Major value added products from vegetable and by products management

Fundamenta of Processing of vegetable

1. Course – fundamental of processing of vegetables. Topic- major value added products from vegetables, utilized of by products of vegetables processing industry, management of waste from processing industries. Course code- VSC-504 Course credit- 2(1+1). Submitted To Submitted By Dr. Shishir Prakash Sharma Name – Dipika kaushik (Dept. of fruit science ) M.sc previous year vegetable science

2. VALUE ADDITION Definition It is the process of changing or transforming a products from its original state to a more valuable state. Value addition by changing their form color and other such methods to increase the shelf life of perishables.

3. Major value added products from vegetables Freezing of process vegetables and juices Suitable vegetables: Beans, cauliflower, peas, carrot etc. I. Beans Beans (mature) → Removal of strings (fibre) → Cutting into 2 cm pieces → Blanching for 5 min (Direct immersion, no cloth bag) →Arranging in carotene → Freezing by plate frozen (takes about 2 hrs to reach -1 to -5 ºc when product is considered to be frozen) → Storage at - 18 ºC. II. Carrot Carrot → Washing → Peeling of skin → Cutting into 2 cm pieces → Blanching for 3 min (no cloth bag) → Cooling → Packing in polythene bags → Sealing → Arranging in cartons → Freezing at –1 to –5o C → Storage → 18o C.

4. III. Peas Peas → Washing → Removal of shell → Washing → Blanching for 4 min → Cooling → Preliminary grading by density gradient using 10% brine ( Flaters → immature peas, sinkers → mature peas) → Further grading of mature peas, using 9%, 13% and 15% brine → Packing in polythene bags. Floaters 9% - A grade, 13% - B grade, 15% - C grade, → Sealing → Arranging in cartons → Freezing at – 1o C to – 5o C → Storage at – 18o C. IV. Cauliflower Cauliflower (mature) → Cutting into bits – Blanching for 2 min → Cooling → Dipping in 0.05% KMS solution for 5 min → Draining → Packing in polythene bags → Sealing → Arranging in cartons → Freezing at –1 to –5o C → Storage at –18o C

5. PREPARATION OF CHUTNEYS The preservation of food in common salt (or) in vinegar is known as pickling. It is one of the most ancient methods of preserving fruits and vegetables. Pickles are good appetizers and add to the palatability of a meal. They stimulate the flow of gastric juice and thus helps in digestion. Cucumber pickle ( Preservation with vinegar) Cucumber – 1.0 kg, salt – 200 g red chilli powder – 15 g, cardamom (large), cumin, black pepper (powdered) each – 10 g, cloves – 6 Nos., vinegar – 750 ml. Process Cucumbers → Washing → Peeling → Cutting into 5 cm round pieces → Mixing with salt → Filling in jar → Standing for 6-8 hrs → Draining off H2O → Adding spices and vinegar → Keeping in sun for a week → Storage.

6. Green chilli pickle :(Preservation with oil) Green chillies – 1 kg, salt – 150 gm mustard (ground) – 100 gm lime juice – 200 ml (or) amchur – 200 gm, fenugreek cardamom (large) turmeric, cumin (powdered) each – 15 gm, mustard oil – 400 ml. Process Green chillies → Washing →Drying → Making incision → Mixing all spices in a little lime juice → Mixing with chillies → Filling into jar → Adding lime juice and oil → Keeping in sun for a week – Storage.

7. Tomato pickle :( Preparation with mixture of salt, oil, spices and vinegar) Tomatoes – 1 kg, salt 75 g, garlic (chopped) – 10 g, ginger (chopped)- 50 g, red chilli powder, cumin, cardamom (large), cinnamom , turmeric, fenugreek – each – 10 g, cloves – 50 nos , asafoetida (powdered) – 2g, vinegar – 250 ml, oil – 300 ml. Process Tomatoes (ripe, firm and pulpy) → Washing → Blanching for 5 min → Cooling immediately in water → Peeling → Cutting into 4-6 pieces (or) mashing → Frying all ingredients in a little oil except vinegar → Mixing with pieces → Heating for 2 min → Cooling → Addition of vinegar and remaining oil → Filling in jar → Storage.

8. PREPARATION OF TOMATO PRODUCTS FLOW-SHEET FOR TOMATO PASTE

9. 2.TOMATO SAUCE / KETCHUP * It is made from strained tomato juice or pulp and spices, salt, sugar and vinegar, with or without onion and garlic, and contains not less than 12 per cent tomato solids and 25 per cent total solids .

10.   3.TOMATO CHUTNEY*

11. 4.TOMATO SOUP MIX** Preparation of tomato powder Fully ripe and firm tomatoes were washed well in running tap water. Then it was cut into small pieces and dried in the cabinet drier at 80oC for 10 hours. The dehydrated pieces were then ground into powder in a mixie . Preparation of tomato soup mix Ingredients Tomato powder   5.0 g Onion powder 0.5 g Corn flour         2.0 g Cumin powder   0.5 g Pepper powder   0.3 g Salt                    1.5 g Aginomotto      0.5 g. Method:   All the ingredients were mixed thoroughly and packed in polythene bags. Preparation of onion powder:   Disease free big onions were selected and the skin was peeled off. Then it was washed in the running tap water and cut into small pieces. It was dried in the cabinet drier at 60oC for 7 hrs. The dehydrated flakes were ground into powder and packed in polythene bags. Ten gram of the prepared tomato soup mix was added to 150 ml of boiled water and stirred thoroughly.

12. 5.DeHydrated Tomato

13. Cabbage (sauerkraut) Sauerkraut is a traditional vegetable product usually produced by spontaneous fermentation that relies on lactic acid bacteria (LAB) naturally present in white cabbage . 

14. Carrot (kanji)

15. Potato (chips)

16. Potato(French fry)

17. Management of waste products in vegetable processing industries

18. the three areas of waste management in vegetable‐processing operations: (1) waste generation; (2) waste management and treatment; and (3) value‐added utilization of vegetable wastes. Vegetable waste  Vegetable waste is a biodegradable material generated in large quantities, much of which is dumped on land to rot in the open, which not only emits a foul odor, but also creates a big nuisance by attracting birds, rats, and pigs—vectors of various diseases. • Vegetable wastes include the rotten, peels, shells, and scraped portions of vegetables or slurries .

19. Reasons of vegetable wastes Production exceeds demand. Premature harvesting. Strict quality standards of processing and marketing. Poor postharvest handling and storage infrastructure. Chemical abuse for shelflife extension of produce. Lack of processing facilities. Wide range of processed product.

20. Life cycle of waste generation from vegetables Extraction production distribution consumption Final disposal Primary production waste Industrial waste Municipal and industrial water Municipal waste Waste waste waste waste

21. Risks associated with vegetable wastes Water pollution Solid or liquid waste pollutes  aquatic life in rivers, lakes, and sea Soil pollution Solid pollution Undesirable changes in soil composition Air pollution Malodorous compounds in air  Unhygienic conditions  Unhygienic conditions Breeding of pathogenic microbes, flies, mosquitoes and rodents Unhealthy environment and spread of an epidemic  Aesthetics  Solid waste Loss of aesthetic value of an area

22. waste management plan and strategy the objective of any waste management plan and strategy should be twofold: (1) minimization of waste; and (2) selection of appropriate waste treatment and/or disposal strategies. The definition of waste minimization include three elements: (1) preventing and/or reducing the generation of waste at source; (2) improving the quality of the waste generated, such as reducing the hazard; and (3) encouraging reuse, recycling, and recovery.   Characterization of waste Flow measurement of waste Segregation of highly contaminated waste Reduction, Reuse and recycling Treatment and disposal of waste  Physically • Moisture • Weight • Temperature • Colour • Total solids • ash. Chemically • cellulose, • hemicellulose, • starch, • Reducing sugars, • protein, • Total organic components • BOD,COD, • pH, and toxic metal. Biologically • Presence of organism and pathogens.

23. Flow measurements of waste Determine the volume of solid and liquid waste generated daily and annually. Segregation of highly contaminated waste: This initial determination is important because the volume of wastewaters requiring treatment determines the size of the treatment plant. Reduce Minimize solid waste production. Recover Reclaim waste utilization to produce byproducts/coproducts (e.g., nonfermented and fermented products).   Existing Methods • composting, • landfill, • Incineration or combustion, gasification , pyrolysis and • Animal feed.

24. Animal feeding   • Vegetable processing, packing, distribution and consumption generate a huge quantity of waste that is usually disposed of either by composting or dumping into landfills/rivers, causing environmental pollution. • Such resources can act as an excellent source of nutrients due to enrichment of functional compounds, such as polyphenolics, carotenoids and dietary fibre . • This has potential to be used in the production of animal feeds especially for cattle and dairy cows, and processing the waste into silage.

25.   Landfilling Landfill is the most economical, though not always environmentally safe, way of disposal where the waste is buried into the earth. In landfills, main macronutrients present in organic matter are hydrolyzed to soluble products and finally to biogas through methanogenesis. Application: production of electricity, hot water, and steam as an energy source Disadvantages • Traditional landfills were not managed in a scientific way. • Landfill gases pollute the air and cause greenhouse effect, • Leachate contaminates the ground water .

26.   Gasification The gasification process breaks down the hydrocarbons left into a syngas using a controlled amount of oxygen at elevated temperatures 700°C. The gasification process occurs as the char reacts with carbon dioxide and steam to produce carbon monoxide and hydrogen. • Syngas may be burnt directly for heating and/or electricity production or may be further converted to act as a substitute for almost any fossil fuel.   Advantages • Gasification in conjunction with gas engines obtains higher conversion efficiency than conventional fossil- fuel energy generation. • Disadvantages High temperatures required to break down any waste containing carbon. • Not economically attractive.

27.   Composting Composting is an old and inexpensive method that converts organic waste into useful compost that can be used as a soil conditioner and organic fertilizer. • It is an exothermic biodegradation process that involves a complex web of bio- chemical reactions in which facultative and aerobic micro- organisms catabolize substrates to produce carbon dioxide (CO2) and heat, and finally transformed into stable composts. Anaerobic Digestion Since the all stages of anaerobic digestion are controlled by bacteria, the product form varies with the type of bacterial population. Increased reaction rates Less capital cost as a result of smaller digester size Highly efficient technologies for anaerobic digestion of FVW High stability, a high depuration rate and energy recovery with a good process economy Significant biogas productivity and better effluent quality from fruit and vegetable wastes anaerobic digestion . Rapid acidification of fruit and vegetable wastes decreasing the pH in the reactor Larger volatile fatty acids production (VFA), which Stress and inhibit the activity of methanogenic bacteria. Depression of the overall performance of the reactor by increasing the feed concentration

28. Biodiesel production By transesterification of vegetable oils with simple alcohols either using a catalyst or without it. • By the fermentation of carbohydrate plants (sugar or starch based vegetable waste such as sugarbeet or potato peel ). • Reaction temperature, alcohol to oil ratio, mixing speed, and purity of reactants are the other parameters which influence biodiesel production.   Conversion of waste palm oil by transesterification to produce ethyl esters gives a product comparable to applying the process to neat VOs with properties comparable to those of the local diesel fuel. Emission of less pollutants by biodiesel production. Deterioration of biodiesel combustion performance at the higher energy input due to its high viscosity, density and low volatility

29. Vermicomposting Vermicomposting technology, the bioconversion of organic waste into a biofertilizer through earthworm activity, is globally becoming a popular solid waste management technique. • The earthworms feed on the vegetable waste and their gut acts as a bioreactor whereby the vermicasts are produced. Vermicomposting Advantages: • Rapid and Economical • Environment friendly • End product is disinfected and detoxified .

30. Reference Srivastava R. P. Fruit and vegetable preservation principles and practices. Third edition CBC publication 2002. E-reference https://www.researchgate.net https://www.agritech.tnau.ac.in

31. PREVIOUS YEAR QUESTIONS Raw materials for Tomato processing ? Discus in detail the raw materials required for processing ? Described in detail the effective management of wastes from processing plant ? Explain the procedure for making tomato sauce along with flow sheet ?

32. Thankyou