Heat Exchangers and Coffee Processing: Key Technologies in the Food Industry

www.pmg.engineering Vol .02-Issue .22-June 2023 TECH-KNOWLEDGE The Official PMG Engineering Newsletter FOOD & BEVERAGE INDUSTRY ENGINEERING & DESIGN SCIENCE & TECHNOLOGY A PMG DESIGN+BUILD FOOD FACTORIES. ONE STOP ENGINEERING SOLUTION Vol .02-Issue .22-June 2023 CONTENTS 1. WHITE PAPER A. Heat Exchangers B. Insight to coffee processing 2. INDUSTRY BUZZ Latest Food Industry News Updates 3. WEEKS HIGHLIGHT A Look Into The Main Events Of The Week 2-6 7-8 9-10 4. DID YOU KNOW? Fascinating Food Facts To Expand Knowledge 11-14 PMG DESIGN+BUILD FOOD FACTORIES. ONE STOP ENGINEERING SOLUTION Vol .02-Issue .22-June 2023 HEAT EXCHANGERS Introduction Heat Exchanger may be defined as a process equipment which works on principle of Second Law of Thermodynamics i.e.it transfers the energy from a hot fluid to cold fluid with maximum rate and minimum investment and running cost. Working the temperature of In heat exchangers, the temperature of each fluid changes as it passes through the exchangers and hence the dividing wall between the fluids also changes along the length of the exchangers. For the heat transfer to occur two fluids must be at different temperatures and thermal contact must be present between them. Heat Exchangers involve convection in each fluid and conduction through the separating wall. Classification In order to meet widely varying applications, types of heat exchangers have been several developed which are classified on the basis of nature of heat exchange process, relative direction of fluid motion and design and constructional features. 1. On the basis of Nature of Heat Exchange Process 1.1 Direct contact Heat Exchangers In this type of heat exchanger the exchange of heat takes place by direct mixing of hot and cold fluids and transfer of heat and mass takes place simultaneously. It is used in condition where mixing of two fluids is either harmless or desirable. e.g Direct Steam Injection 1.2 Indirect Contact Heat Exchangers In this type of heat exchanger, heat transfer between through wall which separates the two fluids. E.g. Regenerators and Recuperators. fluids accurs 2. On the basis of Heat Exchanger’s Flow Arrangement 2.1 Parallel-Flow In parallel-flow heat exchangers, the hot and cold fluids enter the heat exchanger from the same end and flow parallel to each other. 2.2 Countercurrent-Flow In countercurrent-flow heat exchangers, the hot and cold fluids enter the heat exchanger from opposite sides and flow toward each other. 2.3 Cross-Flow In cross-flow heat exchangers, the hot and cold fluids enter the heat exchanger at different points and as they travel through the heat exchanger they cross paths with each other, often at right angles. READ MORE.... PMG DESIGN+BUILD FOOD FACTORIES. ONE STOP ENGINEERING SOLUTION Vol .02-Issue .22-June 2023 3. On basis of Design and Construction PLATE HEAT EXCHANGER 3.1 Tubular Heat Exchanger It is the most common type of heat exchanger used for heat transfer. It consists of series of tubes containing fluid which is required to be heated or cooled and are enclosed inside the cylindrical shell. In this one of the fluids is usually passed through pipes or tubes, and the other fluid is passed round or across these. Local temperature differences and the heat transfer coefficients are the main parameters in this heat that control the heat transfer exchanger. The fluids can be single or two phase and can in a parallel or a cross/counter flow arrangement. Shell and tube heat exchangers are typically used for high pressure applications (with pressure greater than 30 bar and temperature greater than 260 °Celsius) owing to its robustness. flow It consists of four major parts: Front End: this where the fluid enters the tubeside of the exchanger Rear End: This where the tubeside fluid leaves the exchanger or where it is returned to the in exchangers with multiple front header tubeside passes. Tube Bundle: this comprises of the tubes, tube sheets, baffles and tie rods etc, to hold the bundle together. industry for operating 3.2 Plate Heat Exchangers This is the popular type of heat exchanger having widespread applications in food and low viscous beverage food. A plate exchanger consists of a series of parallel plates that are placed one above the other so as to allow the formation of channels for allowing fluids to flow between them.The size of a plate can range from a few square centimeters (100 mm x 300 mm side) up to 2 or 3 square meters (1000 mm x 2500 mm side). The number of plates in a single exchanger ranges from just ten to several hundred. The most frequently used materials for the plates are stainless steel (AISI 304, 316), Just like Shell its plates are also and Tube Heat Exchangers corrugated for increasing surface area in order to increase provides mechanical rigidity. Corrugation is achieved by cold forging of sheet metal with thicknesses of 0.3mm to 1 mm.The main advantage of this Heat Exchanger is that its dismantling is easy and quick. turbulence which the 3.3 Scraped Surface Heat Exchangers This is the kind of heat exchanger which consists of an internal cylinder within a jacketed cylinder in an concentric manner and is fitted with scraping blades (or shafts). Continuous scraping of the surface with the help of steel blades avoids fouling, provides a longer running time and sustainable heat transfer rate during the process. This type of heat exchanger is mainly used for processes such as freezing, gelatinization, Khoa Preparation and cooling of high viscosity products jams such as .Scraped surface exchangers can also be used to process to mechanical stress. Coefficients of heat transfer vary with speeds of rotation and with heated fluid characteristics, and are quite high, in the order of 900-4000 J m-2 s-1 °C-1. ice creams, chocolate, yoghurt, to heat and/or sterilization, sensitive foods Nature of process, process temperature, type of fluid, fluid velocity, fluid viscosity, etc are some of the performance factors which we need to keep in mind while selecting and designing of Heat Exchangers. Moreover, the material of construction must be corrosion resistant as well as it must prevent the accumulation of solids leading to Fouling. Fouling is the most common issue of Heat Exchangers which if not controlled may lead to the serious problems like failure of process operation and food safety programmes. Therefore Heat Exchangers must be selected in such a way that it provides best heat transfer efficiency by reducing problem of fouling, pressure drop and heat leakage. PMG DESIGN+BUILD FOOD FACTORIES. ONE STOP ENGINEERING SOLUTION Vol .02-Issue .22-June 2023 INSIGHT TO COFFEE PROCESSING Introduction Coffee scientifically known as Coffea sp. is an elite plantation crop , famously known for its use in specialty beverages. Be it a hot cappuccino , latte or some cold brew or Frappuccino , Coffee beverages are loved in all forms. Coffee as we all know is mainly used for its stimulating effect due to its caffeine content. It can also be used as an analgesic and as memory enhancer. Several useful bioactive components , trigonelline and nicotinic acid are also present in coffee that make it beneficial to health. like chlorogenic acid Majority of the coffee consumers know that coffee is a bean which is grinded and then added to a wet ingredient like milk or water to prepare a coffee beverage. But what about knowing ; how coffee plant is cultivated and harvested ? what types and grades of coffee exist? What type of processing methods are used? In this article , we will give you an insight on coffee processing about how a small brown bean turns into your refreshing cup of hot and cold beverage. Botany of coffee plant The coffee plant is a shrub belonging to the Family- Rubiaceae, which hosts dark green lanceolate leaves. The coffee shrub bears small ,white flowers that are fragrant in nature. This shrub also gives rise to. This shrub grows in high tropical altitudes of 600 – 1200 m with an annual average temperature of 15–25°C and moderate moisture and cloudiness. The shrub hosts the coffee fruit known as “cherry” which range from a green to red color indicating the ripeness of the fruit.. This fruit contains our known coffee beans. The commercial species of coffee are Coffea arabica (Arabica) and Coffea canephora (Robusta). There are several Coffea arabica varieties like Bourbon, Typica, Caturra, Mundo Novo, Tico, San Ramon, Jamaican Blue Mountain. Coffea canephora variety is Robusta. Anatomy of coffee cherry The coffee cherry consists of layers. The outer skin layer is called the exocarp. The middle thin layer of pulp is the mesocarp, followed by a slimy layer called the parenchyma. The coffee beans inside the cherry are covered in a paper-like envelope named the endocarp, more commonly referred to as the parchment. The Bean consists of two elliptical hemispheres with flattened adjacent sides which are each covered by seed skin called spermoderm , generally called as silver skin in the trade world of coffee. READ MORE.... PMG DESIGN+BUILD FOOD FACTORIES. ONE STOP ENGINEERING SOLUTION Vol .02-Issue .22-June 2023 Coffee Harvesting Processing of coffee In general, coffee species are harvested during November to December in case of Arabica species and from January to February for Robusta. The harvesting of coffee is done when the coffee cherries are bright red all over. The cherries are usually picked using different types of picking methods by hand – Fly picking , Main picking , Stripping, or cleanings. :Done as thefirst picking ·Fly picking in the season. Selective picking of ripe berries is done and continued till February. ·Main picking: Well-formed and fully ripened berries are harvested 4 to 6 times at 10 – 15-day interval from Dec. Bulk yields are obtained during this period. ·Stripping : During the Final harvest , this type of picking is done where berries left on the plant are hand-picked irrespective of referring stage. ·Cleanings collection of all the dropped berries are collected. : This type of picking consists of After harvesting, the coffee is processed mainly in two ways, either wet processing or by dry processing. Wet processing: This type of processing of coffee yields parchment coffee and this methodinvolves pulping , demucilaging and washing , drying of coffee beans. Here , the coffee cherry is squeezed in a pulping machine to remove the outer fleshy layer and obtain just the bean. This bean with mucilage is fermented and then washed and dried either by sun/tray drying which may take up to 1-2 days. There may be a risk of contamination due to over fermentation of the beans which may degrade quality of the bean. Dry processing: In this type of processing, the coffee cherries are immediately dried after harvesting by sun drying/solar artificial driers. It takes about 12-15 days under bright sun for the cherry to dry completely. The dried cherry is now hulled to separate the bean and then winnowed. is comparatively better than wet This method processing as is environment friendly even though it is time taking. If proper drying of the cherries is done, then high-quality beans with exclusive flavor and aroma can be obtained. it Roasting The beans obtained either by wet/dry processing now undergo a process called roasting. Roasting is an important procedure in coffee processing as it determines the color and flavour of the coffee bean. PMG DESIGN+BUILD FOOD FACTORIES. ONE STOP ENGINEERING SOLUTION Vol .01 Newsletter READ MORE.... Vol .02-Issue .22-June 2023 Usually a typical roasting process takes place by drum/hot air roasting at about 200 degrees Celsius for 15-20 minutes based on requirements. The roasting causes an increase in volume of bean , changes the colour of bean from green to brown and makes the bean brittle. Typically, there are four types of roasts of coffee. They are light , medium ,medium-dark, and dark roast. Type of roast Color and Flavor Bean Surface Light Light brown and mild Non-oily Medium Medium brown and strong Non-oily Medium- dark Rich dark brown with slightly bitter aftertaste Barely oily Dark Dark Brown Black with pronounced bitterness Very Oily Grading, Sorting & Packaging sorted and After roasting , grinding of roasted beans is done in rolling mills for obtaining a ground texture of coffee. Usually an 8-10-hour grinding is required for ground coffee. Arabica and Robusta beans are classified as washed primarily (parchment unwashed plantation) (natural).They are further classified into 25 grades based on the size of beans and the number of imperfections. are Arabica Plantation A, Arabica Cherry AB, Robusta Parchment AB and Robusta Cherry AB. The major types of grades are : Superior grades and or •Grade 1: Specialty Grade: no primary defects, 0‐3 full defects, sorted with a maximum of 5% above and 5% below specified screen size or range of screen size, and exhibiting a distinct attribute in one or more of the following areas: taste, acidity, body, or aroma. Zero quakers allowed. Moisture content between 9‐13%. •Grade 2: Premium Grade: Same as Grade 1 except maximum of 3 quakers. 0‐8 full defects. •Grade 3: Exchange Grade: 50% above screen 15 and less than 5% below screen 15. Max of 5 quakers. Must be full defects. •Grade 4: Standard Grade: 24‐86 full defects. •Grade 5: Off Grade: More than 86 full defects. faults. 9‐23 from free After gradingthe beans as whole or after grinding are packed in glass jars (for ground powder) , jute bags/sacks ( beans ) , paper bags ( for both beans and powder form). PMG DESIGN+BUILD FOOD FACTORIES. ONE STOP ENGINEERING SOLUTION Vol .01 Newsletter FOOD INDUSTRY INDUSTRY BUZZ Indian delegation attends Codex Committee on Food Labeling's 47th session. Symega is named the Most Innovative Plant-Based Food Company at the second Plant-Based Food Summit. The Food Safety and Standards Authority of India (FSSAI) sent a delegation from India to the 47th session of the Codex Committee on Food Labelling held in Gatineau (Ottawa), Quebec, Canada, from May 15 to 19, 2023. The team was led by Dr. Harinder Singh Oberoi, Advisor (Science & Standards, Codex), FSSAI. and non-governmental in several debates at the The delegation took part international conference, which was attended by delegates from 59 nations and members of 23 global government organizations, including the WHO and FAO. Standards for food labeling requirements, the application of new technologies in labeling, labeling for e- commerce were among the topics covered at the session. In two E-working groups labeling for E- commerce and the use of new technology in labeling, India has also been appointed co-chair. labeling food allergies, and (EWGs) on Symega Food Ingredients was recently honored as the "Most Innovative Plant-Based Food Company" at the Plant-Based Foods Industry Association's 2nd Plant-Based Foods Summit. The Ministry of Food Processing Industries, the Agricultural and Processed Food Products Export Development Authority (APEDA), and the Indian Chamber of Commerce all assisted with the event. The award was given to Symega in honor of the company's unwavering dedication to innovation, sustainability, and quality in producing plant-based foods. A varied selection of cutting-edge plant-based solutions that not only help brands satisfy the changing demands of conscientious customers but also deliver great taste and nutritional value have been developed by Symega's committed team of experts. PMG DESIGN+BUILD FOOD FACTORIES. ONE STOP ENGINEERING SOLUTION Aashirvaad Atta with Multigrains and PFNDAI put light on Indians' digestive health. Mr. Milkman partners with DMS to streamline and automate supply chain operations 2022 REVENUE GROWTH FOR CARGILL OF 23% TO $165 BILLION The Protein Foods & Nutrition Development Association of India (PFNDAI) and ITC's Aashirvaad Atta with Multigrains emphasized the fact that a substantial portion of Indians doesn't get enough fiber each day. These results align with the annual World Digestive Health Day on May 29. The research reveals that a startling 69%+ of Indians consume less fiber than their recommended daily intake (RDA) among the 69,000+ participants in Aashirvaad Atta with Multigrains' Fibre Metre Test on the website Happy Tummy. Dietary fiber is crucial because it promotes regular bowel movements, helps maintain normal digestion, and keeps you fuller for longer. With the launch of their cutting-edge and all-encompassing platform, Distribution Management Solution (DMS), Mr. Milkman, leading SaaS platform, which provides dairies and milk brands with customer subscriptions and deliveries, forays into the B2B ecosystem for agriculture, food, and beverage product categories. India's industries, The system intends to modernize supply chain operations across all including the food, beverage, and agricultural sectors and the dairy sector. By automating fulfillment creation, demand optimization, DMS reduce waste and inefficiencies. tracking, intended order and to is World Food India 2023: First Inter- Ministerial Committee Meeting The First Inter-Ministerial Committee Meeting comprising top members from Ministries, Departments, and Boards was recently presided over by Anita Praveen, Secretary of Food Processing Industries. The purpose of the committee meeting was to discuss the participation of the various Ministries, Departments, and Organisations in the event and to inform the officials of the preparations that have been taken so far for World Food India 2023. This was another in a series of conversations to identify new cooperation areas and inform the public on the Ministry's strategy for the upcoming World Food India 2023. Senior officials from important central government departments and ministries participated in the roundtable. In her speech, Praveen asked the authorities to outline a clear plan of action for their involvement in or engagement with the Mega Food Event, which will take place in New Delhi from November 3–5, 2023. PMG DESIGN+BUILD FOOD FACTORIES. ONE STOP ENGINEERING SOLUTION N O N - T E C H N I C A L C O N T E N T WEEKS HIGHLIGHT 26 MAY HEAT AWARENESS DAY On May 26, the Government Declared National Heat Awareness Day to "urge employers and workers to notice the warning symptoms of heat illnesses and keep workers safe." 30 MAY NATIONAL CREATIVITY DAY National Creativity Day was established on May 30th of each year. This event serves as a reminder that we are all creative people, and it attempts to inspire people to utilize their creativity to make the world a better, or at the very least, more fascinating place. DESIGN+BUILD FOOD FACTORIES. ONE STOP ENGINEERING SOLUTION E N U J PMG 31 MAY NO TOBACCO DAY Every year on May 31, World No Tobacco Day (WNTD) is observed to raise awareness about the harmful effects of tobacco use on one's health and the World Health other Organization (WHO) declared World Tobacco Day. In 1987, issues. N O N - T E C H N I C A L C O N T E N T 1 JUNE WORLD MILK DAY World Milk Day, celebrated on June 1, provides an opportunity to focus attention on milk and raise in healthy diets, awareness of dairy's part supporting responsible livelihoods and communities. food production, and E N U J PMG DESIGN+BUILD FOOD FACTORIES. ONE STOP ENGINEERING SOLUTION DID YOU KNOW? T E C H N I C A L C O N T E N T 1/5 2/5 3/5 4/5 E N U J PMG DESIGN+BUILD FOOD FACTORIES. ONE STOP ENGINEERING SOLUTION Vol .01 Newsletter Fact 1 Smoking in meat production is the process of exposing meat to smoke from burning wood or other materials, to add flavor and preserve the meat. Though, Smoked foods must be eaten sparingly as smoked, cured, and salted meats are seen as stomach cancer risk. 5/5 T E C H N I C A L C O N T E N T 1/2 2/2 Fact 2 Frozen mushrooms are a type of frozen food product that consists of mushrooms that have been picked, cleaned, and frozen to preserve their freshness. They offer the benefit of extended shelf life and can be a valuable ingredient to have on hand in any season. DESIGN+BUILD FOOD FACTORIES. ONE STOP ENGINEERING SOLUTION Vol .01 Newsletter E N U J PMG T E C H N I C A L C O N T E N T 1/5 2/5 3/5 4/5 E N U J PMG DESIGN+BUILD FOOD FACTORIES. ONE STOP ENGINEERING SOLUTION Vol .01 Newsletter Fact 3 Frozen meat-based ready meals are pre-prepared meals that are frozen and can be heated and eaten at home. These meals are usually made with meat as the main ingredient, such as beef, chicken, pork, or fish. They are a good option for people who are looking for a quick and easy meal that is also tasty and filling. 5/5 T E C H N I C A L C O N T E N T E N U J PMG DESIGN+BUILD FOOD FACTORIES. 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