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Food Technology-I FOOD TECHNOLOGY-I A. K. Singh P. N. Raju & A. Jana FOOD TECHNOLOGY-I Course Developers A. K. Singh & P. N. Raju Dairy Technology Division NDRI, Karnal A. Jana Dairy Technology Department Anand Agricultural University, Anand Editor Index Lesson Lesson Name Page No No Module 1: Status of food processing industry and future prospects 1 Introduction to food processing in India 1-7 2 Status of food processing industry abroad 8-10 3 Magnitude and interdependence of dairy and food industry – I 11-16 4 Magnitude and interdependence of dairy and food industry – II 17-19 5 Recent developments and future growth in the food industry 20-25 Module 2: Post-harvest management of fruits and vegetables 6 Harvesting, transportation and storage of fruits and vegetables 26-31 7 Post-harvest processing – I 32-34 8 Post-harvest processing – II 35-38 Module 3: Processing of fruits and vegetables 9 Canning and other methods of thermal processing 39-45 10 Freezing: Principle, methods and applications 46-49 11 Drying: Principle, methods and applications 50-60 Module 4: Fruits and vegetables juice processing 12 General steps in juice processing 61-67 13 Equipment and methods of extraction, clarification and preservation 1 68-75 14 Processing of selected fruit juices – I 76-81 15 Processing of selected fruit juices – II 82-89 16 Concentration and drying of fruit juices 90-96 Module 5: Jam, jelly, marmalade, and glazed and crystallized fruits 17 Role of sugar and other ingredients in fruit preservation 97-105 18 Jam, Jelly and Marmalade 106-113 19 Fruit preserves 114-116 20 Glazed and crystallized fruits 117-119 Module 6: Tomato and tomato based products 21 Tomato juice extraction and juice characteristics 120-125 22 Tomato puree, paste, sauce and ketchup 126-134 23 Novel tomato products 135-139 Module 7: Beverages 24 Scope and classification of beverages 140-145 25 Additives for fruit-based beverages 146-156 26 Carbonated beverages 157-162 27 Fruit beverages and drinks 163-167 Module 8: Tea 28 Tea-Introduction and classification 168-172 29 Tea leaf processing 173-179 30 Specialty tea products 180-183 Module 9: Coffee 31 Coffee: Types and characteristics 184-186 32 Coffee processing 187-194 33 Instant coffee 1 195-199 Module10: Pickles and sauerkrauts 34 Principles and classification 200-203 35 Technology of selected pickles - I 204-207 36 Technology of selected pickles - II 208-211 Module 11: Confectionery products 37 Principles and classification 212-218 38 Candies 219-221 39 Chewing gums and bubble gums 222-226 40 Toffees and caramels 227-233 Module 12: Cocoa and chocolate products 41 Cocoa bean processing 234-236 42 Chocolate liquor, cocoa butter and cocoa butter replacers/extenders 1 237-245 43 Chocolate products – I 246-252 44 Chocolate products – II 253-261 Module 13: Functional foods 45 Present and future scope of functional foods 262-267 46 Phytochemicals in relation to human health 268-275 47 Milk ingredients as nutraceuticals 276-286 48 Future of functional ingredients 287-291 Module 1. Status of food processing industry Lesson 1 INTRODUCTION TO FOOD PROCESSING IN INDIA 1.1 Introduction India has emerged a leading producer of certain food products such as buffalo meat, black tea, milk, and fruit and vegetables. The country is in possession of premium food products such as Basmati rice, Darjeeling tea and Alphonso managoes to offer to the world. 1.2 Factors Influencing the Consumers to seek Processed Foods Some of the factors which have led to the growth of processed foods in India are: a) Emerging urban and rural middle class population with requisite purchasing power. b) Socio-cultural changes, strongly influenced by the communication media. c) Changing demographic pattern. d) Increase in working women population. e) Consumer competitiveness with alternate and substitute products, and f) Entry of modern and self-service market outlets. 1.3 Constraints in Food Processing Sector Despite being one of the largest producers of food items, only 2.0% of the total produce is processed as against an average of 40.0% in many developing and 70.0% in most developed countries. Moreover, because of the bottlenecks present in the supply chain, about 30.0% of the harvested produce is spoilt during distribution to the consumers. The factors that have impeded the growth are summarized below: a) Non-availability of the right quality of processable raw materials. b) Seasonal excesses and scarcities of raw material causing wide fluctuations in the prices. c) High taxation. d) Complicated administrative and legislative processes. e) Streamlining of food laws. f) Lack of interface between research institutions and the farmers and also between research institutions and the processors. g) Indifference about the quality systems in the food processing sector. h) Lack of awareness of intellectual property rights, and i) Unpreparedness of the industry to meet the challenges posed by WTO agreement. FOOD TECHNOLOGY – I 1.4 Status of Food Processing Industry in India The food industry has a turnover of Rs. 2,50,000 crores and accounts for 26.0% of GDP and provides 61% of employment. The processing of fruits and vegetables is as low as 2.0%, ~ 35.0% in milk, 21.0% in meat and 6.0% in poultry products. By international comparison, these levels are very low i.e. the processing of agriculture produce is ~ 40.0% in China, 30.0% in Thailand, 70.0% in Brazil, 78.0% in Philippines and 80.0% in Malaysia. The value addition to food production is only 20.0% in India as against 23.0% in China, 40.0% in Phillippines and nearly 200% in UK. The annual wastage is estimated to be valued at ~ US $ 13 billion. A study by the Confederation of Indian Industries and Mc Kinsey and Co. has predicted that the consumption of items preferred by the lower and middle classes such as packaged attas, milk and bakery products and poultry items will grow by over 15.0% a year. The current status of food processing industry is depicted in Table 1. Table 1.1 Status of food production in India Food item Year Quantity produced per Growth rate Ranking in world annum (%) Fruits 2009-10 63.50 million tonnes 10.0 % 3rd Mango 2010-11 16.18 million tonnes 1st Banana 2007-08 10.4 million tonnes 1st Vegetables 2009-10 126.0 million tonnes 13.28% 2nd Food grains 2010-11 235.0 million tonnes 6.2% 3rd Rice 2010 94.5 million tonnes 2nd Wheat 2010 84.0 million tonnes 2nd Coarse cereals 2007-08 40.73 million tonnes Pulses 2009-10 14.59 million tonnes Oilseeds 2009-10 24.90 million tonnes Maize 2010 30.00 million tonnes Sugar cane 2010 340.00 million tonnes Bakery products 1999 30 lakh tonnes 8.0% Biscuit – 2nd Chocolate products 2000 22,000 tonnes 10-12% Milk 2011 120 million tonnes 1st Black tea 2010 1.07 million tonnes 2.51% 1st Breweries 1996 5.0 million hectolitres Spices 2000 2.7 million tonnes 1st Cashew 2010 6.3 lakh tonnes 1st Mushroom 2000 1.0 lakh tonnes Fish 2008-09 7.6 million tonnes 3rd Eggs 2006-07 50.7 billion numbers Broilers 2005-06 450 million Chicken meat 2006-07 2.0 million metric tonnes Meat and meat products 2008-09 6.50 million tonnes 4.0% 2 WWW.AGRIMOON.COM 1.4.1 Fruit and vegetable processing Mango, banana, citrus, guava and apple account for 75.0-80.0% of fruit production. The installed capacity of fruit and vegetable processing industry is about 2.1 million tonnes in 2006. The processing of fruit and vegetables is about 2.2% of total production in India. The fruit and vegetable processing industry has registered an average annual growth rate of 30.0% in 2008-09. India‟s share in the world production is about 10.0% in fruits and about 13.28% in vegetables. Some recent products introduced include vegetable curries in retortable pouches, canned mushroom and mushroom products, dried fruit and vegetables and fruit juice concentrates. Contract farming in wheat is practiced in Madhya Pradesh by HLL and by Pepsi Foods Ltd. in Punjab for tomatoes, potatoes, food grains, spices and oilseeds are examples of contract farming in India that has promoted cultivation of processable variety of farm produce. 1.4.2 Plantation Tea, coffee, cashew, cocoa, etc. are major plantation crops in the country. India‟s principal plantation crops accounted for about 5.0-6.0% of India‟s aggregate export earnings. India is the world‟s leading producer and exporter of cashew kernels and accounts for ~ 31.0% of the world production of raw cashew and nearly 48% of the world‟s export of cashew kernels in the year 2007-08. 1.4.3 Food grains Grain processing is the biggest component in the food sector, sharing over 40.0% of the total value. There is predominance of primary processing sector, sharing 96.0% of the total value; with secondary and tertiary sector contributing about 4.0% of the total value addition. In 1999-2000, there were 91,000 rice hullers, and 2,60,000 small flour mills engaged in primary milling. There were ~ 43,000 modernized rice mills/huller-cum-shellers. An estimated 820 large flour mills in the country converts ~ 10.5 million tonnes of wheat into wheat products. There are over 10,000 pulse mills, milling about 75.0% of pulse production of 14 million tonnes in the country. Indian Basmati rice commands a premium in the international market. There is some headway in preparing value added foods viz., breakfast cereals and rice analogue from broken rice.
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