermentative odour. The pH value measured at ambient temperature with a pH meter (Meenune et al.,

2011).pH value gives a measure of the acidity or alkalinity of the product and to ensure the quality of the same. These turbid results also showed that Sap contained a pH value ranging from 10.92±1.24 indicating that it was strong basic in nature at the time of collection.

Titratable acidity gives a measure of the amount of acid present in the product. As there was an increased alkaline pH, one could expect for titrable acidity values of fresh Neera to range from 0.38± 0.38%(gl -1). If on contrary, a higher value in Titrable acidity is observed which might be due to the traditional methods of production which are non-standardized in terms of raw materials, equipment and finished products quality and handling (Wonang and

Opoefe, 1999). High percentage of total acidity indicated the initial spoilage or fermentation of fresh palm sap as a raw material used for palm sugar concentrate production.

The fresh Sap, as a clear liquid will never be viscous or turbid in nature and thus, the analyzed viscosity results were almost nil or negligible (0.54±0.53). The determined turbidity parameter values of sap indicated its clarity and thereby its purity for a healthy drink. Ash content of palm sap was in the range of 0.14±0.03.The physio-chemical properties of traditional local drink of palm sap showed that the fresh sap contains 17.5±3.04 % of total soluble solids (%) 0Brix(TSS) as a suspension of soluble solids.

The boiling point required for conversion of fresh sap to a palm candy was found to be as 108-110 °C. Excess boiling temperature might result in the maillard reaction, an untoward effect, and then the brown color of the palm sugar concentrate sample will be

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produced during heating. Low temperature from the observed nominal boiling point might not lead to crystal formation from palm sap. The microorganism like yeast and lactic acid bacteria observed in the palm sap (being present naturally) or in collecting mud pots (may be retained during previous collection of sap) and serves as an inoculums. It is also believed that the lactic acid bacteria increased the acidity and ascorbic acid content. It was also reported that the fermentation caused the increase in alcohol content. The increase in protein content might be because of the yeast cells itself.

Proximate nutrient composition

The proximate nutrient composition of the selected samples are shown in table 9 and figure

Table–8. Proximate composition of Fresh palm Neera

S.No Sample (Sap ) Protein Carbohydrate Fat Calories (gm/100ml) (gm/100ml) (gm/100 ml) (Kcal/100ml) 1. KS1 12.8 28.3 0.03 109

2. NS2 17.5 29.5 0.06 108

3. KS3 12.31 23.2 0.07 114.9

4. VS4 17.2 20.5 0.05 117.5

KS1-Kilakkarai sample, NS2-Narippayur sample, KS3-Kanirajapuram sample, VS4-Vembar sample

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Figure 9 Proximate composition of palm Neera

Table–10 Sugar content of fresh Palm Neera

S.No Samples Parameters (Fresh Sap) Total sugar Glucose Fructose Sucrose (gm/100ml) (gm/100ml) (gm/100ml) (gm/100ml) 1. KS1 14.66±2.07 0.08±0.46 0.14±0.05 154.72±27.46 2. NS2 26.48±1.80 1.28±0.23 0.14±0.03 149.79±39.05 3. KS3 16.22±1.62 1.17±0.59 0.12±0.07 167.45±82.91 4. VS4 13.04±0.95 1.28±0.07 0.28±0.30 119.82±8.97 KS1-Kilakkarai sample; NS2-Narippayur sample; KS3-Kanirajapuram sample; VS4-Vembar sample

The total sugar content of health drinks of particular food types might vary considerably with variety, soil, climatic conditions, socio-economic factors, methods of production and raw materials or containers being used. The concentration of fructose and glucose was analyzed to be less than that of sucrose, a less calorific sugar so as to prevent the browning effect of the formed syrup. When once the probability of maillard reaction is

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controlled by having a reduced heating temperature and heating time during the production process, then the inversion of sucrose i.e. the conversion of sucrose into their individual monosaccharides, fructose and glucose also does not occur. Owing to the above mentioned reaction and reason, the less calorie sucrose was present in comparatively higher than the diabetic causing glucose content and thus the palm sugar and its precursor material, palm Sap become most essential as sugar free food supplement.

Palm sugar syrup heated by vacuum evaporator can reduce the loss of sucrose more than palm sugar syrup heated by open pan. This is probably due to this process using a lower temperature and a shorter time. Additionally, this process can also minimize sucrose inversion, therefore lower reducing sugar contents of fructose and glucose were obtained. The reducing sugar content is an important parameter that affects the properties of palm sugar syrup during storage since it can act as a substrate for maillard reaction.

Table–10. Estimation of vitamins in Fresh Neera

S.No Samples Vitamin Niacin Pyridoxine Thiamine Riboflavin (Fresh Sap) A (IU) (IU) (mg) (mg)

1. Market sample 2.351 0.110 NQ NQ NQ

2. KS1 1.657 0.000 NQ NQ NQ

3. NS2 2.346 0.132 NQ NQ NQ

4. KS3 1.214 - NQ NQ NQ

5. VS4 2.438 0.002 NQ NQ NQ

KS1-Kilakkarai sample, NS2-Narippayur sample, KS3-Kanirajapuram sample,VS4-Vembar sample,NQ-Negligible quantity.

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Only β-carotenes (2.3-2.4 IU) were found to be present in appreciable quantities comparing to all other vitamins like Niacin (just 0.110 NU) and Pyridoxin, Thiamine and

Riboflavin (very negligible or almost nil in quantities). Protein, carbohydrate, fat, calories and ash contents were determined by dry weight basis. The fat content observed was very less and negligible in the fresh toddy. The protein content was found to be 17.5 gm/100 ml matching to most of the standard nutritional health drinks and thereby assuring its role as a dietary material.

The determination of calorific contents of palm Sap led to a fact of obtainable energy source as around 114.9-117.5 Kcals and thus it acts as a very good energy provider and a rich energy supplements in food items.

Figure 10 Analysis of Vitamin A

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Table-11. Estimation of Minerals in Sap

S.No Samples Parameters (Fresh Sap) Ca Fe P Na K Zn Mg Mn (µg/gm) (µg/gm) (µg/gm) (µg/gm) (µg/gm) (µg/gm) (µg/gm) (µg/gm) 1. KS1 17.4 0.212 2.234 3.213 21.43 1.231 0.246 0.213

2. NS2 14.2 0.343 2.318 3.428 25.42 1.245 0.342 0.124

3. KS3 16.5 0.322 2.110 3.183 18.56 0.333 1.247 0.117

4. VS4 15.5 0.257 2.414 2.124 22.43 0.236 1.213 0.011

KS1-Kilakkarai sample; NS2-Narippayur sample; KS3-Kanirajapuram sample; VS4-Vembar sample

All these nutritional and functional characteristics can ensure the quality and purpose of palm sap as a rich food supplements. The quantities of minerals present in different samples of Sap from different places of Ramanathapuram district in tabulated -9. In most of the determination of minerals like Ca, Fe, P, Na, K, Zn, Mg and Mn, the Naripayyur samples was found to have the maximum concentration for almost all of the minerals and the results were 17.4 µg/gm of Ca, 0.343 µg/gm of Fe, 2.318 µg/gm of P, .428 µg/gm of Na, 25.42 µg/gm of K, 1.245 µg/gm of Zn, 0.342 µg/gm of Mg and 0.213 µg/gm of Mg. All these results confirmed the nutritional importance of Naripayyur Sap sample in terms of minerals and vitamins. All these results confirmed the nutritional importance and enriches of Naripaiure Neera sample in term of minerals and vitamins. The composition of mineral contents would in turn be reflected by that of ash content.

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Figure 11 Comparison of phosphorus and calcium content in Neera

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PHASE II

4.2.1.1 STUDY ON EXISTING METHODS OF PALM SUGAR PREPARATION

AROUND TAMIL NADU

Table–12. Survey on Palm Neera Process in various parts of Tamilnadu

S. Areas of study Products being Type of Quantity Production Yield No. prepared by mentioned Neera (liter) time (days) (kg) area 1. Palm society of Ramnad, Palm Gur, Narippayur 100 40 12-13 Palm Candy

2. Central Palm Gur Unit, Palm Gur, Madhavaram Palm Candy, Palm taffy, 100 30 30-33 Neera Preservation 3. Private Small Scale Palm Gur, 100 40 10-12 Industry, Thiruchendure Palm Candy 4. Small scale unit, under Palm Neera (Pathaneer) Palm Neera self-help group of Palm Gur, 100 40 13-14 Women, Sayalkudi in Palm Candy Ramnad District

The results of a survey on palm Neera process in various parts of Tamilnadu were

tabulated in table-10. Palm products like palm gur, palm candy, palm taffy and Neera

preservation carried out by Central Palm Gur Unit, Madhavaram has produced a very high

percentage yield of 33 % in just 30 days. Whereas, the other areas though were able to produce

the same palm products, their percentage yield and the duration were found to be less favorable

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as they were just 10-14 % yield and in only 40 days respectively. Also the quantities being produced in case of Madhavaram was 300 liters whereas, for others, it was just 100 liters. This because, Palm product workers in Naripayyur, Thiruchendur and Sayalkudi areas are not trained professionally about palm work processing; usually carry out such processes as in traditional, unhygienic processing environment and with no care of quality of products; their general aim of expectation would usually to sell the palm jaggery, obtained by just a one day process instead of a long term production of palm candy i.e. 45 days as the latter just yields only a very narrow differences in profits in spite of lot of investments for the same. The wholesaler usually sets a very low price for the palm products obtained from palm processing family workers as a marketing strategy and also as the products obtained from them would generally be spurious and less standard.

The palm workers in above said areas were not able to manufacture a very high percentage yield for the above mentioned reasons, whereas, those in Madhavaram area are very professionally trained by central palm gur unit for palm cookies or taffy or Neera preservation and do care for both quality and for profits of the process. A Central Training School was established in Madhavaram to train the tappers in tapping, preservation and sale of Neera, distributing improved tools and equipment and arranging demonstrations and exhibitions for propagating Neera and Gur as main facets of development programme. The reason for such success by central unit is that they have many workers to be working on more than 100 trees simultaneously for Neera collection and thus both the weaker section of the society as well as the central unit are mutually benefitted.

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Figure 12 pH variations in Palm Neera

Table-13. Identification of hazards in Palm candy and Palm jaggery

S. No Potential Type of hazards Residues Residues hazards in candy (%) in Jaggery (%)

1 Physical Mud 1 2 Sand 3 5 Thread 4 3 Stone 5 2 2 Chemical Superphosphate 10 9

3 Microbial load Bacteria/yeasts + ++

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The contaminants in Jaggery are more comparing to that in candy irrespective of the types of hazards. Jaggery deteriorates faster and becomes watery within 1 or 2 weeks due to its hygroscopic nature and thus deteriorates its quality through microbial fermentation. The different types of hazards that the palm candy or jaggery producers usually come across during their traditional manufacturing processes can be aimed to be alleviated in this innovative method involving a natural organic clarifier or a modern machine, a palm sugar extractor. As there is a rich demand for palm products in society and through which, a huge employment scope can be raised in these palm products processing, we focus to plan for a high quality and a hazard free methods for palm sugar production.

Raw materials and ingredients used in the processing should be obtained from certified vendors. Raw materials should be maintained at proper storage conditions, the production should follow HACCP principles and standard operating procedures to minimize risk of contamination and quality defects.

Table-14. Raw materials for Palm candy/sugar preparation

S.No Area Raw material Actually added Acceptable level of quantity of Superphosphate Superphosphate 1 Naripaiyur • Neera • Superphosphate 10 g in 1/4 liter of 5-7 g in 100 liters of solution Neera Neera 2 Madavaram • Neera • Superphosphate 8 g in 1/2 liters of 5-7 g in 100 liters of solution Neera Neera

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Though the acceptable level of superphosphate to be added in palm candy/sugar preparation permits only 5-7 g in 100 liters of Neera but in actual, the palm candy producers of

Naripayyur or the palm sugar producers of Madhavaram do utilize the quantities of superphosphate for production as 10 g or 8 g just for ¼ liters or ½ liters of Neera so as to improve the percentage yield of production inspite of realizing the hazardous facts caused by such superphosphate solution. According to Thomson Linda (2002), superphosphate is a chemical used in food industry, excess consumption of superphosphate will lead to cancer and neurological disorders. We thus planned to avoid or replace the role of this hazardous chemical by a natural organic clarifier.

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Table-15. Types of clarifier used in Palm sugar preparation

S. Neera Initial pH Method of Palm Quantity No quantity Clarifier of Plant preparation of Neera (g) (ml) extracted extract 1. Standard 250 Super phosphate 5 6.5 - solution

2. NS 2 250 Hibiscus leaves 10 7.2 Soaked in water for (extract) about 2-4 hrs, ground and crushed. Added this mucilaginous liquid 250 Ladies finger 10 6.6 do (extract) 250 Malai Poovarasu 10 7.8 do Stem (extract)

NS 2 – Narippayur sample of Neera

On the basis of the review of literatures, the stem extracts of plants viz., Hibiscus, Ladies finger and Malai Poovarasu were found to possess a large quantities of clarifying property and it was shown in Table-15. In Standard method, superphosphate was used as a clarifier as a traditional method existing in village pockets, Clarification of palm Neera is very important for making light yellow colored, crystallized and impurities free a gur, suitable for storage. The purpose of clarifier in such preparation is to clarify the collected Neera from their adjunct dusts or debris and also to promote the crystal formation along with the use of vinegar. Clarification of palm Neera is called Deliming process is done by using commercial superphosphate solution and thus the neutral reaction is brought out by pH adjustment with vinegar. The dissolved impurities in the Neera are removed with the help of vegetative clarificants. Instead of 5 g quantity of the chemical clarifier, superphosphate, all the natural clarifiers were taken in 10 g quantities in 250

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ml Neera in order to achieve the most preferable crystallization of palm sugar with maximum concentration.

Table–16. Difference between the existing palm candy and organic palm candy

S. No. Parameters Existing Palm Candy Organic Palm Candy

Calcium Hydroxide Calcium Hydroxide coated, 1. Container coated pot, U - sterilized mud pot Shaped metal chamber Hibiscus leave extract, Ladis pH maintainer and 2. Superphosphate Finger stem extract, Malai cleanser poovarasu extract 3. Temperature 110 0C 108 0C 4 Cooling condition Upon Soil In rooms Duration of Storage 6 45 days 12 days (for crystal formation)

Neera at the time of collection do usually contain the value of pH as around 11, a strong alkaline nature which to be decreased to a low basic pH like around 6.5-7.5, which is best achieved by Malai Poovarasu stem extracts. The purpose of coating the containers with calcium hydroxide is to prevent the process of fermentation. Though the temperature condition for both existing and organic palm sugar preparation did not differ much, but there was a big deal of variation in the duration of crystal formation i.e almost 25-30 days had been saved in the production process and indeed it is a huge point of consideration in profit point of view.

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Table-17. Preparation of Palm syrup

S.No Sample Initial pH of Final pH of Temperature Boiling Cooling Neera Neera ( o C) time time (min) (min) 1. Standard 12 8 106 – 108 60 10

2. KS1 10.2 8 106 – 108 30 10

3. NS2 9.8 8.3 109 – 110 45 10

4. KS3 11 7.8 107 – 108 40 10

5. VS4 11.8 8 106 – 108 25 10

KS1-Kilakkaraisample,NS2-Narippayursample,KS3-Kanirajapuramsample, VS4-Vembar sample.

Different samples of Neera, obtained from various villages of Ramnad district, were subjected for the preparation of palm syrup and the observed the reaction parameters were shown in the Table-14. Strong alkaline pH of Neera (10-12) at the time of collection has been decreased to neutrality i.e. to weak alkaline pH (7.8-8) using apple vinegar before boiling. The optimum boiling temperature of the process was found to be 109-110 o C, given out by Naripayyur sample.

As boiling proceeds, the froth and foam coming up to the surface is removed by means of a perforated laddle and the same was stirred at intervals to facilitate mixing and rapid evaporation.

The optimum boiling and cooling time, after comparing all the four samples, were found to be as

45 and 10 minutes respectively.

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The results of a survey on palm sap process in various parts of Tamilnadu were tabulated in table-10. Palm products like palm jaggery, palm candy, palm taffy and sap preservation carried out by Central Palm Gur Unit, Madhavaram has produced a very high percentage yield of 33 % in just 30 days. Whereas, in the other areas though they were able to produce the same palm products, their percentage yield and the duration was found to be less favorable as they were just 10-14 % yield and in only 40 days respectively. Also the quantities being produced in case of Madhavaram was 300 liters whereas, for others, it was just 100 liters.

This because, Palm product workers in Naripayyur, Thiruchendur and Sayalkudi areas are not trained professionally about palm work processing; usually carry out such processes as in traditional, unhygienic processing environment and with no care of quality of products; their general aim of expectation would usually to sell the palm jaggery, obtained by just a one day process instead of a long term production of palm candy i.e. 45 days as the latter just yields only a very narrow differences in profits in spite of lot of investments for the same. The wholesaler usually set a very low price for the palm products obtained from palm processing family workers as a marketing strategy and also as the products obtained from them would generally be spurious and less standard.

The palm workers in above said areas were not able to manufacture a very high percentage yield for the above mentioned reasons, whereas, those in Madhavaram area are very professionally trained by central palm gur unit for palm cookies or taffy or Sap preservation and do care for both quality and for profits of the process. A Central Training School was established in Madhavaram to train the tappers in tapping, preservation and sale of Sap, distributing improved tools and equipment and arranging demonstrations and exhibitions for propagating Sap and Gur as main facets of development programme. The reason for such success by central unit

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is that they have many workers to be working on more than 100 trees simultaneously for Sap collection and thus both the weaker section of the society as well as the central unit are mutually benefited.

The contaminants in Jaggery are more comparing to that in candy irrespective of the types of hazards. Jaggery deteriorates faster and becomes watery within 1 or 2 weeks due to its hygroscopic nature and thus deteriorates its quality through microbial fermentation. The different types of hazards that the palm candy or jaggery producers usually come across during their traditional manufacturing processes can be aimed to be alleviated in this innovative method involving a natural organic clarifier or a modern machine, a palm sugar extractor. As there is a rich demand for palm products in society and through which, a huge employment scope can be raised in these palm products processing, we focus to plan for a high quality and a hazard free methods for palm sugar production.

Raw materials and ingredients used in the processing should be obtained from certified vendors. Raw materials should be maintained at proper storage conditions, the production should follow HACCP principles and standard operating procedures to minimize risk of contamination and quality defects.

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Table 18 Difference between the Conventional and Innovative method of palm sugar production

S.No Particulars Conventional method Innovative method 1 Raw material used Palm sap 50 litre Palm sap 50

pH monitoring - pH meter

Clarifying agent superphosphate Hibiscus extract

Type of boiler Aluminium vessel Food grade electronic boiler

Boiling time 3 h ours 1.5 hrs

Crystallization Manual Chiller method Crystallization 24hrs/ 50 litre 6hrs/50 litre time Time duration for 37 days 24 hours production Type of Fuel Wooden Chulas Power operated

4 Centrifugation No Centrifuge used

5 Drying time 24 hr/ 5 kg 1 hr/5 kg

6 Storage period 1 year 1 year

Though the acceptable level of superphosphate to be added in palm candy/sugar preparation permits only 5-7 g in 100liters of Sap but in actual, the palm candy producers of

Naripayyur or the palm sugar producers of Madhavaram do utilize the quantities of superphosphate for production as 10 g or 8 g just for ¼ liters or ½ liters of sap so as to improve the percentage yield of production in spite of realizing the hazardous facts caused by such

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superphosphate solution. According to Thomson Linda (2002), superphosphate is a chemical used in food industry, excess consumption of superphosphate will lead to cancer and neurological disorders. thus planned to avoid or replace the role of this hazardous chemical by a natural organic clarifier.

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FABRICATION OF PALM SUGAR EXTRACTOR

Based on the primary and secondary data gathered through this study, the researcher tenured to design the equipment for the preparation of palm sugar. Newly designed and fabricated palm sugar extractor has the following components

1. Boiler with four shell layers

2. Chiller

3. Centrifuge

This has been fabricated with the help of a mechanical engineer working in Research and

Development, SITRA, Coimbatore. The whole process consists of three units. Each unit is

designed in a manner to reach maximum quality and quantity, as follows :

Collection of Sap (Pot Coated With Lime)

Boiling unit

Cooling unit

Centrifuge unit

Dried under sun light

Storage Fig-15.1Flow chart for new concept of palm sugar preparation 104

CONSTRUCTION OF PALM SUGAR MANUFACTURING MACHINE

This machine can hold a capacity of 20liters of Sap and can produce approximately 3kg of palm sugar. The construction of palm sugar machine is shown in figure .4.1.

It has three units and they are,

1. Boiling unit,

2. Cooling unit,

3. Centrifuge unit.

Palm sugar machine is constructed using steel frame section. In left side of the steel frame section, boiler is located which is used to boil the palm water under 120°C and it consist of temperature controller unit and stirred motor. Palm syrup is fed through the cooler unit that is connected with the stirrer motor. Centrifuge is connected next to the cooler unit for further process.

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Fig-16 Schematic diagram of palm sugar manufacturing machine

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4.1 Boiling unit

Fig-17 Boiling unit

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The boiler used to remove the water content and calcium. The elements of the boiler are illustrated below.

1. Frame 2. Boiler 3. Heating coil 4. Outer cover 5. High temperature insulation 6. Temperature controlling sensor 7. Stirrer

1. Frame A frame is a structural system that supports other components of a construction. It is made of mild steel and has a dimensions 25mm square and 3mm thickness.

2. Boiler Boiler is used to boil the Sap .The capacity of the boiler is 20 liters and made by

AISI304L (food grade stainless steel). The thickness of the boiler drum is 1.6mm; the rationale behind using less thickness is the fact that it is open to the atmosphere. Steam outlet pipe is provided in the top of the boiler to flush out the steam from the system.

3. Heating coil Heating coil is placed directly under the bottom outer surface of the boiler. Heating coil has Ø190mm , Voltage of 220V, xx Watts and xx Ampere. It is used to raise the temperature of the boiler to remove the water content in the Sap.

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4. Outer Cover

The outer cover acts as a second layer insulation over the boiler. Heatfrom the insulation wool is transferred to the outer cover this ensures minimal heat loss in the process. The main advantage of using the outer cover is it acts as a support for the insulation wool; hence there is no need of support strips for the insulation wool. The outer cover is made of Mild steel; its dimensions are Ø 300(mm)x 300 (mm) length.

5. High temperature insulation

At the time of startup, it is essential that heat does not escape through conduction and convection, Insulation plays a critical role in maintaining the temperature in the system, Ceramic wool is used as insulation for this system, the low values of thermal conductivity of ceramic wool aids in retaining the heat in the boiler. A thickness of 25mm is provided to optimize heat transfer rates.

6. Temperature controlling sensor

A temperature sensor is fixed at the bottom of the boiler; it displays the temperature of the system at any given time. It also acts as a feedback to the system, if in a given case there is a temperature rise above 120ºC. The sensor triggers the heating coil and switch off the system.

7. Stirrer

The stirrer assists in mixing of the contents in the boiler. It essentially consists of a stainless steel shaft, which is connected to a motor at one end and rotary blade at the other end.

Its rpm range is between 80-100 rpm. This ensures good coagulation and easy evaporation of water in the Sap.

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4.2 Cooling unit:

Figure 18 Cooling unit

The semi-solid palm extract which is obtained from the boiler unit has to be cooled to room temperature; this is handled by the cooling unit at the exit of the boiler unit. The main elements of the cooling unit are illustrated below-

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1. Inner Vessel 2. Water storage vessel 3. Stirrer

1.Inner Vessel The material of construction for the inner vessel is stainless steel; Stainless helps in cooling the semi-solid extract, owing to its high thermal conductivity. The capacity of the inner vessel is 10L.

2. Water storage vessel

This module of the cooling unit is responsible for holding the coolant which is instrumental in heat transfer from the inner vessel, which is alsoessential in reducing the temperature of the extract. The material used for this component is stainless steel. The idea of using stainless steel is to ensure that there is minimal corrosion involved in the process as the coolant used in this process is water, which has a tendency to cause corrosion over a period of time.

3. Stirrer

The stirrer assists in mixing of the contents in the vessel. It essentially consists of a stainless steel shaft, which is connected to a motor at one end and rotary blade at the other end. Its rpm range is between 80-100 rpm. This ensures uniform cooling in this process.

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Figure 19 Centrifuge unit

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Fig-4.4 Centrifuge unit

Thepurpose of this unit is to separate palm sugar crystals from molasses or mother liquor using centrifugal force. This system constitutes the following parts.

1. Basket 2. Outer Case 3. Bottom plate 4. Filter 5. Power unit 6. Funnel

1. Basket

The basket receives input from the power unit causing it to rotate and separate the water from the extract, It acts as a perforated cylinder which ensures that water which exits through the filter is separated out. It also acts as reinforcement for the filter. The cylinder is made of stainless steel and has dimensions of Ø 280mm x 300 mm length. Inside the basket there is a cone helps in obliterating the molasses which finally aids in separating the sugar crystals.

2. Outer Case

The outer case remains stationary while the basket rotates. It ensures that the water which is being separated get contained within the unit. It is welded to the bottom plate. It is made of stainless steel and has dimensions of Ø 400 mm x300mm length.

3. Bottom plate

The bottom plate is stationary and is welded on to the frame; it contains bearings which are used to couple the shaft and the pulley. The bottom plate ensures the stability when the centrifuge is on operation

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4. Filter

Filter element is used in the inside of the basket to filter the palm sugar crystal from molasses. It is made of stainless steel and has dimensions of 200mm diameter x 250mm length.

5. Funnel

Funnel is used to pour the semi-solid palm extract exactly to cone. It is welded to the top of the outer case. It is made of stainless steel and has dimensions of Ø 80mm x 150mm length.

6. Power unit

It comprises of a motor, driven pulley and belt. It is the source of the centrifuge’s power. To have a higher rpm in the centrifuge we use a smaller driven pulley, the motor pulley arrangement is such that it increases the rpm, and the driver pulley has a higher speed ratio to the driven pulley.

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Phase III: PHYSICAL PROPERTIES OF STANDARD AND DEVELOPED PALM

SUGAR

Table 19 Physical properties of standard and developed palm sugar

Sample Ash(mg) Total soluble Colour Titratable pH (Normal 6.7 solids ( °Brix %) Acidity % to 7.2) (gl -1) Standard sugar 7.9 0.03 9.5 Acceptable 74mg/kg

Developed 7.2 0.04 10.5 Acceptable 60mg/kg palm sugar

Since composition of physical parameters of palm sugar is found in various quantities,

above table present data for the evaluation of pH, Total acidity, and °Brix during the storage of

palm sugar. The pH of the sugar nearly neutral around (pH 6.8), this value was measured at

ambient temperature with a pH- meter (Inlab) which calibrated with pH 4.0 and 7.0.No

significant variation was noted for pH in sugar and pH values oscillate around a value of 7.6.

The acidity was estimated by titrating against 0.1 N sodium hydroxide using phenolphthalein as

the indicator. Acidity was expressed as a percentage of acetic acid, the Titratable acidity varies

between standard and developed palm sugar 74mg/kg and 60mg/kg. Moreover an increase in

Titratable acidity and decrease in pH is also responsible for the inversion reaction (Naknean et

al., 2010). The total soluble solids of palm sugar were determined as °Brix using hand

Refractometer (Reichert, Model 10430).

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Figure 20 Total soluble solids in developed Palm sugar

Table 20. Rapid Visco Analyzer (RVA) analysis of the sample

P H C P.T

Sample BD SB

(cP) (cP) (cP) min

Palm Sugar -Developed 5 -28 33 -30 -2 1.07

Palm Sugar - Standard 4 -22 26 -19 3 1.47

Parameters tested are not covered under the scope of NABL accreditation\

Where , P – Peak Viscosity, H – Hot Paste Viscosity, C – Cold Paste Viscosity, BD – Breakdown, SB – Setback, P.T(min) – Pasting time, cP – Centipoises (Viscosity unit)

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Table- 21 Comparative analytical data on Nutritional properties of standard and developed palm sugar

Samples Nutritional parameters

CHO Protein Fat Calories Glucose Fructose Sucrose g/100gm g/100gm kcals/100gm mg/100gm mg/100gm mg/100gm

Standard 58.25 1.08 0.24 220.50 0.032 0.004 1.015

Developed 66.56 2.09 0.36 227.84 0.094 0.007 2.621

The above table indicates the proximate composition tested existing palm sugar

(standard) and developed sugar prepared by using new process .The Carbohydrate, protein, fat and calories contents of the standard sugar was 58.25g, 1.08g, 0.24g and 220.50 Kcals respectively. Concerning sucrose content of sugar was comparatively high in other quality from other sugars. It is apparent from these data that, sucrose content in both palm sugar samples varied between 1.015 to 2.621mg. However, reducing sugar and protein contents were higher in palmyrah palm sugar compared to standard and sugar developed by new process.

The crystal palm sugar is suggested by the health expert because low calorie content if compared with the granulated sugar. The palm sugar has Glycemic Index lower about 35 while at the granulated sugar about 58( Nenania, 2011 ). The Glycemic index will impact to pancreas fatigue index, the higher Glycemic Index the higher the pancreas fatigue Index, so the palm sugar is more suggested for diabetic sufferer compared with the granulated sugar.

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Table -22 Fat soluble vitamins analysis of standard and developed palm sugar

Sample Vitamin A Vitamin C Alpha - Vitamin K Cholecalciferol mg/100gm mg/100gm Tocopherol (E) (D3)

Standard 0.120 489 0. 690 0.332 0.010

Developed 0. 436 712 0. 877 0. 63 8 0.0 23 palm sugar

Quantitative analysis of vitamins was analysed on the basis of 100g of standard and

developed palm sugar, the data was presented in Table 22. Comparison study was made on the

amount of vitamin A, Vit C, Alpha Tocopherol and Vit K, Choleclciferol found in the standard

sugar and developed sugar samples to those presented in table. The vitamin Acontent 0.120 and

0.436, found in both standard and developed sugar at moderate amount, comparatively other

sugars these sugars contains vitamins content two times greater than that found in palm sugar.

Developed sugar was also considered to be rich in vitamin E with moderate amount of vitamin

K,vitamin D3 and vit E. HPLC method was used to vitamin analysis of the palm sugar.

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Table 23 Water soluble vitamins analysis of standard and developed palm sugar

Sample Niacin Pyridoxine Thiamine Riboflavin (mg/ml) (mg/ml) (mg/ml) (mg/ml)

Standard 0.021 0.011 0.235 0.012

0.025 0.016 0.467 0.001 Developed palm sugar

Table 24 Analysis of ICP- OES of Standard and developed Palm Sugar

Sample Calcium(317.93 Iron Sodium(589.59 Pottasiu Zinc(206.200 3) (mg/kg) (238.204)(mg/k 2) (mg/kg) m ) (mg/kg) g) (766.490) (mg/kg) Standard 8.54 0.47 0.92 Below 1.05 detection limit 9.66 0.50 0.98 Below 2.10 Develope detection d palm limit sugar

The composition of minerals of palm sugar samples is shown in table 24. Calcium, Iron, and Sodium, potassium, Zinc contents are high compared to other minerals for the standard samples. These five elements called Macro-minerals are distinguished from the micro-minerals by their occurrence in the body, as they required in amounts greater than100 mg per day.

Pottasium presented the below detection limit in the two samples. The calcium content was abundant in both palm sugar samples. All the mentioned macro-minerals have vital physiological and biochemical functions in human body. Only Sodium were found in fair amount and zinc content was good in developed sugar (2.10mg/kg) . The greatest biological significance of zinc in the organism is associated with its occurrence in active sites of many enzymes and proteins.

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Table 25. Flavonoids compounds of standard and developed palm sugar

Sample Gallic acid Caffeic(mg/ml) Rutin(mg/ml) Quercetin(mg Ferulic acid (mg/ml) /ml) (mg/ml)

Standard 0.013 0.015 0.013 0.001 0.062

0.010 0.014 0.002 0.011 0.085 Developed palm sugar

The beneficial effects derived from phenolic compounds have been attributed to their

antioxidant activity and studies have suggested the role of phenolic compounds as the major

sources natural antioxidants in foods of plant origin. The results of (table 25) showed lower than

palm sugar (Galic acid 0.013 and 0.010 mg/ml, caffeic 0.015 and 0.014). Ferulic acid was found

in standard sugar 0.062mg, developed sugar 0.085mg. The total phenolic contents of dried palm

sugar decreased with the increased temperature of drying.

The influence of different drying processes on the concentration of phenolic compounds

can be attributed to the varying stability of different phenolic compounds under the drying

conditions (Joshi et al ., 2011).

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Table 26. Antioxidant activity assay in standard and developed Palm Sugar

S.No Concentration % Free radical scavenging activity ( IC 50 values) mg/m % of inhibition of % of inhibition of % of inhibition of ethanolic extract Ascorbic extract BHA Sample Standard Developed Standard Developed Standard Developed palm Palm palm Palm palm Palm Sugar sugar Sugar sugar Sugar sugar 1. 10 mg 32.57 48.34 22.38 19.05 25.69 50.04 2. 20mg 20.98 57.21 29.45 22.15 57.01 69.05 3. 30mg 31.05 49.13 16.30 24.02 84.79 76.05

The scavenging of the DPPH radical by hydrogen donating antioxidants (AH, equation 1) is characterized by a rapid decline in the absorbance at 515 nm, followed by a slow step where the absorbance depreciates more gradually. The above table shows the total phenolic content of standard palm sugar possessed higher antioxidant content, while the lowest antioxidant activity observed in ethanolic extract shows that there exists higher anitioxidant activity in the developed sugar .The free radical scavenging activity of ethonolic standard sugar and developed palm sugar extract against total antioxidant activity is (32.57,20.98, 31.05)( 48.34, 57.21, 49.13) respectively. The inhibition of ethanolic extract (10,20,30).

I n this study, DPPH residual scavenging activity % was plotted against the sample extract concentration and a linear regression curve was established in order to calculateIC 50 which is the amount of sample required to decrease the absorbance of DPPH free radical by

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50%. IC 50 values of ascorbic acid for both sugar were 10,20 and 30mg/ml, respectively. Ascorbic extract has the lowestIC 50 value compared to the two samples. In DPPH assay, the lower theIC 50, the better it is ability to scavenge the radicals.

The DPPH radical scavenging activity of gallic acid, ascorbic acid ,crude and ethanol extracts increase in a dose-dependent manner. Gallic acid exhibits higher DPPH radical scavenging activity than either ascorbic acid or palm sugar extracts when tested at concentrations of 0.2-1.0 Mm GAE. For example, at a concentration of 1.0 Mm, the DPPH radical scavenging activity of gallic acid (94.5+0.35) was more than 6 times that of ascorbic acid(14.6+1.1%),crude extract (15.4+0.4%),and ethanol extract (14.2+0.7%).On the other hand

,the radical scavenging activities of the extracts are comparable to that of ascorbic acid.

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Phase: IV SHELF LIFE ANALYSIS OF DEVELOPED PALM SUGAR STORED IN DIFFERENT PACKAGING MATERIALS

Table 27 Impact of packaging and storage conditions on Brix and moisture content of palm sugar

AFTER 30 DAYS BRIX MOISTURE LDPE HDPE AF LAP LDPE HDPE AF LAP % % % % % % % % Room 1.04 1.03 1.02 1.02 2.9 2.8 2.7 2.5 Temperature Refrigeration 1.03 1.02 1.02 1.02 2.7 2.6 2.5 2.5 Humidity 1.00 1.03 1.01 1.02 2.5 2.6 2.6 2.5 11% Humidity 1.06 1.04 1.02 1.02 2.9 2.8 2.6 2.5 75 % Humidity 1.07 1.06 1.03 1.02 3.1 2.9 2.7 2.6 86 % AFTER 60 DAYS BRIX MOISTURE LDPE HDPE AF LAP LDPE HDPE AF LAP % % % % % % % % Room 1.10 1.08 1.04 1.05 3.2 3.1 2.9 2.6 Temperature Refrigeration 1.08 1.06 1.04 1.04 2.9 2.7 2.6 2.6 Humidity 1.06 1.05 1.04 1.04 2.6 2.7 2.6 2.6 11% Humidity 1.09 1.08 1.04 1.04 3.1 2.8 2.7 2.6 75 % Humidity 1.12 1.09 1.05 1.04 3.4 2.9 2.7 2.6 86 % AFTER 90 DAYS BRIX MOISTURE LDPE HDPE AF LAP LDPE HDPE AF LAP % % % % % % % % Room 1.16 1.13 1.10 1.09 3.4 3.2 2.9 2.7 Temperature Refrigeration 1.11 1.09 1.09 1.08 3.1 3.0 2.8 2.8 Humidity 1.10 1.09 1.08 1.08 2.9 2.7 2.7 2.7 11% Humidity 1.11 1.10 1.09 1.08 3.2 2.9 2.7 2.7 75 % Humidity 1.13 1.11 1.10 1.09 3.5 3.3 2.8 2.7 86 % It becomes necessary to undertake the study of impact of packaging materials for the prepared palm sugar as the shelf life of the palm candy is very short and also the tapping of 117

palm juice and the preparation of palm candy is just a seasonal process. The problem can be overcome by developing an economic packaging and working out a suitable environmental condition so as to make this product available at affordable price throughout the year. In any industrial production particularly in agro-industries the raw material should be consistent enough in quality to ensure the uniform quality and standard in the finished product.

Keeping all the very important therapeutic uses of palm candy in mind and its storage difficulties, introduction of a suitable method of appropriate packaging technology becomes essential to promote their product quality, to increase the shelf life, to prevent undesirable physical changes during storage period due to the environment factors and other factors, to evaluate the impact of packaging and storage methods and to map the variations in the palm sap quality and also for marketing strategy.

Different packaging materialsviz., 150 guage High Density Polyethylene (HDPE), 80 guage Low Density Polyethylene (LDPE), Aluminium Foil (AF) and Laminated Aluminium

Pouches (LAP) were used to pack the freshly prepared palm candy in order to protect the prepared products. After packaging, the products were subjected for checking various shelf- life parameters like storing at room temperature, refrigeration temperature and three different relative humidity conditions (11%, 75% and 85%) to observe for any physical/chemical changes during their storage period. Saturated aqueous solution of lithium chloride, sodium chloride and potassium chloride were taken in three different desiccators so as to achieve the desired humidity conditions.

The parameters Brix and Moisture contents of palm candy were checked out for every

10 days, 20 days and 30 days to observe for any undesirable property changes in the prepared palm candy. Brix had been checked out by Refractrometer and the moisture content had been determined by infra red absorption by moisture meter. In samples which were packed in

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LDPE and HDPE packages, both brix and moisture content were increased as the days of storage increased and fluctuations also observed in the determined values. Whereas, in the samples packed in aluminium foil and laminated aluminium pouches, very slight increase in brix and moisture content was found.

From the above study, it was suggested that laminated aluminium pouches with storage conditions at refrigeration condition and with lower RH were better suited for maintaining palm candy than other packagings and storage conditions. No much differences were found in the properties of palm candy when they were packed using laminated

Aluminium pouches and kept at refrigeration condition and lower humitidies.

PHASE V ANTIMICROBIAL STUDY OF DEVELOPED PALM SUGAR Table - 28 Antimicrobial activity of palm sugar standard and developed palm sugar against bacterial pathogens

S.No Test Organisms Zone of inhibition in millimeter (in diameter)

Standard Developed Solvent Standard palm sugar Palm sugar control Nalidixic acid (30 µg/ml) (30 µg/ml) (30 µg/ml)

1. Shigellaflexneri 13mm 14mm 6mm 20

2. Escherichia coli - 9mm 16 10mm 3. Pseudomonas - - - 16 Aeruginosa Solvent used : Ethanol, Standard used : Nalidixic acid 30 µg/ml

The above table showed that all Ethanol extracts of palm sugar were active against the locally isolated human pathogens like Shigella flexneri , Escherichia coli and Pseudomonas aeruginosa. The organic extracts provided more powerful antimicrobial activity as compared to aqueous extracts. This observation clearly indicates that the existence of non-polar residues

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in the extracts which have higher both bactericidal and bacteristatic abilities. Shigella flexneri reflects higher amount of zone of inhibition in the range of 14mm in developed palm sugar with the concentration in (30mg/ml), when compare to other two species.

Jaggery deteriorates faster and becomes watery within 1 or 2 weeks due to its hygroscopic nature and thus deteriorates its quality through microbial fermentation. The quality of the stored jiggery mostly depends upon the moisture content which is favorable for inversion and development of different types of fungi and bacteria in the jiggery resulting in changes in tastes and colours because of the organic acid and decomposition of complex decomposition of products (Tiwari et al., 2004).

Table -29 Total Bactorial count from standard and experimental palm sugar

S.No Standard of Serial Number of colonies / plate Number of colonies / plate dilution (10 -3,10 -4, 10 - (experimental sugar)- cfu/gm (Standard palm sugar) - 5, 10 -6, 10 -7) cfu/gm 1. T1 99.00±97.78 101.80±103.26

2. T2 99.00±80.52 104.80±87.71

3. T3 98.60±98.28 123.80±140.58

4. T4 102.20±96.17 109.00±112.23

5. T5 94.40±91.69 104.80±93.55

(T1 – T5 : Dilution 10 3 to 10 7) TLTC = Too Low To Count

The microorganisms found in the standard and developed palm sugar were counted through TLTC method . No significant difference was recorded in both the bacterial and fungal counts. The pour plate method was used to cultivate serially diluted portions of the sugar samples under investigation. The mean heterotrophic bacterial and fungal counts of the different sugar samples ranged from 94.40±91.69 to102.20±96.17 cfu/g. This might be due

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to lack of proper storage facilities and sales infrastructure within the markets visited, hence the standard palm sugar failed to resist contamination. The moisture content of the palm sugar should always be maintained at minimal levels to reduce the rate of microbial proliferation .

Inadvertent contamination by microbial or chemical agents during processing could also caused deterioration, thereby compromising safety and quality, and rendering the plant material less effective and possibly harmful to the consumer.(WHO, 2003)

The presence of the fungal contaminant shows the possibility of poor storage conditions. This is a serious contaminant since some common species of fungi produce toxins like Aflatoxins. According to the WHO , aflatoxins in herbal drugs can be dangerous to health even if they are absorbed in minute amounts. The limits of microbial contamination are total aerobic bacteria 105 CFU/g yeast and mould 103 CFU/g. However, none of the herbal suspensions exceeded the recommended total aerobic counts. The absence of contaminants may be due to hygienic packing or presence of bacteriostatic substance that would have killed possible microbial contaminants. Investigation of possible antimicrobial adulterants in the herbal suspensions is suggested.

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SUMMARY AND CONCLUSION

Palm sugar is a delicious natural sweetener used traditionally by south Indians. Palm

Sugar is rich in Nutraceuticals and functional properties. In the traditional process of preparing Panamkalkandu (Tamil equivalent for palm sugar ) with the presence of impurities like thread, sand and dust the researcher attempted to remove such deleterious materials in the preparation of palm sugar, so a necessity has arisen to develop an alternative, new processing technology to remove the materials. The final outcome the study has been taken up for not only improving the quality of palm sugar available in the domestic market but also for facilitating the entry of this product into foreign market as purity and consistency in quality is assured.

Ramanathapuram district, a coastal area in Tamilnadu, India has been selected for this study taking into consideration the following facts. The review of literature indicates the existence Palmyra trees are enormous in this district. The Brix value of Neera is found to be high in these areas when compared to the available Neera in other parts of the State. This district is an arid and backward area with thick unemployed population and literacy rate is low when compared with other districts. The study also reveals the tappers’ (persons collecting the sap from trees) families do not like to climb the palm trees for tapping Neera and selling the same at low price. More over it is a seasonal job of the locals. If better Neera preservation and processing techniques are evinced, sizable proportion of the unemployed youths can get an assured employment potential in palm industry, by engaging them in palm sugar production and packaging for export market, which is a challenging outcome to meet the international market of this region. Cultivation of more palm trees for income generation activities is the need of the hour. The cultivation of palm trees does not require much water

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resources when compared with other plantations. It is also an important factor in maintaining the eco-system of this region too.

The population of Palmyrah palm tree is found to be tremendously high in the Eastern coastal line comprising from Kilakarai to Thiruchendur and most of the inhabitants of this area do have their mainly focused occupation as palm tapping, which in turn leads to easy and ready availability of manpower for all processes like sap collection, palm products processing.

The selected four villages had a total of 1600 palm sap tappers. For the study purpose one hundred palm sap tappers from the 4 villages at randomly were selected for collection of information . Care was taken to select palm sap tappers who were continuously involved and did the production of palm jaggery and palm candy. The information viz socioeconomic status, method of palm sap collection, economics involved in palm sap and palm jaggery production was collected using a specially designed interview schedule. The selected four villages viz Kilakarai, Narippayur, Kannirajapuram and Vembar the sap was collected from the palm tappers. The collected palm sap was filtered through a fine muslin cloth or a fine cotton cloth to give a clear sap. The samples were stored immediately in a sterilized bottles an ice box (0-8 °C) and transported to the laboratory for analysis the physico-chemical and nutritional properties on the same day. Fermentation might be observed if temperature is altered above, resulting in the formation of alcohol, undesirable product. Every time during the process it becomes necessary to confirm the palm sap is not fermented.

The collected palm saps from the four villages were subjected to physiochemical and nutritional properties. The physio chemical properties viz Moisture, pH, Acidity, Colour,

Brix, viscosity, Boiling point were analysed. The nutrient composition viz proximate composition, Vitamins, minerals were analysed.

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Four units suggested by the Khadi and Village Industries Commission was contacted and the method of production was observed and the products was collected for testing the physical and chemical hazards. The following were observed in the four units for understanding the conventional method of production 1. Materials used 2. pH monitoring 3.

Clarification materials used 4. Crystallization methods 5.The type of vessels used 6.

Standardazation of production 7.Time duration of production 8. Microbial load of the product 9.Fermentation process.

Traditionally, palm sap is manually collected from each inflorescence of the Palmyra palm tree. Palm sugar concentrate was produced by evaporating the palm sap in a large opened pan (approximately 60-100 liters/pan) and heated using the twigs and palm leaves as fuel till the required consistency (deep brown colour) was obtained. Inorder to overcome all these disadvantages modified new process was carried out and new equipment was designed and fabricated .

This natural clarifier overtakes the property of commercial superphosphate in the preparation of Neera, as the latter may cause neurological disorders as they are synthetic based comparing to the former organic. The Sap collected from palmyra trees from four different locations viz. , Kilakarai, Narippayur, Kannirajapuram and Vembar in

Ramanathapuram district, were analysed for their nutritional and functional properties. On the basis of the analyzed results, the sample of Neera obtained from Narippayur village was found to be of more quality, nutritious and the best for crystal formation.

Traditionally, palm sap is manually collected from each inflorescence of the Palmyra palm tree. Palm sugar concentrate is produced by evaporating the palm sap by using wood fired stove and the process ends up by observing the intensity of brown colour thickness and viscosity of the on-going product. Overheating process would alter its unique flavour and

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colour and the total soluble solids with sugar in the finished product should be at least 65 0

Brix or above for food safety purpose.

CONCLUSION

This study is an eye-opener to all food scientists, nutritionists and policy maker throw open a new vista of knowledge to promote this palm industry is particular-production of palm sugar is all areas of our nation, which are wide spread is particular in Tamilnadu. Which can promote this industry with the combination of traditional skills with the emergency technology to nature this is a commercial way to install the machine developed by the researcher is all pockets of palm trees regions in Tamilnadu. To produce palm sugar which is a real natural replacement of synthetic low calories sugar and other white sugar / brown sugar available is the market for obesity and diabetes mellitus.

The district rural development authority can initiate to have an exclusive cooperative society to promote Neera collection during the seasonal months by having chilling vans to collect Neera from the rural population engaged in this activity to promote the production of palm sugar, in these belts of Ramanathapuram district. The palm sugar, an organic product having low glycemic index, rich in minerals and other micro nutrients is a boon for health conscious population. Which the world is looking around for replacement of white sugar which has brought out serious health concerns and awareness to prevent the usage of white sugar is India.

This study has brought out are insight to native people to refurbish this traditional food and to grow more palm trees which are diminishing at a faster rate due to the non availability of manpower to climb large huge trees. This is also are big challenges to review the palm industry and the conservation of these trees, a treasure of Indian food industry. We 125

need to bring out new strategies to train our rural folk in this palm industry, assure confidence to review this industry, is a big way. The MSME, Govt of India, shall focus on this issue, to review our traditional cottage industry near future.

AKNOWLEDGEMENT

All praise goes to the Almighty for his manifold to carry out my research work successfully. I gratefully acknowledge UGC, New Delhi for their financial support in this major research project. The investigator records her gratitude and sincere thanks to

Alhaj.B.S. Abdur Rahman , Founder, the Dr. Rahmathnisha Rahman , Correspondent, for encouraging the research work in the area of palm sugar processing and providing me an opportunity to work in this esteemed institute.

I would like to express my deep sense of gratitude to my Professor Dr. S. Sumayaa ,

Head & Principal, Department of Home science and Research Center for her inspiring guidance and unstinted help throughout my Research work and for extending all possible help towards completion of this research.

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