| | | | | | |
 

 

Crop Production
Crop Protection
Crop Improvement
Sustainable Agriculture
Organic Farming
Indigenous Farming

 Cereals :: Wheat      

Weather
Soil
Water
Seed
Farm Enterprises
Nutrition
Post Harvest Technology
Bio Technology
Bio-Fuels

VALUE ADDITION

1. PROCESSED PRODUCT

Top

a. Malted Wheat: The process of malting consists following steps

  1. Good quality grain is steeped in cold water for 36 hours in warm climate with two or three changes of water.
  2. The steeped grain is spread on wire mesh trays of 2-3" thickness, which are kept in a stand.
  3. The germination is allowed to proceed for 3 days in a warm climate. During germination amylases and proteases are formed.
  4. Germinated grain is allowed to slow dry during which the amylases act on starch, hydrolyzing them. The drying should be at a low temperature to conserve as much of the enzyme activity as possible. During drying, the water soluble carbohydrates and nitrogen (peptones and peptides) increase.

The characteristic malt flavour is developed.

The malt is dried to moisture content of about 13%.

b. Amylase Rich Food (ARF) is germinated cereal flour, which is extremely rich in the enzyme alpha-amylase. The alpha-amylase cleaves the long carbohydrate chains in the cereal flour into shorter dextrins. Just half a flat teaspoon of any ARF can reduce even a very high total solid concentration of 45g, made up of 25g flour, 15g sweetener and 5g oil cooked in 100ml of water to a soupy consistency. This remarkable property makes it possible to offer the weaning child a low viscosity yet high energy dense preparation. Malted cereal flour is inexpensive and can be used in brewing and in the preparation of malt extract for pharmaceutical purposes and in the preparation of malted milk powder.

c. Puffed wheat

Whole grain wheat are cleaned and conditioned. It is then fed into an externally heated, sealed pressure chamber. Steam is injected to raise the internal pressure in the chamber to about 14 kg/cm2 and then suddenly released by opening the chamber when owing to the expansion of water vapour the grain is blown up to several times its original size.  

d. Popcorn

has been a traditional snack food. Expansion volume is the most critical quality factor for pop corn. The texture (tenderness and crispness) is positively correlated with popping volume. Most commercial popcorn has a 30-40 fold expansion popping occurs at about 177 which is equivalent to a steam pressure of 2.5 tonnes/cm2 inside the kernel. The water in the kernel is super heated and at the moment of popping gets converts to steam, which provides the driving force for expanding the IP80 thermoplastic endosperm after the kernel ruptures.

e. Wheat flakes : Cleaned grains are tempered in bins and subsequently steamed at atmospheric pressure until they attain moisture of 21%. The steamed wheat is passed through steam rollers which ruptures the bran coat and flatten the whole grain thus making the kernels more permeable to moisture during the cooking step. The flattened kernels are then cooked in rotating retorts along with malt, salt, sugar etc. for 90 min at 20 psi steam pressure. After cooking the grains become soft, translucent and brown and contain moisture around 45-50% with completely gelatinized starch. The cooked grains are heated to 80-85 to impart plasticity then flaked in a roller flakes. To impart desired crispness the flakes are toasted and dehydrated to less than 3% moisture.

2. BAKERY PRODUCTS

Top

a. BREAD*

PROCESSING OF WHOLE WHEAT BREAD *

PREPARATION OF HIGH FIBRE BREAD **

b. BUN *

c. CAKES *

d. RUSK/SOUP STICK **

Ingredients

Whole wheat flour

85 g

Defatted soy flour

15 g

Sugar

2.5 g

Salt

2.0 g

Gluten

2.5 g

Vegetable fat

2.5 g

Yeast

1.0 g

Water

40 ml


 

 

 

 

PROCESSING OF RUSK AND SOUP STICKS

PREPARATION OF HIGH FIBRE RUSK **

e. COOKIES *

PREPARATION OF NUTRIENT DENSE LOW-COST INFANT WEANING BISCUITS **

f. DOUGHNUTS *

Doughnuts are served quite extensively in hotels, restaurants and snack bars in many countries of the world. When made attractive and tasty, doughnuts can be served at most festive occasions. Doughnuts can become very popular in India for serving at tea time. The ingredients that go to make doughnuts are :

Flour

100 %

Sugar (ground)

35 %

Shortening

7 %

Baking powder

4.5 %

Egg

30 %

Salt

1.5%

Nutmeg powder

0.5%

Cinnamon powder

0.5%

Baking soda

0.45%

Milk powder

5.0%

Water (variable)

40%

Lemon yellow colour

as required

 

 

 

 

 

 

Method

            1.  Sieve together correctly scaled flour, salt, nutmeg powder, cinnamon powder, milk powder and baking powder thoroughly.
            2.  Cream shortening and ground sugar thoroughly
            3.  Add well beaten eggs to creamed shortening and sugar
            4.  Add lemon yellow colour to water
            5.  Add baking soda to creamed shortening and sugar to which beaten eggs have been added.
            6.  Mix to a smooth dough
            7.  Roll out the dough on a lightly floured board. Rolled dough should be 1/3 cm. thick.
            8.  Use doughnut cutter which has outer 7 cm diameter and 2½ cm inner diameter.
            9.  Place doughnuts into frying pan. The fat temperature should be around 380°F. The doughnuts will rise after few seconds. Then turn upside down. Fry till golden brown. Strain fat by using frying spoon before wrapping or serving.
            10. When using 500 g of flour and the above recipe, three dozen doughnuts of the size mentioned above could be obtained.

g. PUFF PASTRY *

Puff Pastry is a rolled pastry in which layers of shortening are interleaved between layers of dough so that upon baking an open network of crisp and flaky layers are formed. The main ingredients used in puff pastry making are flour, shortening, salt and water.

Maida  

1 kg

Fat                         

250 g

Salt                        

1 tsp

Baking powder

½ tsp

 

 

 

Fillings

Boiled potato

            ½ kg

Carrot             

            100 g

Beans             

            100 g

Green peas     

            200 g

Onion (big)     

            100 g

Tomato           

            150 g

Chilly powder            

            2 tsp

Turmeric powder

            1 tsp

Coriander powder

            3 tsp

Cumin seeds   

            ½ tsp

Garam masala

            1 tsp

Curry masala  

            2 tsp

Ginger / garlic paste

            2 tsp

 

 

 

 

 

 

 

h. PIZZA *

Ingredients

Maida

200 g

Fat      

30 g

Salt     

½ tsp

Yeast  

5 g

Sugar  

5 g

Egg     

1 No

Milk    

40 ml

Oil      

30 ml

 

 

 

 

 

Fillings

Tomato

3 Nos.

Cheese

4 pkts

Chillies

4 or 5

Onion

2 big

Coriander/curry leaves

One bundle(small)

Salt     

for taste

Capsicum/mushroom

as required

 

 

 

 

Method

  1. Sieve the flour twice.
  2. Disintegrate yeast in luke warm water with little sugar
  3. Dissolve salt in the remaining water and mix with flour roughly.
  4. Beat the egg in the ferment.
  5. Add the beaten egg in flour and knead to smooth and soft dough.
  6. Knead in vanaspathi.
  7. Rest the dough for 40 minutes.
  8. Roll the dough to 1/8th of inch thickness and line the greased and dusted trays and dock with a fork.
  9. Pour the filling on it and scattered the grated cheese on it.
  10. Rest it for 15 to 20 minutes to have a good body to the pizza.
  11. Bake the pizzas at 450 F for 25 to 30 minutes.
  12. Serve hot.

PREPARATION OF KHAKRA *


Khakra is an Indian flat bread, like chapathi and is a popular traditional food in Western India, particularly Gujarat. Atta (whole wheat flour) is kneaded with water into chappathi dough consistency and rolled (flattened) to 1 to 1.5 mm thickness and 17 to 25 cm diameter. These are toasted on a hot pan (tawa), with frequent pressing of the khakra for uniform contact heating. Some of the commercially available khakra are masala khakra which is prepared by adding good amount of spices, bhoji khakra is prepared by incorporating green leafy vegetables, ghee khakra is prepared by adding ghee, sweet and plain khakra. The crisp texture and long storage life of khakra are two characteristics which make it a convenience food constituting one of the major items in lunch packs, breakfast foods, anytime snack or in food packs during travel. They are served accompanied by Sabji (cooked vegetables). Pickle and sweet or hot chutney or can be even dipped in tea or coffee and eaten. The price of khakra is also comparable to that of chappatis.

Ingredients

Wheat flour

100 g

Salt     

  3 g

Water

About 75 ml

 

 

Method

  1. To 100 g of wheat flour, 3 gm of salt and sufficient amount of water was added, to prepare a dough.
  2. Kneaded for 10 minutes to obtain a dough.
  3. The dough was portioned into 15 g balls. Each ball of dough was rolled into then chappati using a corrugated aluminium roller, which would prevented puffing of khakra during toasting. The khakra was rolled to a thickness of 1.25 mm and 15 cm diameter.

Khakra were toasted on tawa. The khakra was pressed and turned frequently with a cloth bundle (a thick cloth was folded into a 10 cm square of thickness 5-6 cm. The folded material was placed in another piece of cloth and made into a bundle, so that it was handy to use. This cloth bundle was used to press the khakra while toasting. The pressing process ensured even distribution of heat all over the khakra). The khakra was cook in five minutes. The temperature was 160. The prepared khakra was organoleptically evaluated.

PREPARATION OF HIGH FIBRE KHAKRA **

3. PREPARATION OF EXTRUDED PRODUCTS

Top

Extrusion is the process of cooking moistened starch food material by combination of heat, pressure and mechanical shear. The minor ingredients which may be added are edible groundnut flour, tapioca flour, soya flour, milk powder, casein, gluten vegetables and spices. Besides they may also be enriched with vitamins and minerals.

The manufacturing process for macaroni, spaghetti and vermicelli

Extruded products are made from suji or maida, with or without other ingredients, with cold or lukewarm water, kneading it and then extruding it through and extrusion press fitted with a die of the desired shape. The extruded product cut to a given length is then dried to definite moisture content under controlled conditions of temperature and humidity. The dried product is suitably packed depending on the market requirements.

Flow Chart

a. Plain Noodles  *

Maida

 1 kg

Egg

 4 Nos

Corn flour

 50 g

Water 

 required quantity

 

 

 

  • Beat egg lightly.
  • Sieve maida, make well in the centre, add beaten egg.
  • Knead to soft dough with required water and leave it for 15 minutes. Cover with a wet cloth to prevent drying.
  • Knead lightly and make lime size balls. Roll the ball as thin as possible.
  • Arrange the rolled dough one above the other. Lightly dust the circles with cornstarch while arranging.
  • Roll the circles into a narrow shape. Cut into thin strips of the desired size of noodles.
  • Shade dry and pack in polyethylene covers and store
Preparation

  • Boil 3 cups of water. Add 200 g of noodles and cook.
  • Drain and cool in running water.
  • Separate the noodles with the help of fork and use for noodle preparation
Pulses, Fruits, Vegetables and Mushroom Incorporated Noodles

Replace maida with 20 per cent pulse flour or millet flours or fruit pulp or vegetable puree to enrich the nutritive value. for example.

  • Maida + 20 Per cent carrot pulp
  • Maida + 20 Per cent beetroot pulp
  • Maida + 20 Per cent mint pulp
  • Maida + 20 Per cent pumpkin puree
  • Maida + 20 Per cent bengalgram flour
  • Maida + 20 Per cent soya flour
  • Maida + 20 Per cent mushroom flour

 

Noodle Masala Mix

Onion

 100 g

Garlic

 20 g

Ginger

 10 piece

Turmeric

 2 g

Green chillies 

 5 g

Salt                 

 5 g

 

 

 

 

  • Dry and grind all the ingredients together
  • Mix and sieve the powder
  • Add salt. 

a. PREPARATION OF NOODLES **

 PREPARATION OF HIGH FIBRE NOODLES  **

b. Macaroni products

Macaroni products also termed as pasta product, include macaroni, spaghetti, vermicelli and noodles. Macaroni is a formed hollow tubes, spaghetti is a small solid rods, vermicelli is a tiny rod and noodles are flat strips. Pasta products are also available in the shapes of shells and alphabets. Pasta products are made from coarser durum wheat except noodles are made from wheat flour. Other materials used are groundnut meal, soya flour and cassava flour. The preparation can be enriched by addition of vitamin and amino acids. 

c. DEVELOPMENT OF VERMICELLI  *

Method

Ingredients required

Maida flour

100 g

Salt

2 g

Water

35 ml

 

 

The maida flour was steamed for 5 minutes and conditioned by adding the required quantity of water and salt. The mixture was fed into the extruder by selecting the die (vermicelli). The dough was extruded. The extruded vermicelli were steam cooked for 5-10 minutes and dried at 60 for 6 hrs in a cabinet drier, cooled and packed in polyethylene pouches.

Special Technologies  
SRI-System of Rice Intensification
Precision Farming
GAP | GLP | GMP
  
 
 
 
 
 
 
 

d. DEVELOPMENT OF SPAGHETTI AND MACARONI

Method

spaghettiIngredients required

Maida flour

100 g

Salt

2 g

Water

35 ml

 

 

The maida flour was steamed for 5 minutes and conditioned by adding the required quantity of water and salt. The mixture was fed into the extruder by selecting the die (spaghetti and macaroni). The dough was extruded. The extruded spaghetti and macaroni were steam cooked for 5-10 minutes and dried at 60 for 6 hrs in a cabinet drier, cooled and packed in polyethylene pouches.

PREPARATION OF NUTRIENT ENRICHED EXTRUDED PRODUCTS **

Method

Ingredients

Wheat flour    

80 g

Defatted soya flour

20 g

Water            

32 ml

Salt                 

2 g

 

 

 

The wheat flour and defatted soya flour was mixed thoroughly. The flour was steamed for 5 minutes and conditioned by adding the required quantity of water and salt. The dough was prepared and extruded through an extrude. The noodles were steam cooked for 5-10 minutes and dried at 60 for 6 hours in a cabinet drier. The noodles were cooled and packed in polyethylene pouches.

PREPARATION OF EXTRUDED PRODUCTS UTILIZING COMPOSITE FLOUR MIX **

Preparation of noodles

Ingredients

Maida flour    

800 g

Mixed pulse flour

200 g

Salt                 

2 g/ 100 g

 

 

Mixed pulse flour

The ground pulse flour (Bengal gram, green gram and peas) were mixed in the proportion of 1:1:1 to prepare mixed pulse flour.

Method

  1. The maida flour was steamed separately for 10 min in the idli cooker.
  2. The mixed pulse flour was also steamed for 15 min in the idli cooker.
  3. Then the steamed flour was cooled and sieved again through the
    BS 60 sieve and mixed (maida + pulse flour + salt).
  4. The above prepared mix was put into an automatic extruder.
  5. Water was added (400 ml/kg) to the mix.
  6. The kneading was continued for 15-20 min and extruded into noodles (0.8 mm dia).
  7. The prepared noodles were steamed for 12 min in the idli cooker for partial gelatinisation.
  8. Then tempered at room temperature for overnight (10 hr) and dried in the cabinet direr at 50 for 2-4 hr.

SUITABILITY OF THE DEVELOPED EXTRUDED PRODUCTS FOR THE PREPARATION OF SAVOURY AND SWEET ITEMS

SAVOURY

1.  Uppuma

Ingredients needed

Extruded product      

100 g

Onion                         

  15 g

Green chillies            

4 nos.

Curry leaves               

Few

Mustard                      

½ tsp,

Bengal gram dhal       

½ tsp,

Black gram dhal         

1 tsp.

Salt                 

3 g

Oil                              

20 ml

Water                          

250 ml

 

 

 

 

 

 

Method: The oil was heated in a frying pan and the mustard was added and allowed to crack. Then the black gram and bengal gram dhal, onion, green chillies and curry leaves were added to it. When the onion turned to golden yellow colour, required amount of water was added and boiled. Extruded product and salt were added to the boiling water and stirred. Cooking was continued till the sample became soft.

2. Curd bath

Ingredients needed

Extruded product

100 g

Mustard          

2 g

Green chillies 

4 nos

Ginger            

2 g

Curry leaves   

2 g

Curd               

100 ml

Oil                  

10 ml

 

 

 

 

Method: Extruded product was steam cooked and kept aside. Green chillies and ginger were cut into pieces. Seasoning was done using oil, mustard, green chillies and curry leaves and mixed with the curd. The cooked sample was added to curd, mixed well and served.

3.  Tomato bath:  Ingredients needed

Extruded product

100 g

Tomato           

25 g

Green chillies

4 nos.

Curry leaves   

2 g

Onion            

20 g

Spices(clove, cardamom
and cinnamon)           

2 g

 

 

 

 

Method:  Sample was steam cooked and kept aside. To the heated oil the spices and finely chopped onion, green chillies, tomato and salt was added and continued cooking for 5 minutes. The cooked sample was added and mixed well.

4.  Lime bath: Ingredients needed

Sample           

100 g

Lime juice

25ml

Chopped onion

20 g

Red chillies

5 g

Chopped ginger

2 g

Bengal gram dhal

5 g

Mustard

2 g

Turmeric powder

2 g

Oil      

10 ml

Salt                   

To taste

 

 

 

 

 

 

Method:  Cooked sample was seasoned with mustard, bengal gram dhal and chillies. Lime juice, salt and turmeric powder were added and mixed well.

SWEET

   1.  Sweet product 

Ingredients needed

Sample           

100 g

Coconut scrapping

40 g

Sugar                

20 g

Ghee               

10 g

 

 

 

Method

The sample was steamed in the idli steaming vessel for 15 minutes.Before serving, ghee, coconut scraping and sugar were mixed with the steamed noodle.

Payasam

Ingredients needed

Sample           

100 g

Milk                

100 ml

Sugar              

50 ml

Cashew nut    

10 g

Raisin            

5 g

Powdered cardamom

2 g

 

 

 

 

Method:  Milk was boiled and sugar was added followed by slightly roasted sample was added to it and cooked well. Cashew and raisin (ghee) and powdered cardamom was added. Continued cooking for 5 minutes and served hot.

PREPARATION OF VERMICELLI WITH CARROT, AMARANTHUS, CURRY LEAVES AND MULLUMURUNKAI **

PREPARATION OF VERMICELLI WITH SPICES **

4. INSTANT MIXES *

Top

a. PROCESSING OF CAKE FROM THE FRUIT BASED EGG LESS INSTANT CAKE MIX

 

b. PREPARATION OF RAVA DOSA MIX  *

Dosa is a fermented product used in India. This is usually prepared from a fermented batter of rice and pulse in the proportions ranging from 6:1 to 10:1. Both the ingredients are finely ground, unlike the idli batter, which contains the rice component in a coarse consistency. The dosa batter is very thin and dosa is baked on a hot pan. A number of varieties of dosa can be prepared in hotels and uses.

Among those masal dosai, onion dosai and rava dosai are highly popular irrespective of all the age groups.

Rava dosas - South Indian breakfast tiffin item

 

Procedure

Preparation of rice flour

The parboiled rice – IR –20 was soaked in water for 5 hours. Then the water was drained completely and dried in solar drier for 5 hrs. The dried rice was ground in a mixie and sieved through BS 36 sieve.

Materials required

Rice flour, maida, semolina (white ravai), salt, cumin, citric acid, dehydrated green chillies.

Raw ingredients (g)

 

Maida

100

Semolina

100

Rice flour

100

Cumin

5

Dried and powdered green chillies

4

Salt

6

Broken pepper

2

Citric acid

0.05% (5 mg)

NaHCO3

0.2 % (20 mg)

Yeast

Nil

 

 

 

 

 

 

Method

All the ingredients were mixed thoroughly and packed in an airtight container for future use.

Preparation of rava dosa

For one part (measure) of instant rava dosa mix two part (measure) of water was added and mixed well. The prepared batter was allowed to stand for 30 min at room temperature before preparing dosa. The dosa tava was heated and oil / ghee was smeared it well. One cup of batter was spread on the tava and baked on both the sides by using low flame.

c. Bombay Halwa Mix  *

Ingredients

Maida flour      

80 g

Corn flour        

20 g

Kesari colour  

little.

 

 

Method

All the ingredients are dried in a cabinet drier at 80 for 2 hrs. Then it is cooled and all the ingredients are mixed thoroughly and packed in a polythene bag.

Preparation of Bombay halwa

For one measure of the mix (100 g), add two measures of water (200 ml), 2 measures of sugar (200 g) and mix well. Cook the mix after adding dalda (or) ghee (50 g) for 20 minutes by stirring continuously. At the end add the broken cashewnuts (5 g), and melon seeds (5 g). Pour into a greased plate, allow it to cool and cut into pieces.

Maida flour    

 1\2 kg

Corn flour      

 100 g

Milk powder  

 400 g

Powder sugar 

 1\2 kg

Cardamom powder

 5 g

Cashews         

 5 g

Red colours    

 1 pinch

Ghee               

 3 teaspoons

 

 

 

 

 

Method

Mix Maida and corn flour and sieve it thoroughly. Later add milk powder again seive it thoroughly. Add powdered cardamom and required food colour and mix it and store it in the cool air tight container.

Procedure

Whenever in need add water and Instant Halwa Mix in the ration of 1:1, pour it in the kadai  well stir when it thicken add ghee and cardamom,  stir well until ghee oozes out from halwa.

e. PREPARATION OF SWEETMEAT – BOLI  *

 

Technologies Available

*    - Post Harvest Technology Centre, TNAU, Coimbatore.

**  - Home Science College and Research Institute, TNAU, Madurai.

Source

  1. http://www.foodsubs.com/Photos/chapattiflour.jpg
  2. http://nutritionfoundationofindia.res.in/images/Nutrition/Image18.gif
  3. http://www.edme.co.uk/images/flakes_kibbles/malted_wheat_flakes_3.jpg
  4. http://www.wheatmontana.com/store/images/Wheat-Bran.jpg
  5. http://www.recipetips.com/kitchen/images/refimages/bread/types/Italian_bread_500.jpg
  6. http://cohensbakery.com/s/images/Hard%20roll.jpg
  7. http://141.214.84.74/~jeannie/archives/images/JollyPong_kernals.jpg
  8. http://photos.tradeholding.com/barrel_expanded_sweet_popcorn.jpg
  9. http://bp1.blogger.com/sandwich+loaf+2.jpg
  10. www.twosheep.com/blog/?p=451
  11. http://yummies.files.wordpress.com/2006/09/pork-bun.jpg
  12. http://www.hotbreads.net/images/mix_veg_puff.gif
  13. http://haacked.com/images/haacked_com/WindowsLiveWriter/IsPizzaBrainFood_770D/mmm-pizza_2.jpg
  14. http://farm1.static.flickr.com/97/221995664_1b596c071f.jpg
  15. http://www.latinonutrition.org/images/sponge_cake.gif
  16. http://www.meatlessmonday.com/images/content/pagebuilder/30380.jpg
  17. http://www.storminacupcake.com.au/Party_packs/Party_pack_pictures/Fruit%20Cake.jpg
  18. www.cookiemadness.net/?p=1846
  19. http://epicurious.blogs.com/features__editor/images/2007/07/11/krispy_kreme_glazed_doughnut.jpg
  20. http://sukhanipapad.com/images/khakra/big%20diabetes.jpg
  21. http://freethemes.ip.pt/images/shots/wallpaper/20030203-macaroni-wp-800x600.jpg
  22. http://www.foodprocessing-technology.com/projects/nong-shim/images/5-ramen-noodles.jpg
  23. blog.sideline.ca/2007/07/10/hiding-the-spaghetti/foodiememoirs.blogspot.com/
  24. http://blufiles.storage.msn.com/
  25. www.sailusfood.com/.../
  26. homespices.blogspot.com/2007/04/kashi-halwaku...