135, East Coast Road, Kanathur, Chennai - 603 112

ACADEMY OF MARITIME EDUCATION AND TRAINING (AMET) (Declared as Deemed to be University u/s 3 of UGC Act 1956) 135, EAST COAST ROAD, KANATHUR, CHENNAI - 603 112. TAMILNADU, INDIA

EQUIPMENT’S AND PROCESSES FOR PANEER AND CHEESE MANUFACTURE.

A Report on Home based Internship

In Department of Food processing technology

Student Name – J.M.Hema Shri Register Number- FP001

MAY, 2020

ACKNOWLEDGEMENT I would like to sincerely thank the vice chancellor of AMET deemed to be university Col.Dr.Thiruvasagam for introducing the home based internship into our syllabus during the covid-19 pandemic.

I would like to thank my Head of the Department (Food processing technology) Dr. K. Sasi praba for her guidance to complete this home based internship.

I would like to thank my deparment Faculties for their constant support. I would also like to thank my friends who helped me in completing this report.

CONTENTS

LIST OF SYMBOLS AND NOTATIONS PAGE NO 1. ABSTRACT 4 2. INTRODUCTION 4 3. METHODOLOGY 7 4. CONCLUSION 26

ABSTRACT

Paneer, a popular indigenous dairy product of India, is similar to an unripened variety of soft cheese. Paneer is marble white in appearance, having firm, cohesive and spongy body with a close-knit texture and a sweetish-acidic-nutty flavour. Preparation of Paneer using different types of milk and varied techniques results in wide variation in physico-chemical, microbiological and sensory quality of the product. Paneer keeps well for about a day at ambient temperature and for about a week under refrigeration (7 °C). The spoilage of Paneer is mainly due to bacterial action. Similar process is administered for the cheese production rennet enzyme is used for coagulation. In this report I had compiled the manufacturing and equipment’s involved in the processing of Paneer and cheese and also have given the market analysis of those products for better understanding and to give an insight of those operations.

Keywords: Paneer, Milk, Packaging, Shelf life

INTRODUCTION

Few think of Paneer as a cheese but it is a misconception as Paneer do require adding of any enzyme like in the case of cheese.

Hot, curdled milk masses the proteins and fats texturing are pressed together in a cloth producing a smooth white solid that almost everybody in India connects with at some level. In the cheese world, paneer and chhena are classified as direct acid-and-heat coagulated cheeses. Milk is deliberately heated and split, with the action of some acidic ingredient, into curds and whey.

This is different from the world of other well known cheeses, like Cheddar or Parmigiano- Reggiano, that are formed by using rennet to coagulate milk into a solid.

But paneer and chhena are different; conflating their origins and giving the Portuguese credit for bringing cheese to India is quite a leap. Food expert recently supported this idea in his cheese- related podcast on Audiometric.

A complete understanding of dairy traditions all over the subcontinent and Central Asia is necessary to understand the history of cheese a form of pressed or drained curds brought about by the coagulation of milk proteins in India.

HISTORY OF PANEER AND CHEESE

ORIGIN OF PANEER :

There is a strong history of storing milk in different ways than its original form. Asia always had a strong tradition of dairy milk products due to a large number of cattle like goat, sheep, camel, cow and buffalo.

Well, the history of paneer is been a debatable topic as there is many beliefs on its origin. The competitors for the origin of paneer are Vedic Indian, Afghani-Iranian and Portuguese-Bengali. It is known that people of Indus Valley civilization made cheese by adding sour green leaves, yoghurt and berries. The ancient Vedas refer to two types of cheese–Cheese with pores and cheese without pores. This sounds identical to the cheese of today. The word ‘paneer’ itself has many origins. The Persian word ‘panir’, the Turkish word ‘peynir’, the Armenian word ‘panir’, the Azerbaijani word ‘panir’ refers to various types of preserved cheeses.

Cheese exists in every culture as a form of preserved milk. Paneer history also reaches to the nomadic dairy tribes in Central Asia who have been preparing different versions of milk preservation in form of cheese or something else. An article in 2013 journal called ‘Nature’ talks that cattle herding and farming started almost 11,000 years ago in the Middle East. During this time lactose was toxic to human adults and people of this era used to ferment the milk to make it eatable and digestible.

A mention in the texts from the Kushan period talks about a milk product which was relatable to paneer. The text brings up ‘the use of a solid portion from the mixture of warm milk and curds’ to feed warriors and the thin liquid was distributed among the poor people. As Kushans’s rule over India and Central Asia is well-known, this theory works more. Other theory says Persian

7 and Afghani rulers introduced paneer in the north-western part of South Asia in the 16th century. Back at that period, cheeses were made from goat and sheep rennet which were the harbingers of modern-day cheese. Based on the Sanskrit text ‘Charak Samhita’, the earliest evidence of milk product is derived after the heat-acid coagulation of milk. Another reference comes from the Rig Veda 6.48.18 in which a kind of milk product is mentioned that sounds similar to cheese or paneer.

ORIGIN OF CHEESE :

The production of cheese predates recorded history and was most likely discovered by accident during the transport of fresh milk in the organs of ruminants such as sheep, goats, cows, and buffalo. In the millennia before refrigeration, cheese became a way to preserve milk. Although it is unknown where cheese production was first discovered, evidence of early cheese making is prevalent in the Middle East, Europe, and Central Asia.

Cheese is as old as modern mankind, with clues about its existence reaching all the way back to 8,000 BC when first sheep and goats were domesticated by our ancestors. Surviving records about their way of life showed us that they used animal skins and inflated internal organs as storage mediums, leading to conclusion that the first discovery of making cheese was probably accidental. Storing milk in such internal organ storage would bring milk in contact with rennet, which would quickly transform milk into curds and whey. The oldest archeological proofs of cheese existence date back to 5,500 BC, with first visual clue being recorded on the Egyptian tomb walls some 4 thousand years ago. Examples of cheese made in such time in Egypt and Middle East was most likely very salty and strong tasting and crumbly, similar to the modern Feta and cottage cheese. This was done because the average temperature in those regions was pretty high, which forced cheese to have much more natural preservatives in its structure (salt).

As art of making cheese spread from Egypt toward north, Greece and Rome became birthplaces of many more types of cheese, where lower temperature enabled cheese makers to experiment not only with rennet and other acidic agents that can transform milk into cheese, but also many other types of bacteria that can be used for creation of medium and hard cheeses. With less salt and preservatives,

European cheeses were much more pleasant tasting and quickly many distinct aromas were made popular. Many of today’s popular cheeses were made before the arrival of Renaissance and establishment of new trading routes – Cheddar around 1200 and

METHODS IN MANUFACTURING OF PANEER INTRODUCTION

The manufacture of Paneer involves standardization of milk, heat treatment, coagulation, draining of whey, pressing, dipping in chilled water and packaging.

Cow Milk Paneer

Flow chart for manufacture of paneer from cow milk

Recombined Milk Paneer The manufacture of paneer from recombined milk is not too difficult provided appropriate modifications are made to the standard paneer making techniques. The recombined milk is prepared by blending skim milk powder, with butter oil/ cooking butter/ cream and potable water. The milk is standardized to a fat and SNF content of 5.8 and 9.5 per cent, respectively using skim milk powder and fat from above mentioned sources. The standardized milk is suitably homogenized. The milk is kept aside fro 3-4 hours for complete interaction and hydration of milk constituents. The milk is heated to 90oC without holding. Prior to coagulation, 0.10 to 0.15 per cent calcium chloride is added to milk. The milk is coagulated using 10 per cent citric acid solution heated to 90oC. The citric acid solution is added with continuous stirringtill clear whey separated out. The remaining steps are same as employed incase of conventional paneer.

Reconstituted Milk Paneer The whole milk powder of good quality is required for manufacture of acceptable paneer. The low-heat milk powder is preferred for desirable quality paneer. The whole milk powder is dissolved in potable water at 50oC and kept aside for 3-4 hours for proper hydration of milk constituents. To this 0.1 to 0.15 per cent calcium chloride is added and then content is heated to

90oC without holding. The milk is coagulated with 10 per cent citric acid solution at 90oC. The remaining steps are the same as followed in case of conventional paneer making. Normally, the total solids content in reconstituted milk is kept higher (18-20% TS). The purpose of increasing the total solids level in milk is to reduce the bulk handling and also to reduce the requirements of coagulant, water, energy and labour for manufacture of paneer.

Filled Paneer Filled paneer technology involves blending of skim milk with vegetable oils or vanaspati and coagulation of milk with suitable coagulant at desired temperature. Filled milk is prepared by homogenization/ blending/ mixing of skim milk with vegetable oil or vanaspati fat at 40oC. This milk is converted into paneer employing the remaining steps same as in conventional Paneer making.

FILLED MILK PANEER EQUIPMENT FOR PANNER PROCESSING

❖ Paneer vat ❖ Paneer hoops ❖ Paneer press ❖ Ubrine tank ❖ Dicing machine

Working of Paneer Plant and its Features

Paneer is one of the famous dairy items used all over the world. Many dairy industries are available around the world to make the Paneer product. The Paneer Plant consists of different types of Paneer making equipment such as:

PANNER VAT :

For converting the milk from one state to another this equipment is used. In other words, coagulation VAT equipment is used to transfer the liquid milk into a solid or semi-solid state.

Paneer Cooling System:

In order to maintain the quality of the product Paneer produced from the machine is cooled by using this cooling system. Because of this temperature reducing process, the dairy item would not spoiled early. It acts as a refrigerator.

Paneer Press Machine:

The solid state of the milk is called Paneer. It is pressed by using this machine to provide the shape to the dairy item.

Paneer dicing machine:

This machine consists of blades in the equipment that automatically cuts the solid milk state called paneer with respective shape and size. Thus the process of coagulation, chilling, pasteurization, pressing and cutting the Paneer is performed in this Paneer Plant. These equipments are cost effective and are available in different storage sizes. The price of the equipment in the NK dairy equipment is less compared to other dairy equipment company.

METHODS IN MANUFACTURING OF CHEESE

INTRODUCTION

Cheese is made from milk, and that milk comes from animals as diverse as cows, sheep, goats, horses, camels, water buffalo, and reindeer. Most cheese makers expedite the curdling process with rennet, lactic acid, or plant extracts, such as the vegetable rennet produced from wild artichokes, fig leaves, safflower, or melon.

In addition to milk and curdling agents, cheeses may contain various ingredients added to enhance flavour and colour. The great cheeses of the world may acquire their flavour from the specific bacterial moulds with which they have been inoculated, an example being the famous Penicillium roqueforti used to make France's Roquefort and England's Stilton. Cheeses may also be salted or dyed, usually with annatto, an orange colouring made from the pulp of a tropical tree, or carrot juice. They may be washed in brine or covered with ashes. Cheese makers who wish to avoid rennet may encourage the bacterial growth necessary to curdling by a number of odd methods. Some cheeses possess this bacteria because they are made from unpasteurized milk. Other cheeses, however, are reportedly made from milk in which dung or old leather have been dunked; still others acquire their bacteria from being buried in mud.

The unusual texture and flavor of processed cheese are obtained by combining several types of natural cheese and adding salt, milk-fat, cream, whey, water, vegetable oil, and other fillers. Processed cheese will also have preservatives, emulsifiers, gums, gelatin, thickeners, and sweeteners as ingredients. Most processed cheese and some natural cheeses are flavored with such ingredients as paprika, pepper, chives, onions, cumin, car-away seeds, jalapeño peppers, hazelnuts, raisins, mushrooms, sage, and bacon. Cheese can also be smoked to give a distinctive flavour.

Manufacturing Process

Although cheese making is a linear process, it involves many factors. Numerous varieties of cheese exist because ending the simple preparation process at different points can produce different cheeses, as can varying additives or procedures. Cheese making has long been considered a delicate process. Attempts to duplicate the success of an old cheese factory have been known to fail because conditions at a factory do not favor the growth of the proper bacteria.

Preparing the milk

Small cheese factories accept either morning milk (which is richer), evening milk, or both. Because it is generally purchased from small dairies which don't pasteurize, this milk contains the bacteria necessary to produce lactic acid, one of the agents that triggers curdling. The cheese makers let the milk sit until enough lactic acid has formed to begin producing the particular type of cheese they're making. Depending on the type of cheese being produced, the cheese makers may then heat the ripening milk. This process differs slightly at large cheese factories, which purchase pasteurized milk and must consequently add a culture of bacteria to produce lactic acid.

Separating the curds from the whey

The next step is to add animal or vegetable rennet to the milk, furthering its separation into curds and whey. Once formed, the curds are cut both vertically and horizontally with knives. In large factories, huge vats of curdled milk are cut vertically using sharp, multi-bladed, wire knives

15 reminiscent of oven racks. The same machine then agitates the curds and slices them horizontally. If the cutting is done manually, the curds are cut both ways using a large, two- handled knife. Soft cheeses are cut into big chunks, while hard cheeses are cut into tiny chunks. (For cheddar, for instance, the space between the knives is about one-twentieth of an inch . After cutting, the curds may be heated to hasten the separation from the whey, but they are more typically left alone. When separation is complete, the whey is drained

In a typical cheese-making operation, the first step is preparing the milk. Although smaller factories purchase unpasteurized milk that already has the bacteria present to produce lactic acid (necessary for curdling), larger factories purchase pasteurized milk and must add bacteria culture to produce the lactic acid. Next, the curds must be separated from the whey. Animal or vegetable rennet is added, and then the curds are agitated and cut using large knives. As the whey separates, it is drained. The curds are then pressed into moulds, if necessary, to facilitate further moisture drainage, and aged for the proper amount of time. Some cheeses are aged for a month, others for several years.

Pressing the curds

Moisture must then be removed from the curds, although the amount removed depends on the type of cheese. For some types with high moisture contents, the whey-draining process removes sufficient moisture. Other types require the curds to be cut, heated, and/or filtered to get rid of excess moisture. To make cheddar cheese, for example, cheese maker’s cheddar, or finely chop the curd. To make hard, dry cheeses such as parmesan, cheese maker’s first cheddar and then cook the curd. Regardless, if the curds are to be aged, they are then put into molds. Here, they are pressed to give the proper shape and size. Soft cheeses such as cottage cheese are not aged.

Ageing the cheese

At this stage the cheese may be inoculated with a flavouring mold, bathed in brine, or wrapped in cloth or hay before being deposited in a place of the proper temperature and humidity to age. Some cheeses are aged for a month, some for up to several years. Ageing sharpens the flavour of the cheese; for example, cheddar aged more than two years is appropriately labelled extra sharp.

Wrapping natural cheese

Some cheeses may develop a rind naturally, as their surfaces dry. Other rinds may form from the growth of bacteria that has been sprayed on the surface of the cheese. Still other cheeses are washed, and this process encourages bacterial growth. In place of or in addition to rinds, cheeses can be sealed in cloth or wax. For local eating, this may be all the packaging that is necessary. However, large quantities of cheese are packaged for sale in distant countries. Such cheeses may be heavily salted for export (such as Roquefort) or sealed in impermeable plastic or foil.

Making and wrapping processed cheese

Edible yet inferior cheeses can be saved and made into processed cheese. Cheeses such as Emmental (commonly called Swiss), Gruyere (similar to Swiss), Colby, or cheddar are cut up and very finely ground. After this powder has been mixed with water to form a paste, other ingredients such as salt, fillers, emulsifiers, preservatives, and flavorings are added. The mixture is then heated under controlled conditions. While still warm and soft, the cheese paste is extruded into long ribbons that are sliced. The small sheets of cheese are then put onto a plastic or foil sheet and wrapped by a machine.

GENERAL CHEESE PROCESSING STEPS

STANDARDIZE MILK

PASTEURIZE/HEAT TREAT MILK

COOL MILK

INOCULATE WITH STARTER & NON-STARTER BACTERIA AND RIPEN

ADD RENNET AND FORM CURD

CUT CURD AND HEAT

DRAIN WHEY

TEXTURE CURD

DRY SALT OR BRINE

FORM CHEESE INTO BLOCKS

STORE AND AGE

PACKAGE

EQUIPMENT USED FOR CHEESE PROCESSING

Cheese vat :

Versatile cheese making vats from GEA enable curd coagulation and maturation either in whey or out of whey, at precisely controlled temperatures. The machines are constructed with a curd churner that incorporates electro polished blades and stirrers, to ensure that the complete mass of curd is cut and mixed at each turn. At the end of the churning and maturation cycle, the curd is tipped out into drainage trolleys, and any remaining whey is removed. The complete cradle surface is equipped with a steam- or water-heated jacket, to either cook the curd or to maintain a steady temperature.

Drum molding machine

Spherical molding and semi-automatic cylindrical molding with carousels, for continuous braids and knot molding. Electromechanical drives for the augers and molding drum allow for the precise adjustment of both feeder auger and drum speeds, to ensure a constant pressure in the forming chamber and so consistent product weight. GEA drum molding units also feature thermoregulated hot water jackets to ensure maintenance of the required product temperature. A feeler unit in the auger chamber monitors the cheese temperature

The solid aluminium drum molds are easily interchangeable, and guarantee a perfect seal for minimal loss of whey. Drum rotation is effected through a simple, efficient grooved coupling

19 mechanism. drum molding systems can also be configured with a screw unit for tilting the body of the machine by up to 30 degrees. This allows the production of very soft products, including Fior di latte and buffalo milk mozzarella.

CLUB CUTTER

A rotary auger at the end of the accumulation vat transfers the curd to an adjustable rotary cutter. This cuts the curd into small pieces, the thickness of which can be changed by adjusting the position of the cutting knives. The auger speed is also adjustable to vary the amount of curd passing through the cutter. Whey is removed and collected in a recovery vat equipped with grilled strainer. A pipe then connects this vat to the downstream stretching machine.

MODELING AND PRE HARDENING MACHINE

The system is operated via a PLC, and is configured with pipework and sprinklers connected to an external cleaning-in-place plant for efficient cleaning. The feeding unit and carousel are also completely separated when not in operation, which also aids faster and easier cleaning. All product contact parts are Teflon coated, and the augers and carousel are driven by servo-motors for precise control and robust operation.

GEA separately offers both bath (indirect cooling) and shower (direct cooling) machines for cheese molding and pre-hardening

DRY SALT DOSAGE SYSTEM

Dry salt dosage systems for dispensing precisely measured quantities of salt to stretched curd cheese. Addition of salt after stretching and before molding prevents issues with curd structure, elasticity and shelf-life that can otherwise occur due to poor water absorption.

Cheese Brining

We supply cheese brining systems for different kind of situations. Our brine systems are supplied with a circulation pump, and also with an automatic temperature control.Every brine system of Scherjon is tailor-made for every situation.

Pre press vat

Our cheese processor and pre-press vat form an unbeatable combination when it comes to efficiency and ease of use. To give an example, the cheese processor can be filled with fresh milk even while the pre-press is still in production. Before the curd leaves the pre-press vat it will be cut automatically to the dimensions you select. The weight of each block is determined with great accuracy, so all of them are virtually identical. The pre-press vat is equipped with a fully automated cleaning system. With Scherjon Dairy Equipments Holland the making of

cheese changes into an effortless activity.

MARKET ANALYSIS FOR CHEESE AND PANEER IN TAMILNADU

Cheese products Price / kg Paneer products Price / kg

Milky Mist Cheese 120 /200gm Milky mist Paneer 90 /200gm

Amul cheese 122/200gm Amul Paneer 70 /200gm

Britannia cheese 155 /200gm Cavins paneer 85/200gm

Aavin cheese 120 /200gm Aavin paneer 65 /200gm

Hatsun cheese spread 80 /200 gm Hatsun paneer 85/200gm

Mother dairy cheese 105 /200gm Thirumala paneer 85/200gm

Mother dairy paneer 60 /200gm

Dairy Food Regulations

Food products are regulated to ensure that the food supply is safe for all people. Regulations provide minimum standards for all food processors, small and large alike, to ensure quality food that does not harm consumers. Microbial contamination of foods is of particular concern for consumers that are more susceptible to illness, such as infants, small children, pregnant women, the elderly, people on some medications, undergoing treatments, or that may be otherwise immunocompromised.

Some food processing regulations are administered at the federal level and some at the state level or a more local level. Some regulations apply to all food processors such as registering your facility with the FDA and following Good Manufacturing Practices (GMPs), while other regulations may only apply to certain food products, such as pasteurization conditions or yogurt standards.

MMPO REGULATION ACT

The Government of India had promulgated the Milk and Milk Product Order (MMPO) 1992 on 9/6/92 under the provisions of Essential Commodities Act, 1955 consequent to de-licensing of Dairy Sector in 1991. As per the provisions of this order, any person/dairy plant handling more than 10,000 liters per day of milk or 500 MT of milk solids per annum needs to be registered with the Registering Authority appointed by Central Government. The objective of the order is to maintain and increase the supply of liquid milk of desired quality in the interest of the general public and also for regulating the production, processing and distribution of milk and milk products.

Recognizing the necessity suitable amendments in Milk and Milk Product Order-1992 for faster pace of growth in dairy sector, Government of India has amended milk and milk product order-

92 from time to time in order to make it more liberal and oriented to facilitate the dairy entrepreneurs. The Government of India has notified the last amendment proposals in the official Gazette on 26/3/02. Now there is no restriction on setting up of new milk processing, while noting that the requirement of registration is for enforcing the prescribed Sanitary, Hygienic Conditions and Quality and Food Safety Measures as specified in the Vth Schedule of MMPO- 1992.

The silent features of the new amendments made are as follows:-

• The provision of assigning milkshed has been done away with.

• The registrations under MMPO-92 will now cover sanitary, hygienic condition, quality and food safety measures as specified in Vth Schedule of MMPO-1992.

• The provision of inspection of dairy plant has been made flexible.

• The provision to grant registration in 90 days has been reduced to 45 days subject to submission of application in complete form.

• The power or registration of State Registering Authority has been raised from 1.00 lakh liters per day to 2.00 liters per day.

• Altogether the Central and the State Registering Authorities have registered 818 units with combined milk processing capacity 952.93 lakh litre per day in Co-operative, Private and Government Sect or as on 31.3.2007.

The processor has the responsibility to meet the current:

• federal, state, and local regulations that apply to all food processors,

• federal, state, and local regulations that apply to all dairy processors, and

• regulations that apply to the specific food they manufacture, such as yogurt, ice cream, or Gouda cheese.

Pennsylvania allows the sale of raw milk and the manufacture of aged raw milk cheeses. It is recommended that manufacturers of raw milk products be familiar with state and federal regulations and resources for pasteurized products, as some of this information also applies to raw milk products.

Bureau of Indian Standards for cheese

CHEESE

BIS Standards

Characteristi Natural Cheese (h Processed che Processes cheese spr Cheese Powd cs ard variety) ese ead er

1. Moisture % 43 47 60 5 by mass. maximum

2. Milk 42 40 40 40 fat (on dry basis) % by mass. minimum

3.Salt (added 3 3 3 5.5 NaCl) % by mass maximum

4. Coliform - - - 10 count, per gram maximum

5. Stabilizer / 0.1% 4%

6. Sorbic acid 0.1% 0.1%

/ Nisin

Suggested bacteriological standards

S. Product Yeast and Coliform Aerobic Anaerobic No. Mold spore count spore count Coun0t

1. Processed cheese/gm 60 Nil 200 100

2. Processed cheese spread/gm 60 Nil 200 100

ISO 22000: 2018

ISO 22000 standard aims to prevent and reduce food borne hazards in the food and feed chains. It recently released the new version of standard, ISO 22000: 2018, that replaces the old 2005 version.

THE NEW EDITION:

• Adopts the High-Level Structure (HLS) common to other ISO management system standards like 14001 and 9001, to make management systems integration easier for organizations • Introduces a new approach to risk by distinguishing risk at the operational and the business level • Clarifies the PDCA cycle by having two separate cycles in the standard working together: one covering the management system and the other, covering the principles of HACCP.

• Clarifies the operation process by providing a clear description of the differences between key terms like Critical Control Points (CCPs), Operational Prerequisite Programmes (OPRPs) and Prerequisite Programmes (PRPs)

CONCLUSION

In India we are majority using this kind of equipment and process follow are use to prepare the Cheese and Paneer products in industry in larger amount. They need to follow many guidelines and regulations laid down by FSSAI. From the kind of processes being followed from early days to prepare Paneer and cheese till those in our modern culture we have had a change in some types of process and processing method . The modernisation has helped to prepare the product faster and more efficiently. This comparative study shows that the introduction of modernisation in to the operations has had a significant impact on the production.

HOME BASED INTERNSHIP REPORT ON

COMMERCIAL PRODUCTION OF IDLI AND DOSA BATTER

Submitted by,

MOISON C

AFP16015

BACHELOR OF TECHNOLOGY

FOOD PROCESSING TECHNOLOGY

ACADEMY OF MARITIME EDUCATION AND TRAINING

AMET UNIVERSTY-CHENNAI-112

ACKNOWLEDGEMENT

I would like to thank the vice chancellor of Amet university Dr.Thiruvasagam for making the decision to do our final semester internship in our home during this covid19 pandemic period.

And I would like to thank my head of the department (Food processing technology) Mrs.Sasi praba for her guidance to complete this home based internship.

Finally I would like to thank my deparment staffs and my friends who helped me in completing this report.

Table of contents

SERIAL NO CONTENTS PAGE NO

1 INTRODUCTION 4

1.1 Market potential 5

1.2 Basis and presumption 5

1.3 Implementation schedule 5

2 TECHNICAL ASPECTS 6

2.1 Production details 6 2.2 Process of manufacturing 6 – 8 2.3 Nutritional profile 9 – 10 3 FINANCIAL ASPECTS 10

3.1 Land and building 10 3.2 Machinery & requirements 10 – 11 3.3 Working capital (per month) 12 3.4 Raw material (per month) 13 3.5 Utilities (per month) 13 3.6 Other contingent expenses (per month) 14 4 FINANCIAL ANALYSIS 15 – 17

5 CONCLUSION 17

1.INTRODUCTION

Convenience foods provide the housewives novelty, convenience, reducing the drudgery and satisfaction of preparing at home. Idli Mix, Dosa Mix are some of the traditional food items commonly used in Indian homes. The ready mixes provide hygienic products of standard and uniform quality with good shelf life. Ready mixes such as Idli and Dosa were earlier used in southern region but now they find applicability in the day to-day menu all over India. Since, these ready mixes have undergone processing to a considerable extent, only little processing such as mixing with water for making dough, shaping and frying is required at home. Nutritionally also these products are rich and wholesome.

IDLI Idli are a type of savoury rice cake, originating from the Indian subcontinent, popular as breakfast foods in Southern India and among Tamils in Sri Lanka. The cakes are made by steaming a batter consisting of fermented black lentils (de-husked) and rice. The fermentation process breaks down the starches so that they are more readily metabolized by the body. Idli has several variations, including rava idli, which is made from semolina. Regional variants include sanna of Konkan.

DOSA A dosa is a rice pancake, originating from South India, (some say from South East Asia) made from a fermented batter. It is somewhat similar to a crepe in appearance. Its main ingredients are rice and black gram, ground together in a fine, smooth batter with a dash of salt. Dosas are a typical part of diets throughout South India, but the dish is now popular all over the Indian subcontinent. Traditionally, dosas are served hot along with sambar and chutney. They can be consumed with idli podi as well.

1.1. MARKET POTENTIAL

Due to increasing urbanization, a greater number of women taking up jobs, improving financial status of the middle-income group, the market for ready mixes is increasing day-by-day. The estimated future demand for the ready mixes is estimated to be over 4500 tons per annum.

1.2. BASIS AND PRESUMPTIONS i. It is presumed that the unit will run single shift per day and 300 working days per annum. ii. Labour wages have been taken as per market rates. iii. The rate of interest has been taken 10% on an average both for fixed investment and working capital. iv. The rates quoted in respect of Machinery/equipment, raw materials are those prevailing at the time of preparation of report and are likely to vary from place to place and supplier to supplier and necessary changes are to be made as and when required.

1.3. IMPLEMENTATION SCHEDULE

The approximate time required for various activities is given below. However, it may vary from place to place depending upon the local circumstances

i. Selection of site. 1 Month. ii. SSI Registration. 3 days. iii. Project Report Preparation. 1 Month. iv. Availability of Finance. 2 Months. v. Machinery Procurement, Erection, Commissioning & Trial Run, etc. 5th months onward.

TECHNICAL ASPECTS

2.1. PRODUCTION DETAILS

Dosa Mix:

Rice, Black gram and lentil are first passed through Destoner and Shifter to remove any stones, dust and other foreign matters. After this, in a disintegrator powder of these materials is made. Rice Flour, Blackgram flour, lentil flour, salt, fenugreek powder is dried in dryer to required moisture content. After this, Dough raising agents, citric acid and sodium bicarbonate are mixed in a blender and packed.

Idli Mix:

Rice Flour, Black gram flour are dried and then salt, citric acid, sodium bicarbonate, rasins(optional) are mixed in a blender and packed.

• Motive Power Requirement: 20 HP • There are no pollution control problems in the unit.

2.2. PROCESS OF MANUFACTURING

IDLI PROCESS:

The principal components of idli include rice, black gram, salt and water. In general, the idli batter preparation process is progressed by a series of steps. Initially, rice and black gram are soaked in water for 5-10 hours. The soaked water is then drained and the ingredients are grounded in a wet mill, separately, by occasional addition of water. Then, the batters of rice and black gram are combined together in a separate vessel, following addition of salt. Finally, the combined batter is allowed to ferment overnight at room temperature. Next day, the fermented batter is steamed in an idli steaming vessel for 10 min and consumed

FLOW CHART

• The quality of idli is often determined by the type and proportions of rice and black gram used.

DOSA PROCESS:

A mixture of rice and black gram that has been soaked in water is ground finely to form a batter. Some add a handful of soaked fenugreek seeds. The proportion of rice to lentils is generally 3:1 or 4:1. The batter is allowed to ferment overnight, before being mixed with water to get the desired consistency. The batter is then ladled onto a hot tava greased with oil or ghee. It is spread out with the base of a ladle or bowl to form a pancake. It can be made either to be thick like a pancake, or thin and crispy. A dosa is served hot, either folded in half or rolled like a wrap. It is usually served with chutney and sambar. The mixture of black grams and rice can be replaced with highly refined wheat flour or semolina.

FLOWCHART

2.3. NUTRITIONAL PROFILE

IDLI:

➢ Fermentation is an elemental part in idli as it improves the nutritional quality and organoleptic value. ➢ The preparation and fermentation process totally transform the final quality of idli with improved flavor and texture, concurrently with enhanced digestibility. ➢ Nutritionally idli is composed of carbohydrates, proteins, vitamins and minerals. ➢ Rice is the major source of carbohydrates and additionally black gram contributes oligosaccharides (indigestible sugars) - raffinose, stachyose and verbascose in idli. ➢ These oligosaccharides are known to cause flatulence (intestinal gas production) and often elimination of these sugars is considered to be a challenging problem. ➢ The process (soaking, fermentation and steam cooking) of idli preparation was beneficial as it reduced the oligosaccharide content up to 34 %. ➢ As a fermentable substrate, these indigestible sugars possessed to have prebiotic properties that support the LAB proliferation as a carbon source. ➢ Black gram is the vital source of protein in idli. ➢ Further, the protein efficiency ratio was found higher in the fermented idli than in unfermented idli mixture. ➢ Marked increase of amino acids were evident during fermentation regardless of the proportions of rice and black gram. ➢ Especially, methionine content increased in the range between 10 – 60% of the initial content. Nutritionally, methionine increase was advantageous as many legumes lack in sulfur containing amino acids. ➢ Idli fermentation enhanced B-vitamins specially thiamine, riboflavin, folate, niacin, pyridoxine and vitamin B12. ➢ Studies have proven B-vitamin content increase two to three fold after fermentation.

➢ Though the rice and black gram itself contributes a certain amount of B- vitamins, further LAB and yeast participate in the fermentation process contributes to the enhancement. ➢ On the other hand, Idli also has been a source of minerals – calcium, magnesium, zinc, iron and phosphorous.

DOSA:

➢ Dosa is high in carbohydrates and contains no added sugars or saturated fats. ➢ As its key ingredients are rice and black gram, it is also a good source of protein. ➢ One home made plain dosa without oil contains about 112 calories, of which 84% is carbohydrate and 16% protein. ➢ The fermentation process increases the vitamin B and vitamin C content. ➢ There are instant mix products for making dosa which usually contain higher levels of rice.

FINANCIAL ASPECTS

3.1. LAND AND BUILDING

Land-500 sq. mtr. @ Rs. 350/- per sq. mtr. 1,75,000/-

Built up area for production, lab, office, etc – 300 sq. mtr. @ Rs. 4000/- per sq. mtr. 12,00,000/-

Total cost of Land & Building Rs. 13,75,000/-

3.2. MACHINERY AND REQUIREMENTS

Serial No Description of Numbers Price (Rs) Machine

1. Blender/Mixer 1 15,000

2. Disintegrator 1 80,000 with 5 HP Motor

3. Destoner 1 20,000

4. Sifter with 3 HP 1 25,000 motor

5. Cabinet Drier 48 1 85,000 Trays fitted with heating elements and two motors

6. Fumigation 1 25,000 Chamber

7. Platform 1 10,000 weighing Machine- 100 kg. Capacity

8. Air Dehumidifier 1 40,000

9. Self-Indicating 2 3,000 counter Balance

10. Working table 4 12,000 with Al Top

11. Trays & Trolleys LS 10,000

Total 3,25,000

Electrification & Installation charges @ 10% 32,500/-

Total 3,57,500/-

Office Furniture & Equipment’s 25,000/-

Total 3,82,500/-

Pre -operative Expenses. 50,000/-

Total Fixed Capital (1+2+3) 18,07,500/-

3.3. WORKING CAPITAL (P.M)

PERSONNEL:

Serial No Designation Numbers Total (Rs)

1. Manager-cum- 1 12,000 Food Technologist.

2. Production 1 6,000 Supervisor.

3. Unskilled Worker 5 15,000

4. Skilled Workers 2 8,000

5. Sales Supervisor 1 6,000

6. Clerk 1 5,000

7. Peon 1 3,000

Total 55,000

Add pre- 5,500 requisites @ 10%

Total 60,500

3.4. RAW MATERIAL (P.M)

Serial No Particulars Values (Rs)

1. Rice 15.00 MT @ Rs. 2,25,000 1500/- per MT

2. Block Gram Dhal- 8.5 1,70,000 MT @ Rs. 20,000 per MT

3. Lentil Dhal 2.5 MT @ 62,500 Rs. 25000/- per MT

4. Salt, Sodium 30,000 Bicarbonate citric acid, rasins, dry spices

5. Packing material to be 2,50,000 packed in 200 gm packets inside PP outside Card Board total 1,25,000 packs @ Rs. 2/- per pack.

6. Total 7,37,500

3.5. UTILITIES (P.M)

Power - 2240 kwh @ Rs.5.25 per unit. 11,760

3.6. OTHER CONTINGENT EXPENSES (P.M)

Serial No Contingent Amount (Rs)

1. Postage and Stationery 1,000

2. Telephone Charges 1,000

3. Repair & Maintenance. 1,000

4. Advertisement & 1,00,000 publicity.

5. Transport charges 25,000

6. Other Miscellaneous 2,000 Expenses

Total 1,30,000

• Working Capital (Per Month): Rs. 9,39,760 • Working capital for 2 months. Rs. 18,79,520

TOTAL CAPITAL INVERSMENT:

i. Fixed Capital. 18,07,500 ii. Working capital for 2 Months 18,79,520 iii. Total Rs. 36,87,020

FINANCIAL ANALYSIS

COST OF PRODUCTION (P.Y)

Serial No Production Amount (Rs)

1. Total recurring cost 1,12,77,120

2. Depreciation on 1,20,000 building @ 8%

3. Depreciation on 32,500 machinery @ 10%

4. Depreciation on 3,000 furniture @ 20%

5. Interest on total 5,16,183 investment @ 15%

Total 1,19,50,803

TURNOVER PER YEAR:

Dosa Mix 150 MT @ Rs. 45000/- per 67,50,000/- Ton.

Idli Mix 150 MT @ Rs. 45000/- per 67,50,000/- Ton.

Total 1,35,00,000/-

• Net Profit per year = Rs. 15,49,197

NET PROFIT RATIO:

= 15,49,197 / 13500000 x 100

= 11.48%

RATE OF RETURN:

= 15,49,197 / 36,87,020 X 100

= 42 %

BREAK EVEN POINT (BEP):

FIXED COST PER YEAR:

1. Depreciation on 32,500 machinery @ 10%

2. Depreciation on 5,000 furniture @ 20%

3. Interest on total 5,16,183 investment

4. 40% of salary & wages 2,90,400

5. 40% of other expenses 6,24,000

6. 40 % of utilities 56,448

Total fixed cost Rs. 15,24,531

BEP = Fixed Cost x 100 / Fixed cost + Profit

= 15,24,531 x 100 / 15,24,53199 + 15,49,197

= 15,24,531 x 100 / 30,73,728

= 49.6%

CONCLUSION

Hereby I conclude the commercial production of idli and dosa batter production. I hope that I have learned some information about this and I have provided that information in this report. Once again I thank my department head Mrs.Sasi prabha for this opportunity.