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Mt Handbook 0.Pdf TABLE OF CONTENTS Page No. Chapter 1: Introduction 1.1. Status, market size and scope of fruit and vegetable processing 4 industry in India 1.2. Selection and procurement 5 1.3. Supply chain of fruits and vegetables 15 1.4. Pack house handling of fruits and vegetables 19 1.5. Primary Processing of Fruits and Vegetables 26 1.6. Unit operations in fruits and vegetables processing 30 1.7. Minimal Processing of Fruits and Vegetables 42 Chapter 2: Value addition of Fruits and Vegetables 2.1. Processing of fruit pulp/puree 49 2.2. Processing of Jams 50 2.3. Processing of Jellies 54 2.4. Processing of osmotic dehydrated product 59 2.5. Preservation by chemicals 63 2.6. Processing of Sauce 65 2.7. Processing of Ketchup 67 2.8. Processing of Pickles 73 2.9. Processing of Chutneys 80 2.10. Processing of Fruit Juices 82 Chapter 3: Packaging of Fruits and Vegetable Products 3.1. Levels, functions and desirable features of packaging 93 3.2. Packaging materials and their properties 95 3.3. Special Packaging systems 112 3.4. Properties/characteristics of foods, packaging requirement and 115 methods 3.5. MAP of fruits and vegetables 116 3.6. Mechanical injuries of fruits and vegetables 118 3.7. Shelf life of packaged food and its determination 121 3.8. Storage of Fruits and Vegetables 124 Chapter 4: Food safety regulations & certification 4.1. Need for testing of food 130 4.2. List of Notified Reference Laboratories in India – 1 131 4.3. List of Notified Reference Laboratories in India – 2 132 4.4. List of Notified Referral Laboratories and their scope 133 4.5. List of State/ Public Food Laboratories 136 4.6. GMP (Good Manufacturing Practices) 140 4.7. GHP (Good Hygiene Practices) 143 4.8. GLP (Good Laboratory Practices) 143 4.9. HACCP implementation program 162 4.10. FSSAI Regulations and standards for maintaining food safety and 176 quality 4.11. FSSAI packaging and labeling requirements 187 4.12. FSSAI registration and licensing procedure 194 Annexure (PM-FME Guidelines) 198 Indian Institute of Food Processing Technology CHAPTER 1 INTRODUCTION 1.1. Status, Market Size and Scope India being the second-largest producer of fruits and vegetables (311.17 MT in 2018-19), facilitates the fruit and vegetable processing industry in acquiring its primary resources. Canning, dehydration, pickling, provisional preservation, and bottling are some of the methods used in fruit and vegetable processing which help increase the shelf life of seasonal fruits and vegetables. 1.1.1. Major producing states Maharashtra, Andhra Pradesh, Uttar Pradesh, Gujarat, and Karnataka are the leading producers of fruits in India, having a combined share of around 51% in the total fruits production. For vegetables, major producers include West Bengal, Uttar Pradesh, Bihar, Madhya Pradesh, and Gujarat, together accounting for around 55% of the national production. 1.1.2. Market insights The fruit and vegetable processing industry in India is likely to expand at a compound annual growth rate (CAGR) of ~7.62% between FY 2018 and FY 2023 to reach a value of INR 256.4 Bn in FY 2023.Currently, commercial processing of fruits and vegetables is extremely low in India, at around 2.2% of the total production as compared to countries like Philippines at 78%, China at 23% and the United States (U.S.) at 65%. The unorganized sector witnesses a stiff competition, owing to the presence of a large number of players competing for small shares in the overall market. Organized players compete with each other to maintain their market share and gain brand loyalty. 1.1.3. Exports During 2018-19, India exported fruits and vegetables worth Rs. 10236.93 crores/ 1,469.33 USD Millions which comprised of fruits worth Rs. 4817.35 crores/ 692.01 USD Millions and vegetables worth Rs. 5419.48 crores/ 777.25 USD Millions. Grapes, Pomegranates, Mangoes, Bananas, Oranges account for larger portion of fruits exported from the country while Onions, Mixed Vegetables, Potatoes, Tomatoes, and Green Chilly contribute largely to the vegetable export basket. The major destinations for Indian fruits and vegetables are Bangladesh, UAE, Netherland, Nepal, Malaysia, UK, Sri Lanka, Oman and Qatar. 4 Master Trainers Handbook of Fruits and Vegetable Processing Indian Institute of Food Processing Technology 1.1.4. Key growth drivers The demand for processed fruits and vegetables is expected to rise significantly due to the growing penetration of organized retail in the country. Increasing number of nuclear families are also increasing the demand for processed food. Busy lifestyles of such families have increased their dependence on food items that require less time to prepare. 1.1.5. Key deterrents Lack of sufficient storage facilities and improper distribution are hampering the growth of the market. Existing stand-alone and integrated companies and logistics offering cold storage and transportation solutions are unable to meet the entire demand for such services. These factors are adversely affecting the development of the fruit and vegetable processing industry in India. 1.2. Selection and Procurement Maturity is the stage of fully development of tissue of fruit and vegetables only after which it will ripen normally. During the process of maturation, the fruit receives a regular supply of food material from the plant. When mature, the abscission or corky layer which forms at the stern end stops this inflow. Afterwards, the fruit depend on its own reserves, carbohydrates are dehydrated and sugars accumulate until the sugar acid ratio form. In addition to this, typical flavour and characteristic colour also develop. It has been determined that the stage of maturity at the time of picking influence the storage life and quality of fruit, when picked immature like mango develop white patches or air pockets during ripening and lacking in normal brix acid ratio or sugar acid ratio, taste and flavour on the other hand if the fruits are harvested over mature or full ripe they are easy susceptible to microbial and physiological spoilage and their storage life is considerably reduce. Such fruits persist numerous problems during handling, storage and transportation. Therefore, it is necessary or essential to pick up the fruits or vegetables at correct stage of maturity to facilitate proper ripening, distant transportation and maximum storage life. 1.2.1. Factors affecting maturity a) Temperature: Higher temperature gives early maturity e.g. Gulabi (Pink) grapes mature in 100 days in Western India but only 82 days are enough in the warmer Northern India. Lemon and guava takes less time to mature in summer than in winter. Sun-scorched portions of fruits are characterized by chlorophyll loss, yellowing, disappearance of starch and other alcohol insoluble material, increase in TSS content, decrease in acidity and softening. 5 Master Trainers Handbook of Fruits and Vegetable Processing Indian Institute of Food Processing Technology b) Soil: Soil on which the fruit tree is grown affects the time of maturity. e.g. Grapes are harvested earlier on light sandy soils than on heavy clays. c) Size of planting material: This factor in propagated fruits affects fruit maturity. e.g. In pineapple, the number of days taken from flowering to fruit maturity was more by planting large suckers and slips than by smaller ones. 4. Closer spacing: Close spacing of hill bananas hastened maturity. d) Pruning intensity: It enhanced the maturity of Flordasun and sharbati Peaches. e) Girdling: Process of constricting the periphery of a stem which blocks the downward translocation of CHO, hormones, etc. Beyond the constriction which rather accumulates above it. In Grape vines it hastens maturity, reduces the green berries in unevenly maturity cultivar and lowers the number of short berries. It is ineffective when done close to harvest. CPA has an additive effect with girdling. 1.2.2. Maturity index The factors for determining the harvesting of fruits, vegetables and plantation crops according to consumer’s purpose, type of commodity, etc and can be judged by visual means (colour, size, shape), physical means (firmness, softness), chemical analysis (sugar content, acid content), computation (heat unit and bloom to harvest period), physiological method(respiration). These are indications by which the maturity is judged. Various indices are as Follows; a) Visual indices: It is most convenient index. Certain signals on the plant or on the fruit can be used as pointers. E.g. drying of top leaves in banana, yellowing of last leaf of Peduncle in jackfruit. Flow of sap from cut fruit stalk of mango slows down if the harvest is done after maturity but in immature fruits, exudation is more and comes with force in a jet form. in papaya, the latex becomes almost watery. The flow gets reduced on maturity in Sapota. In fruits like banana and Sapota, floral ends become more brittle and shed with a gentle touch or even on their own. In Sapota, the brown scurf on the fruit skin starts propping. In mango, lenticels become more prominent and the waxy bloom gradually disappears. Grapes develop translucent bloom. Other changes like angularity in banana, development of creamy wide space between custard apple segments and the flattening of the eyes in pineapple and tubercles in litchi serve as reliable maturity indices. 6 Master Trainers Handbook of Fruits and Vegetable Processing Indian Institute of Food Processing Technology b) Seed development: It can also be used as an index of fruit maturity, e.g. endocarp hardening for stone and fiber development for dessert in mango. c) Start of bud damage: Occasionally it can be used as an index of fruit maturity in mango. d) Calendar date: For perennial fruit crops grown in seasonal climate which are more or less uniform from year to year, calendar date for harvest is a reliable guide to commercial maturity.
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