Overcoming Challenges in Fruit & Vegetable Processing with Microfiltration

www.pmg.engineering Vol .02-Issue .31-August 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 .31-August 2023 CONTENTS 1. WHITE PAPER A. Preventive measures in F&V industry B. Microfiltration 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 4. DID YOU KNOW? Fascinating Food Facts To Expand Knowledge 10-12 PMG DESIGN+BUILD FOOD FACTORIES. ONE STOP ENGINEERING SOLUTION Vol .02-Issue .31-August 2023 PREVENTIVE MEASURES IN F&V INDUSTRY Introduction In developing countries agriculture is the mainstay of the economy. There should be no surprise that agricultural industries and related activities can account for a considerable proportion of their output. Of various types of activities that can be termed as agriculture based, fruits and vegetable processing are among the most important. Fruits and vegetables, which are among the perishable commodities, are important ingredient in human diet. Due to their high nutritive value, they make significant nutritional contribution to human well- being. They are cheaper and better source of protective foods. These contain non-nutritive secondary metabolites known as phytochemicals that have disease-fighting properties. Some of these phytochemicals are polyphenols, pigments (e.g., carotenoids) and glucosinolates. Fruit and vegetable production and processing involve a complex supply chain from the farm to fork. From many points of view, it is of great importance to strengthen each link in the chain and improve the integration of the supply chain if high quality and safety of produce must be maintained. International trade of fresh fruits and vegetables is a billion-dollar business that has significantly increased in the last decade. This trade is important also from a safety viewpoint, and involves (primary) producers, manufacturers, distributors, and retailers who place a great deal for marketing of value on naturally delicious and nutritious products. reputation their is fruits and vegetables starts with Safety of agriculture and primary production. One major factor leading to food contamination during food preparation and storage time–temperature abuse, which results in the survival, growth, and In recent production of toxins by pathogens. decades, microbial safety has become a concern and a series of large foodborne outbreaks has occurred around the world. The situation is more alarming due to several population explosion, urbanization and changes in lifestyle, consumption of, so-called, minimal processed ready-to-eat foods, international trade in food and animal feed, international tourism and immigration, and a short supply of potable drinking water. A.Types of Hazards prions, viruses, foodborne protozoans interaction. 1. Biological hazards: include pathogenic fungi, bacteria, and helminthic parasites, namely certain trematodes. illness due to These could cause Pathogens most pathogen–host associated with fruits and vegetables include Salmonella, Shigella, Escherichia coli O157:H7, Listeria, Campylobacter, Cryptosporidia, viruses such as Hepatitis A and parasites such as Entomoeba histolytica, Giardia lamblia, Cyclospora cayetanensis, Cryptosporidium parvum, Toxoplasma gondii, and certain trematodes. READ MORE.... PMG DESIGN+BUILD FOOD FACTORIES. ONE STOP ENGINEERING SOLUTION Vol .02-Issue .31-August 2023 PLATE HEAT EXCHANGER There are certain sources/factors that contribute to the microbiological contamination of these products with pathogens, all of which must be controlled. Contamination can arise because of treating soil with untreated manure and sewage sludge, untreated effluent water released from meat industry and from the irrigation water. Additionally, handling and application of technologies such as cutting, slicing, skinning, and shredding (in the case of minimally processed fruits and vegetables) will remove the natural protective barriers of the intact plant and open the possibility for providing a suitable medium for the growth of contaminating microorganisms. The numbers of bacteria present in fruits and vegetables will vary depending on seasonal and climatic. Shredding and slicing were found to increase counts of mesophilic bacteria. B. Control Measures 1. Adoption of Good Agricultural Practices at Primary Producing Stage Soil can contain harmful microbes that can contaminate crops. Soil can be tested before each planting and remediation completed if it contains harmful microbes called pathogens. Contaminated water is one of the most common sources of microbial contamination of crops. Before selecting a field location, growers should examine upstream uses of irrigation water that could lead to contamination. They should also select an area that’s free from flooding or run-off. insect fragments, etc.); 2. Physical Hazards: Physical hazards are commonly called “foreign materials” or “foreign bodies” because their presence in food is unnatural. They include unwanted t field matter (stones, wood, metal, pieces of bone, inadvertent processing residues (glass, metal fragments, pieces of plastic, personal objects, etc.); unintentional materials (employee sabotage) and miscellaneous particulates and (pits, fragments or stones, stems). These may enter foods at almost any point of the food supply. Some foreign matters may not act as a hazard but their finding in food may be indicative of poor hygienic practice and a distressing event for consumers. itself food in potatoes) 3. Chemical Hazard: Chemical hazards may appear in food products either by natural occurrence (e.g. in certain mushrooms, naturally occurring toxin solanine in a raw material or by deliberate or unintentional addition during primary production and/or processing. They could result from several sources: the environment such as heavy metals or radionuclides; agricultural chemicals such as fungicides; packaging materials; cleaning/sanitizing agents; certain toxins; and misuse of food chemicals. insecticides, to is not uncommon It is generally recommended not to irrigate crops for two to seven days before harvest. If water used for irrigation was contaminated, this gap without water provides adequate time for any present harmful pathogens to likely die before the crop is harvested. for manure and other It biosolids to contain harmful pathogenic microbes if it is not treated before use. Raw manure should be stored in a separate area from crops and with protection cross- contamination from occurring. If manure is used as a natural fertilizer on a field crop, it is best practice to wait 120 days before harvesting the produce. In conclusion, site selection and layout planning are critical steps that can significantly impact the success of a food industry business. Careful consideration of these factors will help you create an efficient, safe, and profitable operation. Consulting with experts in food industry design and seeking professional advice can also be beneficial in making informed decisions. accidental prevent PMG DESIGN+BUILD FOOD FACTORIES. ONE STOP ENGINEERING SOLUTION READ MORE.... Vol .02-Issue .31-August 2023 PLATE HEAT EXCHANGER 2. Adoption of Good Manufacturing/ Production Practices at processing Stage Loading docks should be kept clean and free of grass, dirt or outside debris. When not in use, loading docks should be closed and locked to ensure outside pests or traffic cannot enter the processing facility. Any food contact surface should be cleaned and sanitized regularly to prevent cross-contamination or spreading of microbial contamination. This includes counters where food is prepared and tools such as knives and machines used for processing produce. Gloves should be worn when handling produce, and employees should practice good personal hygiene. Restrooms and employee break rooms in a separate area from anywhere should be produce is processed. After blanching produce, it should be frozen rapidly. Reducing the temperature of the product quickly will prevent it from further cooking and help ensure the continued freshness of the product while also slowing the activity of any microbes that might be present. Another effective technique for stopping enzyme activity is by addition of ascorbic acid, commonly known as vitamin C, to prevent any further chemical deterioration. in frozen produce Knowledge of the nature of fruits and as they relate to pre and post-harvest handling, processing, packaging and storage are essential for ensuring their wholesomeness and nutritional value, and for developing the most effective procedures and innovative technologies for maintaining their quality and safety. it is important to visually check While the cleanliness of food contact surfaces, harmful bacterial pathogens are microscopic and cannot be seen with the naked eye. That is why regular testing for microbes on food contact surfaces is essential to identify and minimize any areas of contamination. Good Manufacturing Practices (GMP) and Hazard Analysis and Critical Control Points (HACCP) are essential and effective measures for identifying and controlling risks during produce processing. is an Creating a written preventative plan essential step for food manufacturing safety. Blanching is the process of quickly and briefly boiling or steaming vegetables or fruit. Blanching is an effective method to inactivate enzymes and damage microbes before freezing which can limit deterioration of the produce. PMG DESIGN+BUILD FOOD FACTORIES. ONE STOP ENGINEERING SOLUTION Vol .02-Issue .31-August 2023 MICROFILTRATION Introduction The driving force of the separation process is, for example, differences in concentration or pressure between the two sides of the membrane. industry The use of membrane technology as a handling and is gaining in food separation method importance day-by-day. Membrane separations can be used as a substitute to conventional techniques especially in dairy, sugar, fruits juice processing, and beverage industries. In many cases, membrane processes are more advantageous than traditional technologies and can be considered as green technologies as it does not causes environmental hazards, Using membrane filtration to remove microorganisms for shelf-life extension of foods instead of using additives and preservatives also create a green image for the processed foods as well as for the processing procedure. For example, using cold pasteurization and sterilization with suitable membranes instead of high temperature treatment for the removal of microorganisms is more economical in terms of energy consumption, quality of products, minimize loss of nutritional value. Principle components Membrane separation is a process of separating food semipermeable membranes, based on the molecular size and molecular weight of the components. using by The different membrane processing methods are as follows. Reverse osmosis (RO): Concentration of solution by removal of water Nanofiltration (NF): Concentration of organic components by removal of part of monovalent (partial ions demineralization). Ultrafiltration (UF): Concentration of large and macro molecules Microfiltration separation of macromolecules Removal chlorine bacteria, sodium (MF): and like of unit basic of is the heart technology a The or membrane/microfiltration its membrane which acts as a barrier and separate 2 phases. that sieving mechanism or size of the particle is the basis for separation in MF while in others it is the molecular weight cut off. The main purpose of MF is clarification and turbidity removal. important to note is It As explained Microfiltration (MF) designates a membrane separation process similar to UF but larger membrane pore size allowing with even particles in the range of 0.2 to 2 micrometres to pass through. • The pressure used is generally lower than that of UF(Ultrafilteration process) process. READ MORE.... PMG DESIGN+BUILD FOOD FACTORIES. ONE STOP ENGINEERING SOLUTION Vol .02-Issue .31-August 2023 • MF is used in the dairy industry for making low- heat sterile milk. Membrane-It i.e. is semi-permeable allows some materials to pass through it while restricting others selectively. in nature Process: Solution or the feed is passed with a driving force or pressure through a membrane that is semi-permeable in nature, which causes it to flow. Depending on the pore size, speed, pressure etc. it allows passage of some particle while retain some component on the membrane. the other side of Thus, the feed stream divides into- 1.Permeate-The component that passes to another side or the membrane is known as permeate. 2.Retentate -The components that could not pass through the membrane and remains onone side of the membrane or on the surface of membrane is known as Retentate. Generally, 2 different employed in Microfiltration: flow configurations are filtration 1.Dead-end-flow: It is the most basic form of filtration. In this the complete feed flow is forced through the membrane and the filtered matter is accumulated on the surface of the membrane. The dead-end is a batch process as accumulated matter on the filter decreases the filtration capacity, due to clogging. The next step in the process is to remove the accumulated matter which is required. Dead-end filtration can be an extremely useful for concentrating technique compounds. 2.Cross Flow Micro-filtration: The process is referred to as "cross-flow", because the feed flow and filtration flow direction have a 90 degrees angle With cross-flow filtration a constant turbulent flow along the membrane surface prevents the accumulation of matter on the membrane surface. The membranes used in this process are commonly tubes with a membrane layer on the inside wall of the tube. The feed flow through the membrane tube has an elevated pressure as driving force for the filtration process and a high flow speed to create turbulent conditions It is an excellent way to filter liquids with a high concentration of filterable matter. Applications The application of membrane technology in food industry is growing gradually in both international and domestic market since 1960s. For selected to other applications, microfiltration conventional methods owing to its inherent advances such as low energy consumption, fewer and mild processing separation efficiency, final product quality, eco-friendly and improved ‘cleaner’ processing. steps, greater is superior Application in Dairy Industry The removal of bacteria and spores from milk to extend its shelf-life by MF is an alternative way to ultra-pasteurization. MF for the removal of bacteria and spores can be further applied in the production of other dairy products. Application in Water Industry (drinking water + wastewater processing + water desalination) has the largest commercial market for membranes worldwide. Application in Beverage Industry As an alternate, reverse osmosis is used for beer dealcoholisation prior clarification by microfiltration before pasteurization and bottling MF now successfully employed for beer clarification i.e., for removal of yeasts, microorganisms and for haze without adversely affecting its sensorial attributes. its to PMG DESIGN+BUILD FOOD FACTORIES. ONE STOP ENGINEERING SOLUTION FOOD INDUSTRY INDUSTRY BUZZ Karnataka promotes coffee with a sustainability-focused approach. The Department of Animal Husbandry and Dairy implements the National Program for Dairy Development. Karnataka promotes coffee with a focus on sustainability the circular through economy. Over 70% of the nation's coffee is produced in the state, which is, without a doubt, the leader. regenerative agriculture and resource The state had 2.33 lakh metric tons of coffee in the most recent fiscal year, the most of any form in the nation. The state is developing methods to minimize waste, maximize support environmentally friendly activities throughout the coffee manufacturing process by focusing on sustainability through a circular economy approach. Additionally, regenerative agriculture can help improve and restore the health of the soil, creating a more substantial, more sustainable coffee farm. efficiency, and (NPDD) scheme has been Since February 2014, the National Programme for Dairy implemented Development nationwide by the Department of Animal Husbandry and Dairying (DAHD). The strategy was reorganized/realigned in July 2021 for implementation from 2021–2022 to 2025–2026 with their corresponding goals: listed below and components two the (i)Component on developing/improving infrastructure for quality milk testing equipment as well as primary chilling facilities. focuses NPDD ''A'' the of (ii) Component 'B' of the NPDD program intends to enhance sales of milk and dairy products by improving farmer access to the organized market, modernizing dairy processing infrastructure, and boosting facilities and marketing producer-owned institutions' capabilities. PMG DESIGN+BUILD FOOD FACTORIES. ONE STOP ENGINEERING SOLUTION The FSSAI extends RDA 2020 compliance by six months. After the stakeholders requested extra time, the FSSAI decided to extend the Recommended Dietary Allowance (RDA) 2020 compliance deadline for a period of six months. On July 1, 2023, the RDA 2020 was set to take effect after the FSSAI's July/August 2021 directives concerning the RDA's deadline for compliance. Industry associations reportedly requested a delay in the RDA-2020's implementation due to difficulties with product reformulation and inventories of outdated packaging materials that FBOs had on hand. The directive from the FSSAI states, "After careful consideration, it has been decided to extend further the date of coming into force of Recommended Dietary Allowance 2020 for compliance for six months from July 1, 2023." Friends of the Farmer brew sessions are being introduced by Maverick & Farmer Coffee. The first of Maverick & Farmer's Friends of the Farmer brew sessions, which aims to highlight local coffee producers' outstanding efforts and products, has been announced. This session will feature farmer Lynn Mascarenhas from St Margaret Estate and take place at the Ulsoor cafe. For two months, the highlighted single-estate coffee will also be sold at outlet cafés and online. The sessions, organized by co-founder and farmer Tej Thammaiah of Maverick & Farmer Coffee, provide a venue for local farmers to display their remarkable and inventive produce, with a focus on those who practice maverick farming. Production-related Industry Incentive Program for Food Processing The Production Linked Incentive Scheme for the Food Processing Industry (PLISFPI), a Central Sector Scheme with an outlay of Rs 10,900 crore, was approved by the Union Cabinet on March 31, 2021. It is scheduled to be implemented from 2021–2022 to 2026–2027. The program is divided into three parts: Encouraging the production of food products in the four main food product categories (processed fruits and vegetables, mozzarella cheese, marine products, and ready-to-cook/ready-to-eat foods). Supporting the branding and international marketing of Indian brands. Promoting innovative and organic products made by SMEs. Furthermore, using the savings from PLISFPI, the PLI Scheme for Millet- based Products (PLISMBP) was introduced in FY 2022–2023 at an expense of Rs 800 crore. 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 28 JULY WORLD HEPATITIS DAY World Hepatitis Day takes place every year on 28 July bringing the world together under a single theme to raise awareness of the global burden of viral hepatitis and to influence real change. 28 JULY WORLD NATURE CONSERVATION DAY The World Nature Conservation Day is observed annually on July 28. The occasion aims to create awareness about the need to preserve the environment and natural resources in order to keep the world healthy. 29 JULY J. R. D TATA Jehangir Ratanji Dadabhoy Tata (29 July 1904-29 November 1993) is an inspiration, an idol, a role model, a pioneer, a humanitarian, a nation- builder, and whatnot. He was the strength who not only pushed the automobile and Telecom industry forward but also pushed the society and nation to excellency. JRD Tata is one of the most successful businessmen in India. DESIGN+BUILD FOOD FACTORIES. ONE STOP ENGINEERING SOLUTION T S U G U A PMG N O N - T E C H N I C A L C O N T E N T 29 JULY INTERNATIONAL TIGER DAY Tiger Day is celebrated every year on July 29th as a way to raise awareness about this magnificent but endangered big cat. The goal of the day is to promote a global system for protecting the natural habitats of tigers and to raise public awareness and support for tiger conservation issues. 31 JULY WORLD RANGER DAY World Ranger Day is observed every year on 31 July to commemorate the Rangers killed or injured while on duty and to celebrate the work that Rangers do to protect the world's natural and cultural heritage. 7 AUGUST WORLD BREASTFEEDING WEEK World Breastfeeding week is celebrated globally between 1st to 7th of August. The goal of the week is to highlight the importance of breastfeeding, to encourage and promote breastfeeding and to improve the health of babies and mothers all around the globe. DESIGN+BUILD FOOD FACTORIES. ONE STOP ENGINEERING SOLUTION T S U G U A PMG DID YOU KNOW? T E C H N I C A L C O N T E N T 1/4 2/4 T S U G U A PMG 3/4 4/4 Fact 1 Frozen vegetarian meals are pre-prepared meals that do not contain any meat or fish and are designed to be stored in the freezer for later consumption specifically catered to vegetarians. They provide a convenient option for those who are busy, want to minimize cooking time, or need to maintain a vegetarian or plant-based diet. DESIGN+BUILD FOOD FACTORIES. ONE STOP ENGINEERING SOLUTION Vol .01 Newsletter T E C H N I C A L C O N T E N T 1/5 2/5 3/5 4/5 T S U G U A PMG DESIGN+BUILD FOOD FACTORIES. ONE STOP ENGINEERING SOLUTION Vol .01 Newsletter Fact 2 Water activity (aw) in food is a crucial concept in food science and preservation. It is a measurement of the free or unbound water present in a food product. Water activity is represented on a scale ranging from 0.0 to 1.0, with pure water having an aw of 1.0 5/5 T E C H N I C A L C O N T E N T 1/5 2/5 T S U G U A PMG DESIGN+BUILD FOOD FACTORIES. ONE STOP ENGINEERING SOLUTION Vol .01 Newsletter T E C H N I C A L C O N T E N T 3/5 4/5 Fact 3 A rotary valve in the food industry is a mechanical device used to control the flow of food materials (liquids, powders, granules, or other ingredients) within a processing system. It consists of a rotating disc, drum, or star-shaped rotor with an internal passage or opening that aligns with the inlet and outlet ports. 5/5 T S U G U A PMG DESIGN+BUILD FOOD FACTORIES. ONE STOP ENGINEERING SOLUTION Vol .01 Newsletter Vol .02-Issue .31-August 2023 PMG ENGINEERING About PMG About PMG Delivering End-to-End Engineering Design & Construction Management in Food & Beverage Industry Meeting Global Benchmarks Process Engineering I Project Management I Mechanical I Electrical I Automation I Food Safety PEOPLE DELIVERING RESULTS Safe-by-choice. First Time Quality. Maximize Value. Objectivity. Ownership. Reliable and Trustworthy Business. MAKING CUSTOMERS THE INDUSTRY LEADERS ENGINEERING MUST CREATE BUSINESS VALUE MEET THE EXPECTATIONS OF ALL STAKEHOLDERS OPTIMAL ENGINEERING Website Link Click Here Follow Us on