DEVELOPMENT OF JAGGERY BASED ENERGY BAR
PrateekKhulve Waquar Ahmed Sachin Kumar
(Id No. 42918) (Id No. 42937 ) (Id No. 44882 )
Under the Guidance of
Dr. P.K.OMRE
A Dissertation Report SUBMITTED
IN PARTIAL FULFILMENT OF THE REQUIREMENTS
FOR THE AWARD OF THE DEGREE OF
Bachelor of Technology
In
Agricultural Engineering
DEPARTMENT OF POST HARVEST PROCESS AND FOOD ENGINEERING COLLEGE OF TECHNOLOGY G.B. PANT UNIVERSITY OF AGRICULTURE AND TECHNOLOGY PANTNAGAR-263145 (U.S. NAGAR), UTTARAKHAND, INDIA
JUNE, 2016
ACKNOWLEDGEMENT
The authors express extreme reverence and profound sense of gratitude to their dissertation advisor, Dr. P.K. Omre, Professor and Head, Department of Post Harvest Process and Food Engineering for theinvaluable guidance, continuous encouragement and abundant counsel throughout the dissertation work.
We would like to thank Dr. H.C. Sharma, Dean, College of Technology, for providing necessary facilities and constructive suggestion whenever required during course of study.
We would like to thank Dr. Akhilesh Kumar, Co-ordinator of Agricultural Engineering for providing us assistance and valuable resources whenever required.
We are also very thankful to all the committee members Dr. T.P. Singh, Professor, Department of Farm Machinery and Power Engineering, Dr. P.K. Singh, Professor, Department of Irrigation and Drainage Engineering, Dr.P. S. Kashyap,Associate Professor, Department of Soil and Water Conservation Engineering, Dr. N.C. Shahi, Professor, Department of Post-Harvest Process and Food Engineering.
The authors acknowledge special thanks to all other faculty member and the entire staff members of Department of Post Harvest Process and Food Engineering for rendering excellent council and co-operation whenever required.
PrateekKhulve Waquar Ahmed Sachin Kumar (Id No.42918) (Id No. 42937) (Id No. 44882)
PANTNAGAR
June, 2016 APPROVAL
The Dissertation report entitled ―Development of Jaggery Based Energy Bar‖ submitted by PrateekKhulve(42918), Waquar Ahmed(42937) and Sachin Kumar(44882)is hereby approved.
Dr. P.K. Omre
Professor and Project Advisor ______
Dr. P.K. Omre
Professor and Head ______
DEPARTMENT OF POST HARVEST PROCESS AND FOOD ENGINEERING COLLEGE OF TECHNOLOGY, G.B. PANT UNIVERSITY OF AGRICULTURE AND TECHNOLOGY, PANTNAGAR-263145(U.S. NAGAR), UTTARAKHAND,INDIA
LIST OF CONTENTS
S.No. PARTICULARS 1. INTRODUCTION 2. REVIEW OF LITERATURE 2.1 Types of Jaggery 2.2 Composition of Jaggery 2.3 Value Added Products of Jaggery 2.4 Health Benefits of Jaggery 2.5 Jaggery – Cultural Aspects 2.6 Composition of Chocolate 2.7 Caffeine 2.8 Important Ingredients 2.8.1 Cocoa 2.8.2 Milk Solids 2.8.3 Fat 2.8.4 Emulsifier & Stabilizer 2.8.5 Sugar & sweeteners 2.8.6 Jaggery as a sweetener 2.9 Forms of Jaggery 2.9.1 Powder Jaggery 2.9.2 Solid Jaggery 2.10 Jaggery Chocolate 2.11 Processing of Jaggery Energy Bar 2.11.1 Mixing & Refining 2.11.2 Moulding 2.11.3 Cooling 3. MATERIALS AND METHODS 3.1 Preliminary Experiments 3.2 Procedure of Making Jaggery Energy Bar 3.3 Response Surface Methodology 3.3.1 Considerations in the use of RSM 3.3.2 Steps in RSM 3.3.3 Applications of RSM 3.4 Design of Experiments 3.5 Sensory Evaluation 4. RESULTS & DISCUSSION 4.1 Sensory characterstics of Energy Bar 4.1.1 Appearance 4.1.2 Taste 4.1.3 Colour 4.1.4 Texture 4.1.5 Flavour 4.1.6 Overall acceptability 4.1.7 Optimization of Jaggery Energy Bar Ingredients with Caffeine 5. SUMMARY AND CONCLUSION
REFERENCES APPENDIX – I APPENDIX – II APPENDIX – III APPENDIX – IV APPENDIX – V APPENDIX – VI APPENDIX - VII
LIST OF TABLES
TABLE NO. PARTICULARS
2.1 Composition of Jaggery
2.2 Nutritional composition of Jaggery Energy Bar
2.3 Coding of variables for experimental design using
RSM
2.4 Response surface design of experiments
2.5 Sensory characteristics of Jaggery Energy Bar
Samples
LIST OF PLATES
PLATE NO. TITLE
1. Mixing Apparatus 2. Jaggery bar stored in desiccator 3. Drying of moulded jaggery energy bar 4. Jaggery bar wrapped in aluminium foil 5. Sensory evaluation of jaggery energy bar
1. INTRODUCTION
Jaggery is a traditional non-centrifugal cane sugar consumed in Asia and Africa. It is a concentrated product of date, cane juice, or palm sap without separation of the molasses and crystals, and can vary from golden brown to dark brown in colour. It contains up to 50% sucrose,up to 20% invert sugar, and up to 20% moisture with the remainder made up of other insoluble matter, such as wood ash,proteins, and bagasse fibres. Jaggery is mixed with other ingredients, such as peanuts, condensed milk,coconut, and white sugar, to produce several locally marketed and consumed delicacies.
The quality of the jaggery is judged by its colour; brown means it is higher in impurities and golden-yellow implies it is relatively pure. Due to this grading scale there are malpractices of adding colour or harmful chemicals to simulate the golden colour.
If we examine the modern confectionary products available in the market, for incorporation of jaggery as sweetener, chocolate emerges as a potential choice. It seems that the nature of jaggery in terms of its colour, texture and sweetness would make it very suitable for chocolate like product .Chocolate confectionary has been novelty food item over the years. Consumersof all ages and social classes have been enjoying it in various forms. Once seem as an item for children only, adults now savour chocolates as well.
A chocolate bar is a chocolateconfection in bar form, which distinguishes it from bulk chocolate produced for commercial use. In most of the English-speaking world, chocolate bar also refers to a typically snack-sized bar coated with or substantially consisting of chocolate but containing other ingredients. A chocolate bar made exclusively from chocolate contains some or all of the following components: cocoa solids, cocoa butter, sugar, and milk. The relative presence or absence of these define the subclasses of chocolate bar made of dark chocolate, milk chocolate, and white chocolate. In addition to these main ingredients a chocolate bar may contain flavourings such as vanilla and emulsifiers such as soy lecithin to alter its consistency.
"Chocolate bars" containing other ingredients feature a wide variety of layerings or mixtures that include nuts, fruit, caramel, nougat, and fondant. A popular example is a Snickers bar, which consists of nougat mixed with caramel and peanuts.A wide selection of similar chocolate treats are produced with added sources of protein and vitamins. These include forms of energy bar and granola bar and are sold as snacks and nutritional supplements.
Energy bars are supplemental bars containing cereals and other high energy foods targeted at people that require quick energy but do not have time for a meal. The first energy bar in the American marketplace was Space Food Sticks which Pillsbury Company created in the late 1960s to capitalize on the popularity of the space program. Space Food Sticks were developed by Robert Muller, the inventor of the HACCP standards used by the food industry to ensure food safety.
Energy in food comes from all three main sources: fat, protein, and carbohydrates, but mostly from carbohydrates. In order to provide energy quickly, most of the carbohydrates are various types of sugars like fructose, glucose, maltodextrin, dextrose and others in various ratios. Use of complex carbohydrate sources like oats and barley is limited and such carbohydrate sources are mostly used in protein bars. Proteins come mostly in the form of fast digesting whey protein. Energy bars generally don't contain sugar alcohols, since these bars, due to type of carbohydrate content, don't require low calorie sweeteners to improve their taste. Fats in energy bars are kept to minimum and their main sources are often cocoa butter and dark chocolate.
Caffeine is a bitter, white crystalline purine, a methyl xanthine alkaloid, and is closely related chemically to the adenine and guanine contained in deoxyribonucleic acid (DNA) and ribonucleic acid (RNA). It is found in the seeds, nuts, or leaves of a number of plants native to South America and East Asia and confers on them several survival and reproductive benefits. The most well-known source of caffeine is the coffee bean, a misnomer for the seed of coffee plants. Beverages containing caffeine are ingested to relieve or prevent drowsiness and to improve performance. To make these beverages, caffeine is extracted by steeping the plant product in water, a process called infusion. Caffeine-containing beverages, such as coffee, tea, and colas, are very popular; in 2005, 90% of North American adults consumed caffeine daily. Chocolate derived from cocoa beans contains a small amount of caffeine. The weak stimulant effect of chocolate may be due to a combination of theobromine and theophylline, as well as caffeine. A typical 28-gram serving of a milk chocolate bar has about as much caffeine as a cup of decaffeinated coffee. To remain competitive in the growing industry, confectioners are faced with of creating innovating products with unique shapes, textures and flavours. The technological advancements have expanded the variety of ingredients available. Careful choice of their functionality, ingredients provide just one aspect of complete task developing new products. Ingredient selection is critical, as it can prevent or invite potential problem in the finished condition.
In view of the above, this study on the development of jaggery based chocolate was undertaken using response surface methodology with the following objectives:
1. To develop the process for making jaggery based energy bar with different ratio of skim milk powder, cocoa powder and caffeine. 2. Performance evaluation of the final product based on sensory using 9-point hedonic scale method.
2. REVIEW OF LITERATURE
Jaggery is important sugarcane product used widely in India. It occupies an important place in agriculture economy and diet of rural people. It has been used since ages for various kinds of products like reori, gazak and patti. Being a nutritive sweetener in many traditional confectionaries in India, the scientific literature pertaining to such products is very limited. Most of the literature pertains to different type's chocolates, their composition and related standards. The processing details of the chocolates arc well standardized, although much of it is in the form of patents. Work has also been done on using alternative sweeteners for chocolate manufacture. The literature has reviewed in following parts.
2.1 Types of Jaggery
Roy (1951) has described various types of jaggery being produced in different regions of the country. The common types of jaggery are presented below:
Cream jaggery: this type of jaggery has cream colour and is popular in western U.P. The creamy colour is obtained by treating the juice with activated carbon which removethe colouring matters from the juice.
Natural gur: This gur is prepared for refining purposes and cannot be consumed directly due to its taste. It is prepared by neutralizing the juice before boiling so that the sugar percentage in gur remains high.
Molassinggur: It is manufactured by adopting two boiling as in khandsari system. The solid jaggery from molasses is prepared from molasses obtained after Rab. Whereas the gur prepared from exhaust molasses does not solidify due to very low sugar percentage, the manufacture of gur from first molasses is done in Bombay and adjoining area where the purity of the can juice is much lower.
Chakuminijha:This gur is chiefly manufactured in Meerut, Muzaffarnagar and Saharanpur district of U.P. The clarified juice is boiled but the boiled mass is strucked at slightly lower temperaturethan that of the ordinary gur.
Andraki Gur: It is manufactured in Saharanpur and Dehradun districts of Uttarakhand . The manufacturing process is same as that of ChakuMinijhagur except that in this case only a single layer of cooled mass is spread over the hession cloth. Andrakigur is spiced with powdered gingeroots, cloves, cardamoms, and shredded copra, which added to the boiling juice after crarification. Shakkarjaggery:It is used in manufacturing of inferior kinds of sweets in shops. In thisprocess the boiling is slightly more prolonged than that in the manufacture of Bheligur. The slightly cooled mass is sprinkled with a little soda solution and kneadedwith khurpies until it acquired a pale yellow colour. After further cooling it isrubbed with hands to form powder shakkar.
Pandey and Narain (1993)reported that solid jaggery is obtained bstriking at a temperature of 115-117° C which corresponds to 90° Brix.
Pandey and Narain (1998)have described the conventional jaggery manufacturing process.The process mainly consists of extraction of the juice from sugarcane, clarificationof the juice, concentration of the juice into syrup and its solidification as jaggery,and finishing and moulding of jaggery into different shapes.
2.2 Composition of Jaggery
The composition of jaggery varies depending upon the variety of cane juice, manufacturing quality and grade of jaggery . The composition of jaggery as reported by Dubey, Lal and Tewari (1989) is summarised in the following Table:
Table 2.1: Composition of Jaggery
S.No. Constituent Value (%)
1. Sucrose 60-85
2. Reducing Sugar 6-14
3. Moisture 3.1-10
4. Insoluble Residue 0.525-1.1
5. Ash 80-84
6. Total Minerals 0.6-1.0
2.3 Value Added Products of Jaggery
Anonymous (1995) developed value-added product based on jaggery using food extrusion. Extruded sweets, snacks using wheat flour and jaggery were made.
Anonymous (1999) reported on extruded products based on ground floor, jaggeryand coconut powder. Also a product was developed using wheat flour and jaggery in 60:40
ShyamRamkrishna (2011) reported on formulation of chocolate based on jaggery as a sweetener and optimization of ingredients level using Response Surface Methodology.
Arish Bilal (2011) developed value added jaggery based nuggets using ginger powder.
Neha Kulkarni (2012) reported on ingredients optimization in jaggery based nuggets with spices.
2.4 Health Benefits of Jaggery
Jaggery of any type is better for health than refined white sugar. Its health benefits are explained in greater detail below.
High Fiber and Mineral Content: It is rich in minerals, salts, vitamins and even contains some fiber, whereas sugar, being highly refined, lacks these things. The darker the jaggery is in color, the richer it is in mineral content (particularly iron content) and the better it is for your health.
Better Than Sugar: It is much more complex than refined sugar and therefore does not increase the sugar level of the blood very quickly. It provides energy slowly, over a longer period. Although diabetics should avoid jaggery, it is still better in this respect for diabetics than sugar is.
Respiratory Tract Cleanser: For centuries on the Indian Subcontinent, jaggery (sugar cane jaggery) has been in use as a lung, throat, and respiratory tract cleanser as well as an additive to the local remedies for coughs and colds. This cleansing property of jaggery has been proven over many generations. The regular intake of jaggery is particularly recommended for those who work in kilns, cement factories, stone crushers, dusty workplaces, furnaces and those who have to do a lot of driving, due to the effect that these professions can have on the respiratory system.
Cooling Effect: Palmyra jaggery, usually made into a drink by dissolving in water, has a remarkable cooling effect on the body during the summer. Perhaps that is the reason why Palmyra sap is harvested and jaggery is made only during the summer.
Warming Effect: Date palm jaggery is manufactured and consumed in the winter. It has a warming effect on the body and is nutritious as well.
2.5 Jaggery – Cultural Aspects
Jaggery, made from sugar cane juice or palm sap, reserves a distinct place in Indian culture and is used in many religious activities, rituals & customs. The sugar cane jaggery is considered sacred and is consumed before the commencement of a new venture, journey, or business endeavor. It is customarily consumed after child birth, after attending a funeral, and to celebrate any good news.
Jaggery is an integral part of almost all harvest festivals celebrated in India. In Southern India, rice is cooked in sugar cane jaggery to make Pongal, a dish offered to the gods after the harvest. Similarly, in western and northern India, sweet dishes are made from sugar cane jaggery and newly harvested crops like sesame, ground nuts, rice, and wheat flour to celebrate the harvest.
In Eastern India, fabulously tasty sweet dishes like rice cakes, rice puddings, porridge, milk and coconut sweets are made using rice flour, milk, coconut shredding and date palm jaggery. In that area, this date palm jaggery is also offered to Goddess Saraswati and other gods and goddesses.
2.6 Composition of Chocolate
Chocolate is a homogeneous product obtain by an adequate process from a mixtureof one or more types ofcocoa nibs, cocoa mass, cocoa press cake with sugar, with or without addition of cocoa butter and additives such as emulsifiers, preservatives, antioxidant, flavours etc. ( Joshietal. 1992 and IS: 1163-1971). Riesen (1977) has given the composition a typical dietetic milk chocolate which contains approximately 9% cocoa beans, 15% dried whole milk, 7% dried skim milk,31%sorbitol, 38% cocoa butter, 0.12% cyclamate, 0.69% lecithin, and 0.01% vanilla.The composition of chocolate in the US is specified by FDA (1988C). According to these specifications, chocolate liquor should be 15% for sweet chocolate, 35% for bitter chocolate and 10% for plain milk chocolate.
Mohleret al. (1981) repeated a chocolate coated formulation, which contain 12% cocoa powder.
Weber (1985) states that chocolate made with added Nurupan showed major differences in calorie and fibre contents and only minor diff erences in processing, characteristics, sensory quality and keeping quality.
Anonymous (1986) suggested that 9% use of cocoa powder for providing a full chocolate flavor in milk chocolates.
Hershey (1986) has provided data on the nutritional composition of dark sweet chocolates that is presented in Table2.2
Roesch (1988) described a chocolate coating, spreadable over a wider temperature range than melted chocolate, made from a blend of syrup (80% sucrose/20% glucose ) with melted chocolate (20% of finished mix) and alcohol ( 12% of the final mix)
Table 2.2 Nutritional composition of Jaggery based Energy Bar
Nutrients Dark Sweets Chocolate Milk Chocolate
Energy (Cal) 540.0 540.0
Protein (g) 6.2 8.1
Fat (g) 30.2 30.9
Total Carbohydrate (g) 60.6 57.7
Crude Fibre (g) 1.0 1.1
Sodium (mg) 10.0 75.0
Potassium (mg) 340.0 410.0
Calcium (mg) 19.0 210.0
Phosphorus (mg) 160.0 310.0
Magnesium (mg) 115.0 65.0
Iron (mg) 2.1 1.1
Zinc (mg) 1.5 1.3
Cooper (mg) 0.8 0.4
Manganese (mg) 0.8 0.3
Vitamin A (IU) 20.0 60.0
Thiamine (mg) 0.02 0.08
Biboflavin (mg) 0.24 0.36
Niacin (mg) 0.64 0.36 2.7 Caffeine
Chocolate derived from cocoa beans contains a small amount of caffeine. The weak stimulant effect of chocolate may be due to a combination of Theo bromine and theophylline, as well as caffeine. A typical 28-gram serving of a milk chocolate bar has about as much caffeine as a cup of decaffeinated coffee, although dark chocolate has about the same caffeine as coffee by weight. Some dark chocolate currently in production contains as much as 160 mg per 100 g which is double the caffeine content of the highest caffeinated drip coffee by weight. In humans, caffeine acts as a central nervous system stimulant, temporarily warding off drowsiness and restoring alertness. It is the world's most widely consumed psychoactive drug, but unlike many other psychoactive substances, it is legal and unregulated in nearly all parts of the world. Beverages containing caffeine, such as coffee, tea, soft drinks, and energy drinks, enjoy great popularity. In North America, 90% of adults consume caffeine daily. The shape of caffeine is similar to an important molecule called "adenosine" that regulates brain function (pictured below). Caffeine "mimics" adenosine and binds to the same targets in the brain.
Part of the reason caffeine is classified by the Food and Drug Administration as generally recognized as safe is that toxic doses (over 1 gram for an average adult) are much higher than typically used doses (less than 500 milligrams). Ordinary consumption has low health risks, even when carried on for years — there may be a modest protective effect against some diseases, including Parkinson's disease, heart disease, and certain types of cancer. Some people experience sleep disruption if they consume caffeine, especially during the evening hours, but others show little disturbance and the effect of caffeine on sleep is highly variable. The maximum daily dose limit of caffeine is less than500mg.
How does it works
Caffeine doesn't actually gives you energy that is what it does to your body. Caffeine actually stops the breakdown of energy so we have a surplus. In simple terms, ATP
(Adenosine triphosphate) C10H16N5O13P3. ATP is a nucleoside triphosphate used in cells as a coenzyme. It is often called the molecular unit of currency of intra cellular energy transfer. ATP transport chemical energy within the cells for metabolism. It is one of the end products of Photophosphorylation, cellular respiration, fermentation and used by enzymes and structural proteins in many cellular processes. includingbiosynthetic reactions, motility and cell division.
In simple terms. ATP is what gives us body energy. Food is broken down and stored as ATP which is used as energy. When you start to feel yourself dragging it is because you have used up all the ATP, because ATP cannot be stored for long term.
Caffeine blocks the signal in your body, adenosine, from binding and letting the body know you are out of energy. It tricks your body into thinking that there is energy. The effects of caffeine can kick in within 10 minutes and last up to 4-6 hours.
That's why you crash from caffeine, when the effects run out your body tries to use ATP and there is none there.
2.8 Important Ingredients
2.8.1 Cocoa
U.S federal regulations (FDA, 1988) classify cocoa powders in the following type based on their fat contents: "breakfast cocoa" or high fat cocoa which contain not less than 22% fat, medium fat cocoa, 10-21% fat and low fat cocoa less than 10% fat.
Cocoa with less than 1% fat is also available. It provides a greater colour intensity, improved dispersion properties, improved suspension attributes and better blending traits than its counterparts containing higher fat. The use of 9% cocoa powder for providing a full chocolate flavor in milk chocolate (Anon, 1986), whereas Wieland (1972) suggested 13.21% cocoa powder in milk chocolate and 10% in plain chocolate. Mohleret al. (1981) reported a chocolate coating formulation which contains 12% cocoa powder.
2.8.2 Milk Solids
Milk in its various forms has been usedan ingredient in chocolates. Milk is an important ingredient in milk chocolates and is essential to its flavor, colour, texture, nutrition, appearance and shelf life.
Milkpowder used in chocolates at 12-25% by weight of the chocolate. Minimum milk fat content in regularmilk chocolates is 3.66% and the ratio of solid to milk fat must not exceed 2.43:1 (FDA, 1980). According to FDA (1988b) standard chocolates shouldconsist of 12% milk solids and 3.66% milk fat.
Campbell and Pavlasek (1987) described a milk chocolate composition with 22.75% milk solids along with other ingredients such as cocoa butter. cocoa powder and sugar etc.
2.8.3 Fat
Fat play mainly varied and important roles in confectionaries. They impart a distinctive richness of mouth, feel, body, colour, texture, appearance, flavor-release and shelf-stability (Wainwright, 1986). They also retard crystallization by reducing the rate of moisture loss from finished product and lubricating the confection, improving both its eating quality and its machine handling during cutting (Barnett, 1978).
Cocoa butter is the most important ingredient of chocolate. It is homogeneous, hard and has a brittle fracture and a melting point of about 90°C. Cocoa butter exhibits the law of even distribution where by all the various fatty acids present tend to become evenly distributed in the glyceride molecules. Hence cocoa butter has a greater homogeneity in composition and physical character (Becker, 1951). Cocoa butter contributes natural antioxidants which retard oxidative rancidity.
2.8.4 Emulsifiers and Stabilizers
An emulsifier is a substance that reduces the surface tension at the interface of the two normally immiscible phases, allowing them to mix and form to mix and form an emulsion. Without an emulsifier, the fat and aqueous phases will remain separate (Anon, 1989). Barnett (1978) outlined several other functions of emulsifiers in the confections which are: reductions of viscosity of nuggets and compound coatings, improvement of texture, chewiness, mouth feel and improvement of mechanical actions of cutting extruding and forming.
Confectioners use as an emulsifier like lecithin, monoglycerides, esters and polysorbate60.
Lecithin used as an emulsifier in foods in the commercial name given to a mixture of phosphor-lipids, neutral lipids and free fatty acids, glycol-lipids, carbohydrates and water. It is available in a range of solubility for preparing oil-in-water emulsions. It is chiefly used in chocolates in which it is reduces viscosity, reduces the fat requirement by 3-5% and emulsifiers the sugar and fat (Bonekamp, 1992).
Sorbitan esters are effective "antibloom" agents. The only sorbitan ester cleared by FDA for food use in sorbitanmonostearate which can be used in standardized cocoa products.
2.8.5 Sugar and Sweeteners
Sugar is the mainspring and essential raw material of nuggets. It is the keystone of the enormous worldwide nuggets and sugar confectionary industry. It constitutes 44% of the net weight of all confectionary shipments. Sugar makes up almost 50% of most milk nuggets. Several grades of relined sugar are available. For chocolate manufacture, a very finally ground sucrose produced from sugarcane is used. Sucrose is commercially available as a liquid at 670 Brix (Anonymous, 1989). Sugar provides sweetness, stability, bulk, mouth feel and texture to the product. FDA (1980) specified 45% sucrose to be used in nuggets in nuggets formulations.
A milk chocolate formulation with 58% sucrose was reported by Kieshkoet al. (1990). Mohleret al. (1981)stated that the sucrose content in the formulation could be reduced to 46%
Honey contains about 38% fructose and 31% glucose. It provides sweetness humectancy and flavor to end product. Sugar in nuggets can be replaced with 0.71 lb honey and 0.01 lb water (Anon, 1989).
2.8.6 Jaggery as a sweetener
Pandey and Narain (1993) have described the conventional jaggery manufacturing process. The process mainly consists of extraction of the juice from sugarcane, clarification of the juice, concentration of the juice into syrup and its solidification as jaggery, and finishing and moulding of jaggery into different shapes.
2.9 Forms of Jaggery
Jaggery is commonly produced in three forms viz.powderjaggery, liquid jaggeryand solid jaggery. 2.9.1 Powder Jaggery
Thepowder jaggery is produced by heating the acidified juice (pH: 6 to 6.2) by adding lime as clarification. The charge is boiled up to striking point of 118-120°C and the hot mass is allowed to cool along with thorough mixing for a few minutes. This thick mass is then spread on aluminium tray or cement platform and allowed tocool for few minutes without stirring. At the time of solidification the mass is stirred with wooden scrapers to get the powdered gur(Anon, 1996).
2.9.2 Solid Jaggery
Pandey and Narain (1993) reported that solid jaggery is obtained by striking at a temperature of 115-117° C which corresponds to 90° Brix. The semi-liquid mass solidifies into solid jaggeryafter cooling.
2.10 Jaggery Chocolate
Jaggery is quite suited for making energy like product. Particularly the old gur (jaggery) having darker colour and higher invert sugars can be very well used for its value addition as jaggery energy bar.
Kumar, (1999) designed the experiments based on response surface methodology using half replicate composite rotable design in 5 variables. The initial moisture content of the mix, cocoa, mixing temperature, mixing time and mixing speed were taken independent variables influencing the product. The moisture content, sucrose, reducing sugar, colour and density of jaggery chocolate were taken as the independent variables representing the product quality. Based on this study he gave the optimum process conditions for making jaggery chocolate as under:
Initial moisture content = 15% WB (WET BASIS)
Cocoa % = 13% W.B (WET BASIS)
Mixing temperature = 105° C
Mixing time = 3 min.
Mixing speed = 80 rpm
2.10 Processing of Jaggery Energy Bar
Typical processing of jaggery energy bar has been described by Joshi and Sharma (1992). The extracted bins are kept in a large bin or suitable container for 7 to 12 days to carry out microbiological and enzymic fermentation. The fermented beans are sun dried or machine dried to around 7 % moisture to give them good keeping quality and is ready for further processing.
2.10.1 Mixing and Refining
Mixing
The proper ground chocolate liquor is admixed with finely powdered sugar,milk solids and cocoa butter in a kneading machine. The mass remains in the mixture and resembles well kneaded (Joshi and Sharma, 1992).
Refining
The dried chocolate mass or chocolate crumb is conveyed to the refiners where fine and flaky mass is produced. Further removal of moisture takes place in these refiners. Required quantity cocoa butter, lecithin and flavoring is added to the mass just prior to conching of the same.
2.10.2 Moulding
Mackley (1994) reported the moulding of jaggery energy bar mass using an extrusion process. The confectionary ingredient is fed in to an extruder and is subjected to pressure at a temperature promoting semi solid state upstream of a flow constriction. The outgoing extruded product is homogeneous and has a cross section which is of the same profile as die of the extruder.
The bar mixture is deposited into moulds, and after cooling is knocked from the moulds as solid piece. The design of mould is an expert's job, although the general appearance of the finished block may be decided by the sales staff, the exact design of the impression requires knowledge of the optimum angles for the mould sides and the type of embossing that will facilitate demolding and give good appearance. A complete understanding of the principles of cooling is essential if chocolate products with good appearance and shelf life are to be obtained(Bernard, 1989). 2.10.3 Cooling
Hausmannet al. (1993) observed that 10°C was the optimum temperature for economic cooling of good quality chocolate with good crystallization characteristics. They also observed that additional radiation cooling would result in an approximate 10 % decrease in cooling times whereas decreasing the cooling temperature from 14°C - 10°C would decrease the cooling time by 25%.
3. MATERIALS AND METHODS
3.1 Preliminary Experiments
The preliminary experiments were conducted to identify ingredients and process variables and their range for producing an acceptablejaggery based energy bar. The details of the preliminary trials and their results are summarized.
Sensory evaluation regarding jaggery was done by making samples ofjaggery energy bar using cocoa powder 30, 35, 40, skim milk powder 100, 120, 140 g.
The caffeine content of energy bar can vary greatly. To put this into perspective, moderate caffeine consumption for most individual is about 500mg per day. So we kept 150,250 and 350 g.
3.2 Procedure of making Jaggery Energy Bar
Based on the preliminary experiments, the ingredients and process for making jaggery energy bar was finalized:
1. Weighing of ingredients. 2. Jaggerypowder, Skim Milk Powder, and 20% of total quantity of butter is added in mixer and mix them all up to 3 min. 3. The process will take total time about 10 min. for hot mixing process. 4. Weighed caffeine powder is added and blend withjaggery. 5. The molten chocolate mass is heating at temperature 80-110°C. 6. After the above step, the adequate quantity of cocoa powder is added and then final mixing was completed. 7. The mixture was then moulded in the form of bar usually rectangle in shape. 8. The bars were then allowed to cool and dry for a period of about 6-12 hours from the time of moulding. 9. After 1 hours of natural drying, the bar were wrapped in Aluminium foil and seated in bags for storage.
3.3 Response Surface Methodology RSM is a statistical technique which consists of a group of mathematica1 and statistical procedures that uses quantitative sensory data to determine and simultaneously solve multivariate equations which specify the optimum product for a specified set of factors. This considers interaction among the test factors and can be used determine how the product changes with changes in the factor level (Thompson, 1982).
3.3.1 Considerations in use of RSM
Before adopting RSM, the researcher should know that this technique is dependent on the following assumptions:
1. The factors which are critical to the product are known. 2. The regions of interest where the factor levels influence the product are known. 3. The factors vary continuously throughout the experimental range tested. 4. There exists a mathematical function which relates the factor to the measured response. 5. The response which is defined by this function is a smooth surface.
3.3.2 Steps in RSM
RSM is a four step process:
1. Identify factors: The first is to identify the factors which are critical and account for most of variation in the quality of the product under study. 2. Define factor levels:the second step is to define a range of factor levels which encircle the product quality. These factor levels have to be carefully selected keeping in view the feasibility, cost and government regulation if any. 3. Select test samples:the third step is to select pertinent samples, from among all the possible combinations to be tested using proper statistical design. The experimental design specifies only those samples which are close to the midpoints of these ranges, thereby decreasing the total number of the samples, experiments are conducted and related data for example quantitative sensory data on the product quality are obtained and subjected to appropriate statistical analysis. 4. Data analysis:The data so obtained are analysed by an appropriate computer program, which are further interpreted collectively by a statistician, experimenter sensory scientist and others, who have participated in data collection. The conclusion drawn from the above analysis should then be confirmed by follow up experiments with the optimum (Thompson, 1982).
3.3.3 Applications of RSM
Most of the RSM applications come from areas such as optimal sensory quality, setting sensory standards, new or modified products and chemical engineering processes, industrial research and biological investigations, which emphasis on optimizing a process or system(Thompson, 1982).
3.4 Design of Experiments
According to the process the independent variables were defined as milk powder, Cocoa powder and caffeine. Experiments were designed using Response Surface Methodology. The RSM design was chosen as it allows reduction in number of experiments without affecting the accuracy of results.
3.5 Sensory Evaluation
Sensory quality is important to both the processor as well as the consumer. It is the combination of different senses of perception coming into play into choosing and eating food. The sensory evaluation was done on 9 point Hedonic scale as per IS standard (1S: 6271, 1971) with the help of 10 member panel. The sensory valuation was done for liking on the basis of visual characteristics (colour and surface appearance), texture (mouth feel and hardness) and taste.
To analyse the result the numerical value are assigned to each point on the scale.
Liked extremely 9
Liked very much 8
Liked moderately 7
Liked slightly 6
Neither liked nor disliked 5
Disliked slightly 4
Disliked moderately 3
Disliked very much 2
Disliked extremely 1
4. RESULTS AND DISCUSSION
The experiments were conducted to develop jaggery based energy bar. The experiments were planned Response surface methodology. The skim milk powder, cocoa powder and caffeine were taken as the independent variables. Total numbers of experiments conducted using RSM were 9. The responses studied were appearance, colour, taste, texture, flavour and overall acceptability. The response surface model was fitted to these response variables using multiple regressions.
4.1 Sensory Characteristics of Jaggery Energy Bar Samples
Sensory attributes viz. appearance, colour, taste, texture, flavor and overall acceptability of chocolate samples are reported in Table4.1. The analysis of the variance (ANOVA) for each response was calculated and response surface method was developed for each response. The developed product is analyzed for adequacy to explain variability in responses on the basis of Fcal, coefficient of determination (R2), standard error and lack of fit and adequate precision ratio.
4.1.1 Appearance
The appearance score of jaggery energy bar ranged from 7-8. The lack of fit for the response surface method developed for appearance was significant and the calculated adequate precision was greater than 4 and is desirable. R2 was found to be 45.96%. Therefore the model was acceptable. The ANOVA Appendix-HI for the response indicated that the product was adequate and explained variability. The product was significant on the basis of method "Fcal" value.
The coefficient estimates of appearance shows the skim milk powder, cocoa powder and caffeine in quadratic terms significantly affected the appearance score of the jaggery energy bar.
4.1.2 Taste
The taste score of the jaggery energy bar was found in the range of 6-8. A maximum taste was found in chocolates having 120 g skim milk powder, 40g cocoa powder and 150mg caffeine respectively. The lack of fit for the response surface method developed for taste score was not significant and the calculated adequate precision was greater than 2 and is desirable. R2 was found to be 41.35%. Therefore the product was acceptable the ANOVA Appendix-IV for the response indicated that product was adequate and explained variability. The product was significant (p>0.01) on the basis of method "Fcal" value.
The coefficient estimates of appearance shows that the amount of skim milk powder, cocoa powder and caffeine in quadratic terms significantly affected the taste score of the jaggery energy bar.
4.1.3 Colour
The colour score of the jaggery energy bar was found in the range of 7-8. A maximum and minimum colour was found in chocolates having 120 g skim milk powder, 40 g cocoa powder, 150 mg caffeine and 120 g skim milk powder, 35 g cocoa powder, 250 mg caffeine. The lack of fit for the response surface method developed for colour score was not significant and the calculated adequate precision was greater than 6 and is desirable. R2 was found to be 76.75%. Therefore the product was acceptable. The ANOVA Appendix-II for the response indicated that product was adequate and explained variability. The product was significant (p>0.01) on the basis of method "Fcal" value. The coefficient estimates of appearance shows that the caffeine, composition of cocoa powder and skim milk powder in quadratic terms significantly affected the colour score of the jaggery energy bar.
4.1.4 Texture
The texture score of the jaggery energy bar was found in the range of 7-9. A maximum and minimum taste was found in chocolates having 120 g skim milk powder, 40 g cocoa powder, 150 mg caffeine and 120 g skim milk powder, 35 g cocoa powder, 250 mg caffeine. The lack of fit for the response surface method developed for texture score was not significant and the calculated adequate precision was greater than 5 and is desirable. R2 was found to be 76.05%. Therefore the product was acceptable. The ANOVA Appendix-V for the response indicated that product was adequate and explained variability. The product was significant on the basis of method "Fcal" value.
The coefficient estimates of appearance shows that the skim milk powder, cocoa powder and caffeine in quadratic terms significantly affected the texture score of the chocolate jaggery energy bar.
4.1.5 Flavour
The flavor score of the jaggery energy bar was found in the range of 7-8. A maximum and minimum taste was found in chocolates having 120 g skim milk powder, 40 g cocoa powder, 150 mg caffeine and 120 g skim milk powder, 35 g cocoa powder, 250 mg caffeine. The lack of fit for the response surface method developed for flavour score was not significant and the calculated adequate precision was greater than 3 and is desirable. R2 was found to be 64.91%. Therefore the product was acceptable. The ANOVA Appendix-VI for the response indicated that product was adequate and explained variability.
The product was significant (p>0.01) on the basis of method "Fcal" value.
The coefficient estimates of appearance shows that the parameters significantly affected the flavour score of the jaggery energy bar.
4.1.6 Overall acceptability
The overall acceptability score of the jaggery energy bar was found in the range of 7-9. A maximum and minimum overall acceptability was found in chocolates having energy bar having 120 g skim milk powder, 40 g cocoa powder, 150 mg caffeine and 120 g skim milk powder, 35 g cocoa powder, 250 mg caffeine.
The lack of fit for the response surface method developed for overall acceptability score was not significant and the calculated adequate precision was greater than 3 and is desirable. R2 was found to be 59.10%. Therefore the product was acceptable. The ANOVA appendix-VII for the response indicated that the product was adequate and explained more variability. The product was significant on the basis of method ‗Fcal‘ value. The coefficient estimates of overall acceptability shows that skim milk powder, cocoa powder, caffeine in quadratic terms significantly affected the overall acceptability score of the chocolate.
4.1.7 Optimization of Jaggery based Energy Bar Ingredients with Caffeine
Numerical optimization was carried out using design expert 8.0 statistical software. The goal was fixed in certain range fir skim milk powder, cocoa powder, caffeine, colour, taste, texture, appearance. flavour and overall acceptability. The range for independent variables was 100 to 140g for skim milk powder. 30 to 40g cocoa powder and 150 to 350mg caffeine for colour, taste, appearance, flavour, texture and overall acceptability it was fixed to be 7-9. All the responses and independent variables were given similar (+++) importance.
The optimized levels of skim milk powder, cocoa powder and caffeine were found to be 0.00. 0.00 and 0.00 respectively. And for sensory characteristics it was found to be:
Appearance = 7.5555
Taste = 7.2222
Texture = 7.4444
Flavour= 7.6666
Overall acceptability = 7.7777
5. SUMMARY AND CONCLUSIONS
Planned experiments were conducted on preparation of jaggery energy bar. The experimental design was based on response surface methodology. Sensory evaluation of the product was conducted using 10 member panels. The sensory panel rated their liking or disliking of product on 9 point hedonic scale based on appearance, colour, flavour, taste, texture and overall acceptability. Adequacy of the models obtained for sensory attributes of 2 energy bar was determined using R , Fcal, and lack of fit and adequate precision.
Based on characteristic and quality evaluation results of energy bar, the following conclusions could be drawn:
1. The chocolate prepared in this study had the overall sensory rating of 8. 2. The optimum ingredients level indicating that it was 'liked moderately'. 3. The optimum ingredients level for making jaggery energy bar with skim milk powder 120gm, cocoa powder 40gm and caffeine 150mg.
Plate 1: Mixing Apparatus
Plate 2: Jaggery bar stored in desiccator
Plate 3: Drying of moulded Jaggery Energy Bar
Plate 4: Jaggery bar wrapped in aluminium foil
Plate 5: Sensory evaluation of jaggery energy bar APPENDIX – I EVALUATION CHART FOR HEDONIC RATING TEST
Product: Jaggery based energy bar Date:
Time:
Taste the sample using the appropriate scale to show your like or dislike, the best describe your feeling about the sample. Please give the reason for the attribute. Remember you are the only one who can tell what you like. An honest expression of your personal feelings will help us.
Scale:
Liked extremely 9 Liked slightly 6 Disliked moderately 3
Liked very much 8 Neither liked nor 5 Disliked very much 2 disliked Liked moderately 7 Disliked slightly 4 Dislike extremely 1
Name:
Address:
Signature
APPENDIX – II
Response 1: Color
ANOVA for Response Surface Model
Source Mean Square F-value P-value Remarks
Prob>F Model 0.53 2.57 0.1137 Significant
A(skim milk) -2.665E-015 -1.286E-014 1.000
B(cocoa powder) 1.12 5.43 0.0526
C(caffeine) 0.12 0.60 0.4627
AB -2.665E-015 -1.286E-014 1.0000
AC -2.665E-015 -1.286E-014 1.0000
BC 0.25 1.21 0.383
A2 1.39 6.72 0.0358
B2 1.92 9.26 0.0188
C2 0.13 0.62 0.4560
Residual 0.21
Lack of fit 0.083 0.28 0.8395 Not significant
Pure error 0.3
R2 0.7675
C.V% 6.09
Adeq Precision 6.088
APPENDIX – III
Response 2: Appearance
ANOVA for Response Surface Model
Source Mean Square F-value P-value Remarks
Prob>F Model 0.42 0.66 0.7240 Significant
A(skim milk) 0.13 0.2 0.6708
B(cocoa powder) 8.882E-106 1.397E-015 1.000
C(caffeine) 1.13 1.77 0.2251
AB 8.882E-016 1.397E-015 1.0000
AC 0.25 0.39 0.5505
BC 1.000 1.57 0.2500
A2 0.44 0.7 0.4305
B2 0.76 1.2 0.3103
C2 0.13 0.2 0.6661
Residual 0.64
Lack of fit 0.42 0.52 0.6905 Not significant
Pure error 0.8
R2 0.4596
C.V% 10.67
Adeq Precision 3.884
APPENDIX – IV
Response 3: Taste
ANOVA for Response Surface Model
Source Mean Square F-value P-value Remarks
Prob>F Model 0.27 0.55 0.8027 Significant
A(skim milk) 0.12 0.25 0.6300
B(cocoa powder) -1.776E-015 -3.604E-015 1.000
C(caffeine) 0.12 0.25 0.6300
AB 1.000 2.03 0.1973
AC 0.25 0.51 0.49994
BC -2.220E-015 -4.505E015 1.000
A2 0.76 1.54 0.2542
B2 0.13 0.26 0.6247
C2 0.024 0.048 0.8327
Residual 0.49
Lack of fit 0.75 2.50 0.1985 Not significant
Pure error 0.30
R2 0.4135
C.V% 9.55
Adeq Precision 2.554
APPENDIX-V
Response 4: Texture
ANOVA for Response Surface Model
Source Mean Square F-value P-value Remarks
Prob>F Model 0.55 2.47 0.1233 Significant
A(skim milk) -1.776E-015 -8.022E-015 1.000
B(cocoa powder) 1.13 5.08 0.0588
C(caffeine) 0.12 0.56 0.4769
AB 0.25 1.33 0.3233
AC 2.25 10.16 0.0153
BC -8.882E-016 -4.011E-015 1.000
A2 0.52 2.33 0.1708
B2 0.042 0.19 0.6759
C2 0.67 3.04 0.1264
Residual 0.22
Lack of fit 0.25 1.25 0.4028 Not significant
Pure error 0.20
R2 0.7605
C.V% 6.56
Adeq Precision 5.542
APPENDIX-VI
Response 5: Flavour
ANOVA for Response Surface Model
Source Mean Square F-value P-value Remarks
Prob>F Model 0.73 1.44 0.3229 Significant
A(skim milk) 0.13 0.25 0.6348
B(cocoa powder) 0.50 0.99 0.3538
C(caffeine) 0.13 0.25 0.6348
AB 1.00 1.97 0.2030
AC 2.25 4.44 0.0732
BC 1.00 1.97 0.2030
A2 2.632E-003 5.189E-033 0.9446
B2 0.32 0.63 0.4541
C2 1.16 2.29 0.1741
Residual 0.51
Lack of fit 0.25 0.36 0.7880 Not significant
Pure error 0.70
R2 0.6491
C.V% 9.38
Adeq Precision 3.891
APPENDIX - VII
Response 6: Overall acceptability
ANOVA for Response Surface Model
Source Mean Square F-value P-value Remarks
Prob>F Model 0.41 1.12 0.4489 Significant
A(skim milk) 1.13 3.09 0.1223
B(cocoa powder) 0.13 0.34 0.5764
C(caffeine) 4.885E-015 1.341E-014 1.000
AB 1.00 2.75 0.1415
AC 0.25 0.69 0.4348
BC 0.25 0.69 0.4348
A2 0.095 0.26 0.6258
B2 0.095 0.26 0.6258
C2 0.67 1.85 0.2160
Residual 0.36
Lack of fit 0.58 2.92 0.1639 Not significant
Pure error 0.20
R2 0.5910
C.V% 8.02
Adeq Precision 3.780
Table 3.1 Coding of variables for experimental design using RSM
Coded levels
Independent variable -1 0 1
A. Milk powder (g) 100 120 140
B. Cocoa powder (g) 30 35 40
C. Caffeine (mg) 150 250 350
Table 3.2 Response surface designs of experiments
Experiment No. Skim milk(g) Cocoa powder(g) Caffeine(mg)
1. 0 0 0
2. 1 1 1
3. -1 -1 -1
4. 0 1 -1
5. 1 -1 0
6. -1 0 0
7. 0 0 1
8. 1 0 1 9. 0 -1 -1
Table 3.3 Sensory Characteristics of Jaggery Energy Bar
Expt. Skim Cocoa Caffeine Sensory Responses No. milk powder powder Colour Appearance Taste Texture Flavour Overall acceptability 1. 0 0 0 8 8 7 8 7 8
2. 1 1 1 7 7 8 8 7 8
3. -1 -1 -1 8 8 7 7 8 7
4. 0 1 -1 8 8 8 9 9 9
5. 1 -1 0 7 7 8 7 8 8
6. -1 0 0 8 8 8 7 7 8
7. 0 0 1 7 7 6 7 7 7
8. 1 0 1 8 8 6 7 8 7
9. 0 -1 -1 8 7 7 7 8 8
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