Dehydrated Fruits and Vegetables: Processing, Packaging & Equipment Explained

PMG Engineering Private Limited The End-to-End Engineering Company in Food Industry info@pmg.engineering | www.pmg.engineering www.pmg.engineering info@pmg.engineering Dehydrated Fruits and Vegetables Build World-Class Food Factories PMG Engineering Private Limited The End-to-End Engineering Company in Food Industry info@pmg.engineering | www.pmg.engineering www.pmg.engineering info@pmg.engineering Contents 1 2 3 5 6 Introduction with Benefits Pre-requites/ Minimal processes Processing (with process block diagram) Equipments used References X About PMG Engineering Build World-Class Food Factories 2 PMG Engineering Private Limited The End-to-End Engineering Company in Food Industry info@pmg.engineering | www.pmg.engineering www.pmg.engineering info@pmg.engineering Introduction • Dehydration is one of the oldest method of preservation of fruits and vegetable by removal of moisture present inside. • Moisture removal: 75-90%; reduces water activity to a level sufficient to prevent products from various deteriorative agents. • Done with the help of heat treatment using heat and mass transfer techniques. • Impact of dehydration on fruits and vegetable: - Nutrient loss - Textural degradation - Discolouration - Loss of flavour - Shrinkage - Reduction of shape & size - But extends product’s shelf life • Various innovated designed has been developed to solve these problems such as, osmotic dehydration, freeze drying, vacuum drying, etc. Build World-Class Food Factories PMG Engineering Private Limited The End-to-End Engineering Company in Food Industry info@pmg.engineering | www.pmg.engineering www.pmg.engineering info@pmg.engineering 1.1 Benefit of Dehydration 1. Preserve Fruits and vegetable 2. Extends shelf life 3. Make it move convenient to transport & store 4. Decrease weight and bulk 5. Simple to pack & store at ambient temperature 6. Require lesser numbers of equipments 7. Cheaper than other preservation techniques 8. Handling, transportation, & storage cost lowered Build World-Class Food Factories PMG Engineering Private Limited The End-to-End Engineering Company in Food Industry info@pmg.engineering | www.pmg.engineering www.pmg.engineering info@pmg.engineering 1.2 Factors to be controlled during drying 1.2.1 The external factors are: - Dry bulb temperature: Drying rate directly proportional to temp. gradient. - Relative humidity: Inversely proportional to drying rate; lower relative humidity promotes faster drying - Air velocity: higher air velocity vent off moist air faster from the drying chamber. - Pressure: Lower environmental pressure increases partial pressure of moisture to evaporate faster. - Surface heat transfer coefficient - Arrangement of stacking of produce Build World-Class Food Factories PMG Engineering Private Limited The End-to-End Engineering Company in Food Industry info@pmg.engineering | www.pmg.engineering www.pmg.engineering info@pmg.engineering 1.2 Factors to be controlled during drying (cont.) 1.2.2 The Internal factors are: - Surface to volume ratio: Higher the ratio, fasten the drying - Surface temperature: Higher the temperature higher will be the drying - Rate of moisture loss: Higher the rate higher will be the drying - Composition i.e., moisture, fat: higher the moisture fasten will be the drying but higher fat content hinder moisture removal or drying being a heat insulator, also food with higher salts and sugar loss being content, hinder moisture hygroscopic in nature. Build World-Class Food Factories PMG Engineering Private Limited The End-to-End Engineering Company in Food Industry info@pmg.engineering | www.pmg.engineering www.pmg.engineering info@pmg.engineering 2. Minimal Processing • Processing techniques used before processing (Drying) fruits and vegetables are called minimal processing. • It includes, sorting, grading, cleaning/washing or trimming, peeling, cutting, slicing/Dicing, grating/ shredding etc. • Done to- 1. Enhance drying rate due to increase in surface area and 2. Minimize adverse effect of drying on fruits and vegetable like, browning, non- uniform drying, 3. Decreases microbial load and prevents presence pathogen possible (mostly lie on surface) toxic Build World-Class Food Factories PMG Engineering Private Limited The End-to-End Engineering Company in Food Industry info@pmg.engineering | www.pmg.engineering www.pmg.engineering info@pmg.engineering 2. Minimal Processing *Other two additional treatment, 1. Blanching: Hot water @85oC or steam treatment for shorter time followed by immediate cooling using chilled water. - Prevent discolouration in vegetables like potato, green vegetables etc. 2. Salt or sugar treatment: - Salt treatment prevent dried food from spoilage, - Sugar treatment preserve colour and texture and act as preservative agent. Build World-Class Food Factories PMG Engineering Private Limited The End-to-End Engineering Company in Food Industry info@pmg.engineering | www.pmg.engineering www.pmg.engineering info@pmg.engineering 3. Processing (Drying) Selection of F&V Pre- treatments* Dehydration Receiving raw material Slicing/ Dicing shredding/ pulping Cooling Inspection of raw material Trimming/ peeling/Coring Packaging Sorting/ grading Cleaning/ washing Storage/ Transportation Build World-Class Food Factories PMG Engineering Private Limited The End-to-End Engineering Company in Food Industry info@pmg.engineering | www.pmg.engineering www.pmg.engineering info@pmg.engineering 3.1 Dehydration • Generally, tunnel dryer and cabinet dryer are used with the help of hot air circulation using fan or blower. • Here, drying is done at controlled temperature @55-80oC, velocity and the humidity of the air but their value vary depending upon the type of commodity. 1. Fruits - Dried at a lower temperature than vegetables due to the higher possibility of case hardening. 2. Vegetables - Dried mostly after blanching and/or being treated with common salt or sulphites (SO2/ KMS) at higher temperature. Build World-Class Food Factories Vegetables Preparation Blanching Chemical Treatments Dehydration condition PMG Engineering Private Limited The End-to-End Engineering Company in Food Industry info@pmg.engineering | www.pmg.engineering www.pmg.engineering info@pmg.engineering 3.1 Dehydration # 1. 2. 3. 4. 5. 6. Potato Slices (10mm) Beans/Beet Slices (10mm) Bitter gourd Slices (10 mm) Brinjal Slices (10 mm) Cabbage Fine shreds Cauliflower Small pieces 7. Okra Slices (6 mm) 8. Peas Shelled 3-4 min 10 min 7-8 min 4-5 min 5-6 min 4-5 min 5-6 min 0.5% KMS - 1%KMS/1hr 0.5% KMS/10 min 1%KMS/1hr 0.5% KMS/30 min 0.5% KMS+0.1% NaHCO3+0.1% MgO /3-4 min 60-65°C 60-65°C 65-75°C 50-52°C 55-60°C 55-60°C 55-60°C 50-60°C 50-55°C 45-52°C 60-65°C 9. Fenugreek Stalk removal 2-3 min 10. Garlic Slices (6 mm) - 11. Tomato Slices (1 cm) 30-60°C/2 min - - - Build World-Class Food Factories PMG Engineering Private Limited The End-to-End Engineering Company in Food Industry info@pmg.engineering | www.pmg.engineering www.pmg.engineering info@pmg.engineering 3.1 Dehydration (Cont.) # Fruits Preparation 1. Grapes Stemming 2. 3. Banana Slices (12 mm) Apricot / Peach Cutting into half & destoned 4. Mango Slices (12mm) Chemical Treatments Salting Caustic Sulphuring Dehydration condition - - - - - 0.5%; Boiling - - - 0.5%; Boiling 1 hr 30 min 55- 60°C 55- 60°C 30 min 50- 60°C 2 Hr. - - SO2 or 1-2% KMS /30 min 30 min/ 1-2% KMS; 20 min 2 Hr. 1 hr 50- 60°C 45-50°C 50- 60°C 60-65°C 60-65°C 60-65°C 55- 60°C Date Aonla Apple 5. 6. 7. 8. 9. Grated @40 g/kg Slices (5mm) - Pear Cutting into half 1-2% Brine Papaya Slices (6 mm) 10. Fig - - - - - - - - Build World-Class Food Factories 12 PMG Engineering Private Limited The End-to-End Engineering Company in Food Industry info@pmg.engineering | www.pmg.engineering www.pmg.engineering info@pmg.engineering 3.2 Packaging • Plastic Pouches: Soft fruits and moisture susceptible fruits and vegetable • Glass Jars: being transparent and air-tight container preserve dried goods for long time and product can be visible clearly. • Kraft Pouches: Offer a rustic, eco-friendly appeal. Hardy dried fruits which requires less moisture protection. • Can Packaging: Used to provide premium or gourmet offering. • Tin-Tie Bags: Bags with metal and plastic tie at top, resealable after every opening. • Plastic Tubs: Hard plastic container with lids, for bulk storage. Build World-Class Food Factories PMG Engineering Private Limited The End-to-End Engineering Company in Food Industry info@pmg.engineering | www.pmg.engineering www.pmg.engineering info@pmg.engineering 3.3 Storage • The dried fruits and vegetables can be stored after effective packaging at cool temperature (10-20oC) and dry place (low humidity). Build World-Class Food Factories PMG Engineering Private Limited The End-to-End Engineering Company in Food Industry info@pmg.engineering | www.pmg.engineering www.pmg.engineering info@pmg.engineering 4. Equipment Required 4.1 Tunnel dryer • Hot air-based industrial convectional dryers • Hot air is circulated through a tunnel-like enclosure using Fan or blower - Air moving either in co-current motion, or counter current motion (mostly used) or cross flow. • Removing moisture from the product. • Specification - Tray size: 10–30 kg per m2 - Inlet air temperature: 50°C to 150°C - Outlet air temp: 35-60oC - Air velocity: 2-10 ms-1 Build World-Class Food Factories PMG Engineering Private Limited The End-to-End Engineering Company in Food Industry info@pmg.engineering | www.pmg.engineering www.pmg.engineering info@pmg.engineering 4. Equipment Required • Advantages- - Efficiently, effectively, & Inexpensive, - Easy to construct and install, maintain hygiene and space convenient. - Precise controllable hence, allows customized drying. Cabinet dryers Build World-Class Food Factories PMG Engineering Private Limited The End-to-End Engineering Company in Food Industry info@pmg.engineering | www.pmg.engineering www.pmg.engineering info@pmg.engineering 4.2 Cabinet dryer • Batch drying method; also known as tray drier • Contain closed compartment in which trays containing the food to be dried are placed. • Specification - Capacity: 2000 to 20 000 kg per day - Inlet air temperature: 60–80°C - Air velocity: few ms -1 (according shape, size, and density of food particles) - Duration of drying one batch: 2- 10 Hr. - Maximum nos. of trays: 25 • Advantages - Inexpensive & simple to construct. Cabinet dryer Build World-Class Food Factories PMG Engineering Private Limited The End-to-End Engineering Company in Food Industry info@pmg.engineering | www.pmg.engineering www.pmg.engineering info@pmg.engineering Reference • Storing Dried Fruit: Essential Tips for Freshness and Flavor (dehydratedfoodz.com) • UNIT 1 TEACHING – LEARNING PROCSS : A REVISIT (egyankosh.ac.in) • Food Technology-I: Lesson 11. DRYING: PRINCIPLE, METHODS AND APPLICATIONS (iasri.res.in) • Food Dehydration 101: Drying Fruits and Vegetables - The Seasonal Homestead • Best practice for drying fruit and vegetables | Commercial Dehydrators | Food Dehydrators • AP-42, CH 9.8.2: Dehydrated Fruits And Vegetables (epa.gov) Build World-Class Food Factories PMG Engineering Private Limited The End-to-End Engineering Company in Food Industry info@pmg.engineering | www.pmg.engineering www.pmg.engineering info@pmg.engineering Our Clients Build World-Class Food Factories # We deliver End-to-End Engineering Design and Construction Management Projects in Food and Beverage Industry. Meeting Global Benchmarks In ENGINEERING DESIGN and PROJECT MANAGEMENT for FOOD and BEVERAGE Industry with SINGLE POINT ACCOUNTABILITY Process Engineering | Project Management | Mechanical | Electrical | Automation | Food Safety Key Clients We deliver End-to-End Engineering Design and Construction Management Projects in Food and Beverage Industry. Meeting Global Benchmarks In ENGINEERING DESIGN and PROJECT MANAGEMENT for FOOD and BEVERAGE Industry with SINGLE POINT ACCOUNTABILITY Process Engineering | Project Management | Mechanical | Electrical | Automation | Food Safety Key Clients We deliver End-to-End Engineering Design and Construction Management Projects in Food and Beverage Industry. Meeting Global Benchmarks In ENGINEERING DESIGN and PROJECT MANAGEMENT for FOOD and BEVERAGE Industry with SINGLE POINT ACCOUNTABILITY Process Engineering | Project Management | Mechanical | Electrical | Automation | Food Safety Key Clients