Primary Processing and Value Addition of Horticultural Crops

Primary Processing and Value Addition of Horticultural Crops Dr. R. T. Patil Ex-Director CIPHET & Chairman Benevole Welfare Society for Post Harvest Technology, Bhopal (MP)

Production & Post Harvest Scenario • Agriculture contributes about 15% of GDP, employs 57 % workforce and sustains approx over 65 % of the population • India produces about 265+million tons of food grains and more than 280+million tons of fruits and vegetables and ranks second in world • Low level of processing of fruits and vegetables and hence losses range from 6 - 18 %. • Food processing is employment intensive, creates 1. 8 jobs directly and 6. 4 indirectly for every Rs. 10 lakh investment

Value Addition due to Processing Tomatoes -Rs. 10/kg Fruit- Rs. 15 -20/kg Coriander -Rs. 80/kg Turmeric-Rs. 65/kg Chili- Rs. 200/kg Black pepper-Rs. 100/kg Vegetables-Rs. 10 -20/kg Onion Rs. 3 -10/kg Tomato ketchup-Rs 150/kg Fruits Bar-Rs. 200/kg Fruit Juice- Rs. 85/litre Jam –Rs 200/kg Fruit Chat - Rs. 250/kg Coriander Powder-Rs. 200/kg Turmeric Powder –Rs. 200/kg Chili Powder-Rs. 300/kg B Pepper Powder- Rs. 300/kg Minimal Processed/Ready to Cook -Rs. 100/kg Dehydrated Onion-Rs. 200/kg

Agro Processing in Production Catchment 1. Can provide processed food of highest quality at affordable cost to consumers 2. Help environment by processing food in production catchment with least food miles 3. Ensure traceability of raw materials used for processed product hence great for export and elite urban market. 4. Help effective backward linkage with farmers for processing their raw produce 5. Shorten the supply chain, increase the profitability of farmers and ultimately increase in GDP from agriculture and reduce poverty 6. Reduce post harvest losses and increased availability of by products for further processing.

Unit Operations in Post Harvest Management • • Harvesting at Proper Maturity Safe Harvesting Sorting/Grading Pre cooling and Washing Cool/Cold Storage Safe Handling/Packaging Safe Transport Value Addition

Harvesting at Maturity - Maturity of Mango in Tree • Eating quality and postharvest shelf life of ripe mango depends on its maturity at harvest • Change of peel color and total soluble solids (TSS) are indicative parameters to measure maturity of mango. • A maturity index was defined based on TSS and colour values. • The model was developed to predict maturity using colourimeter • Colour and maturity index chart were also developed to determine maturity • This technique can be employed to sort the mangoes at export, big mandies and in processing plant. Capacity About 100 mangoes per hour

Safe Harvesting Tools Strawberry Clipper

Fruit Saving Gadgets After plucking from tree, fruit is thrown in the trough of fruit saver and collected in a box/container. The fruits are graded on size basis at appropriate places. Smallest grade fruit is collected first and largest grade is collected in last

Banana-Comb (Hand) Cutter It is an useful to de-stem the comb from the banana bunch. It replaces the use of sickle, which was much labor and time consuming. It is safe for human and banana hands and can be used for faster work. 100 to 120 banana bunches can be de-handed per hour. Saves 10 to 15 banana-fingers per bunch (i. e. 2 to 8 % reduction in cutting losses of banana fruits)

CIPHET Tomato Grader • The tomatoes roll down the pipes due to gravity and fall immediately wherever they find the space of their diameter. • Grades 3: 25 -40 mm, 40 -55 mm, 5570 mm and > 70 mm • The collector is inclined at 10° so that the tomatoes slide directly in crates. • The important feature of grader is its ability to adjust the gap between the pipes and inclination of grading table and hopper. • It can also be used for other round fruits and vegetables. Capacity: of 325 kg/hr Overall grading efficiency: 66%. Cost: Rs. 25000. 00

Washing of Fruits & Vegetables

Pre cooling Pre Cooling is provided to fruits and vegetables before long term cold storage. Helps in increasing the efficiency and functional life of the products during long term cold storage. Increases shelf-life of produce/commodity In compliance with international quality standards Cost-effective

Evaporatively Cooled Room for Storage of Fruits and Vegetables • An evaporatively cooled (EC) room (3 x 3 x 3 m. size) was developed for on-farm storage of fruits and vegetables. • The summer temperature inside the EC room was 5 -8 C lower than that inside the ordinary room and winter temperature was 5 -8 C higher than that inside the ordinary room. Compared on the basis of 10% physiological loss in weight (PLW) the shelf life inside the room was 34 days for early kinnow, 23 days for late kinnow, 11 days for cauliflower and 4 days for spinach as compared to 21, 11, 5 and 2 days respectively in an ordinary room at the same time. The cost of the chamber is Rs. 75000 and capacity is 2 tonnes.

Evaporative Cooled Storage Structure • • Storage of fruits and vegetables Evaporatively Cooled Structure (ECS) maintains a moderate low temperature and sufficiently high relative humidity for short term storage of fresh fruits and vegetables. Advantages § Low level consumption of electricity § Less initial investment § Negligible maintenance cost Features – Special design of roof, orientation – Uses wetted pad as cooling medium – 20 o. C below the outside temperature – An ECS of about 5 -7 tonne storage capacity may cost about Rs. 1. 5 – 1. 8 lakh.

Walk in Cooler cum Freezer For Storage of Pulp and Puree Solar Walk In Cooler 12 V - 24 V DC operating voltage featuring shut-off at low voltage Dual Mode - Can work as Freezer and Refrigerator Eco-friendly cooling agent (R-134 a) Maintenance Free Brushless DC Compressor Adjustable interior temperature Very low energy requirement Highly-efficient cooling Low Maintenance Double gasket to keep long cooling Easy to installation

Primary Processing Protocols and Mechanisation

Aloe Vera Gel Extractor • Aloe vara gel should be extracted within 6 hours and processing must be completed within 36 hours. • An inner clear gel that contains 99% water and rest made of glucomannans, amino acids, lipids, sterols, vitamins etc. • The equipment capacity 200 -225 kg gel/h (900 -1000 leaves/h) for motorised and 100 kg gel/h (400 -450 leaves/h) for manual machine. • The extracted gel is clean and without any physical damage.

Heat Pump Dryer for High Value Products • Micro-processor based temperature controller to regulates the drying temperature. • Minimises the loss of vitamins and essential oil of the products and save energy in drying. • For blanched Amla drying, the dryer reduced vitamin-C loss up to 87% as compared to the open sun drying. • The products such as sliced fruits and vegetables is dried in 20 -25 h and medicinal herbs and leaf crops are 12 -20 h. • The cost of the prototype is Rs. 1, 50, 000 and capacity is 30 kg/batch.

Sitaphal Peeling Machine Removing the sitaphal seeds and pulp automatically without disturbing the pulp texture. Capacity: 120 Kg/hr, Efficiency: 94% pulp recovery, Coarse / Intact Pulp recovery: 70 -72%; Fine Pulp recovery: 28 -30%. The machine is licensed to NEXTGEN Drying System, Pune

Small Composite Unit for Tomato Puree and Fruit Pulp The machine has components like a cooker, grinder, mixture, processor and juicer. The machine is capable of processing around 200 kg of herbal products and fruits in an hour. Mr. Dharamvir Singh from Haryana has developed this machine to extract juice; residue is used for making candy, sweets and other items. He has employed 35 women for his business and also sells units of the machine. He even trains buyers on how to use it. He earns about Rs. 24 lakh per year from processed products and the machine is sold for 1. 50

CIPHET Process of Mechanical Dewatering and Drying • Process-The onions were washed, peeled and mechanically dewatered prior to drying with centrifugal juicer. • Partial mechanical dewatering resulted in as high as 60. 98 % less consumption in energy than conventional method besides getting high value products i. e. onion juice and onion powder. • The optimum combinations are 60% dewatering and 60 -70 C temperatures. • Onion juice was concentrated to 75% solids for increasing its shelf life. • Storage studies of onion powder showed that there has been no significant loss in quality even after 2 months storage at room temperature.

Fruit Pulping and Value Added Products

Tomato Crushing and Puree Making

Technology Packages

Minimal Processing of Vegetables

Onion and Vegetable Dehydration

Onion Storage For Processing

Garlic Processing Machines Garlic Bulb Breaker Capacity-800 kg/h Cost-INR 20000 Garlic Peeler Capacity-400 kg/h Cost-INR 20, 000 Garlic Flaking Machine Capacity-40 -50 kg/h Cost-INR 75000

Method to Prepare Dried Garlic Slices • • • The cloves are separated, peeled and sliced across the length. Slices of 3 mm thickness are dipped in 0. 5% sodium metabisulphite solution for 15 min at ambient temperature and dried to 6% moisture content (db) in a fluidized bed dryer at 600 C air temperature. Slices thus obtained should be immediately packed in airtight containers. Plant & machinery : Stainless Steel knives, Fluidised bed dryer, Work tables, Dipping tanks etc. , Manpower : 10 -15 kg raw garlic / person for 8 h, Investment: 2 lakhs approx. , Capacity: 10 -15 kg dried garlic slices / day.

Shrink Packaging of Fruits and Vegetables

Minimal Processing of Pomegranate Arils are treated with Chlorinated water for 5 minutes (Sodium hypochloride 100 ppm) + Antioxidant for 30 seconds (5% W/v Citric acid or Ascorbic Acid) and packed in 25 μ Semi permeable film and store at 5 ± 1ºC Maintains quality, colour and shelf life up to 16 days with good physical and microbiological conditions.

Mechanical Pomegranate Aril Extractor including Hand Tool Capacity 10 kg/h • Higher aril extraction capacity; around 5. 0 quintal per hour • Aril extraction/separation efficiency is in the range of 90 -94% • Mechanical damage received by arils is only 1 -2%

Moringa Processing

Powdering Technology for beetroot It is beneficial to the blood, the heart, and the digestive system. It has been regarded as a laxative; a cure for bad breath, coughs and headaches; and even as an aphrodisiac. More recently, it has been advocated as a cancer preventative and as a means of bolstering the immune system.

Conclusions • India produces variety of nutritious fruits and vegetables if processed has growing upper middle class market and also potential for export. • It can provide 2 direct and 6 indirect jobs with each 10 lakh invested. • Strengthening the primary processing and value addition at production catchment will increase the farmers income substantially while reducing the post harvest losses.

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