Final HOT M

UNIVERSITY OF AGRICULTURAL
SCIENCES, GKVK-BANGALORE
Laboratory Manual
PHT – 402 Commercial Food Processing and Value Addition (0 + 5)
Course Teacher:
Dr. Usha Ravindra
Dr. Shamshad Begum, S.
Dr. M. L.Revanna
DEPARTMENT OF FOOD SCIENCE AND NUTRITION

COLLEGE OF AGRICULTURE UAS, GKVK, BANGALORE
UNIVERSITY OF AGRICULTURAL SCIENCES
BANGALORE
HANDS ON TRAINING (HOT)
Laboratory Manual
(Undergraduate)
Course Title : Commercial Food Processing and

Value Addition
Course No. : PHT - 402
Credit Hours : (0 + 5)
Course Teacher:
Dr. Usha Ravindra
Dr. Shamshad Begum, S.
Dr. M. L.Revanna
DEPARTMENT OF FOOD SCIENCE AND NUTRITION

COLLEGE OF AGRICULTURE
UAS, GKVK, BANGALORE
2018-19
CONTENTS
Experimen Page
Name of practical Date
t No. Nos.
Introduction - Commercial Food Processing and

Value Addition
 Product Development for Commercial
Processing
 Stages in Practical Product Development
 Sequence of Operations in Food Processing
 Food Processing and Preservation Technologies
1. Introduction to Food Processing Equipment’s

Food safety and quality standards
 ISO 22000
2.  Hazard Analysis Critical Control Point
 Food Safety And Standards Regulations (Fssai)
2006
Wheat and its value-added products

 Butter Biscuit
 Coconut Cookies
3.  Masala / Sweet Doughnuts
 Sponge cake
 Instant Rava Idli Mix
 Maida Chakli
Ragi and its value-added products

 Ragi Hurihittu
4.  Ragi laddu
 Ragi Shavige Mixture
 Ragi malt
 Millet dosa mix
5. Processing and Value-Added Products of Maize

 Maize Uppittu
 Maize sweet
 Maize Nutri Pakoda
Green Leafy Vegetables and its Value-Added

Products
 Composite flour of Green Leafy Vegetables
6.  Composite Flour of Carrot Powder
 Preparation of Nippattu from composite flours
 Carrot Composite Flour Laddu
 Multi Grain Sattu
Grain Amaranthus and its Value-Added Products

 Popped Grain Amaranth
 Popped Grain Amaranth Sweet Mixture
7.  Popped Grain Amaranth Mixture Savoury
 Amaranthus Laddu
 Amaranthus Chikki
 Amaranthus Paustic Chapathi
Soybean and its Value-Added Products
8.  Soya Chutney Pudi

 Soya nuts
 Soya Milk and Paneer
Flax Seed and its Value-Added Products

9.
 Flax Seed Chutney Powder
10. Processing of Turmeric Powder

Preparation of Pickles
11.  Bitter gourd pickle (South Indian)
 Carrot Pickles
Tomato and its value-added products

 Tomato Ketchup
12.  Tomato Thokku
 Tomato Carrot Soup

13. Visit to Krishimela
14. Visit to international trade fair
15. Visit to bakery training unit
16. Commercial processing and marketing
University of Agricultural Sciences, Bangalore

Department of Food Science and Nutrition
College of Agriculture
UAS, GKVK, Bangalore-560 065
Certificate
This is to certify that Mr. / Ms..……………....……………… has
satisfactorily completed the course experiments in PHT-402,
Commercial Food Processing and Value Addition (0+5)

prepared by the Department of Food Science and Nutrition, College of
Agriculture, University of Agricultural Sciences, GKVK, Bangalore for IV
B.Sc. (Agri.) during the year 2018-19
Date ……………….. Signature of the Student
Signature of the Teachers
Signature of Head of the Department

T Introduction
he food sector plays an important role in contributing to the development of the
Indian economy. Food and food products are the largest consumption category in
India, with a market size of USD 181 billion. Domestically, the spending on food
and food products amounts to nearly 21% of the gross domestic product of the country
and constitutes the largest portion of the Indian consumer spending more than a 315
share of wallet. Going forward, the Indian domestic food market is expected to grow by
newly 40% of the current market size by 2015, to touch USD 258 billion by 2015 (FICCI-
EY report, 2009).
Food processing industry in India is increasingly seen as a potential source for
driving the rural economy as it brings about synergy between the consumer, industry
and agriculture. A well-developed food processing industry is expected to increase farm
gate prices, reduce wastages, ensure value addition, promote crop diversification,
generate employment opportunities as well as export earnings.
The definition of what constitutes a processed food can vary slightly, but it
usually refers to foods that are packaged in boxes, cans or bags. These foods need to be
processed extensively to be edible and are not found as is in nature. In addition to
going through many complex processing steps, processed foods often contain additives,
artificial flavourings and other chemical ingredients.
Food processing is the conversion of agricultural product to substances

which have particular textural, sensory and nutritional properties using
commercially feasible methods.
Primary Processing
Primary processing is the conversion of raw materials to food commodities. Milling is an

example of primary processing.
Secondary Processing
Secondary processing is the conversion of ingredients into edible products – this

involves combining foods in a particular way to change properties. Baking cakes is an
example of secondary processing.
A considerable variety of products can be made using similar basic ingredients
e.g., to make bread we need flour, water and salt. Breads such as chapati and roti are
examples of unleavened breads. If yeast is added this produces carbon dioxide, given
the correct conditions, this raises the mixture to produce breads such as those they eat
more commonly.
Product Development for Commercial Processing

Stages of Product Development
Product development is the process of making new or modified food products.

The process of product development involves a complex series of stages, requiring the
combined talents of many specialists to make it successful.
The aim of product development is for a company to increase sales and remain
competitive.
1. Development ideas for a new product
2. Test ideas on a small scale: Research is carried out to form a number of

recipes and specify the ingredients to be used. Several versions of the product
are usually made, using slightly different ingredients or processes, i.e., the
products are Prototyped in the company’s test kitchen, often by a professional
chef or food consultant. A small number of staffs, experienced in sensory
evaluation, test the products and evaluate them informally.
3. Sensory evaluation: Sensory evaluation is carried out at many stages of the

development process. Trained panels comment on the appearance, odour, taste
and texture of the products to make sure that the product being developed
displays the desired sensory characteristics.
4. Modify product
5. Pilot plant: A pilot plant is a small version of the equipment used in
manufacture.
6. Sensory evaluation
7. Perform consumer testing

8. Finalize product specification: Product specifications detail exact
ingredients and precise methods of production. The specification is very
important as it will be used for the production of each batch of the product to
ensure consistency.
9. Produce product on a large scale: The manufacturing process is sometimes

organised in unit operations. Such as size reduction, mixing and cooking. These
are controlled to maintain consistent product quality, safeguard staff health, food
safety standards and to avoid problems that may stop the production line
running, which would result in ‘down time’!!! The processes involved in
manufacturing food products are known as ‘unit operations. These include:
 Storage e.g. keeping raw materials in good condition
 Cleaning e.g., removing foreign matter
 Sorting/grading e.g., assessing the quality
 Size reduction e.g., trimming, slicing, crushing
 Missing/combining
 Heat transfer e.g., cooking and cooling
10. Advertise the product
11. Launch new product
Stages in Practical Product Development
The recognized stages for development of new food and drink products includes:
 Small scale bench work i.e., one off production – prototype

 Batch production i.e., repetitive small-scale manufacture
 Pilot scale – factory trials
 Full-scale continuous production – manufacture on a production line
The Sequence of Operations in Food Processing – from delivery of raw materials to
distribution of finished product
Source ingredients
Delivery of ingredients
Storage of ingredients e.g., in hoppers, bins, etc.
Weigh and mix ingredients - formulation
Fillings added
Finish applied
Cooked
Cooled
Packaged and Labelled
Stored usually on pallets
Dispatched for transportation

Why We Process Food?
 To convert to edible products
 To preserve
 To extend availability and provide accessibility
 To provide variety and choice
 To add value
Benefit of Processing and Preservation

 Destroys, inhibits or removes micro-organisms
 Retards or prevents deterious biochemical, chemical and physio-chemical
changes
 Maintains and generates acceptable organoleptic properties
 To add economic value to the product
Food Processing and Preservation Technologies

 Heating
 Drying
 Irradiation
 Concentration
 Freezing
 Chemical preservation
 Chilling
 Fermentation
 A Combination of these technologies
Experiment – 1
To know about Basic Food Processing Equipment’s
Introduction to Food Processing Equipment’s

Objective
A
Date__/__/____
wide range of instruments, machinery and equipment’s are used in food
processing industry. In many cases, this equipment must meet vigorous quality
standards to ensure manufacturers meet proper food handling procedures.
Generally, equipment used in food processing applications serves one of the following
purposes: measurement, preparation, storage, packaging or cooking. Measurement
devices include scales and weighing systems, thermometers, pressure gages, timers and
other precision control components. These instruments are used to analyze ingredients
and machines, and to allow manufacturers to perform and duplicate processing
procedures without complications. They are also used to monitor existing systems and
machinery, whether to log data during product testing or to quantify typical
performance statistics. Measurement devices are particularly important during food
manufacture, as minor changes in cooking temperature, ingredient ratios and operation
times can lead to drastic changes in the finished product.
Preparation and cooking equipment include conveyor systems, ovens, dispensing

machines, mixing and cutting machines, and transport hoses, pipes and tubes. Each
food preparation facility is unique, and many preparation systems are custom designed
for the required application. Storage and packaging equipment used for the food
industry ranges from simple plastic wrapping to vacuum sealing and bottling. Freezers,
coolers and chillers help maintain delicate ingredients and temperature sensitive
products for future use or sale. Various sealing and packing techniques are used by
manufacturers, including shrink wrap, tamper-proof caps, air-tight bags and cardboard
boxes. Pallets, racks, bins and drums are also available for large shipments.
Students will be exposed to the following equipment:
 Cleaning, Grading and Milling

 Driers
 Refrigerators
 Lyophilizors
 Cutting and Grinding Equipment’s
 Sensory Lab Equipment’s
 Extruders
 Baking ovens
 Food Quality Analysis Equipment’s
 Packing and Sealing Equipment
 Display Materials, etc.
Experiment – 2
Objective
To know about major Food safety and quality standards of India
Date__/__/____
F
Food safety and quality standards
ood safety is a scientific discipline describing handling, preparation, and storage
of food in ways that prevent food-borne illness. The occurrence of two or more
cases of a similar illnesses resulting from the ingestion of a common food is
known as a food-borne disease outbreak. This includes a number of routines that should
be followed to avoid potential health hazards.
Food hygiene is the conditions and measures necessary to ensure the safety of
food from production to consumption. Food can become contaminated at any point
during harvesting, processing, storage, distribution, transportation and preparation. Lack
of adequate food hygiene can lead to food borne diseases and death of the consumer.
The five key principles of food hygiene, according to WHO, are:
 Prevent contaminating food with pathogens spreading from people, pets, and

pests.
 Separate raw and cooked foods to prevent contaminating the cooked foods.
 Cook foods for the appropriate length of time and at the appropriate
temperature to kill pathogens.
 Store food at the proper temperature.
 Use safe water and safe raw materials.
Food contamination
 Physical contamination
 Chemical contamination
 Biological contamination
SAFE food handling (from market to consumers)

Proper storage, sanitary tools and work spaces, heating and cooling properly and
to adequate temperatures, and avoiding contact with other uncooked foods can greatly
reduce the chances of contamination. Tightly sealed water and air proof containers are
good measures to limit the chances of both physical and biological contamination
during storage. Using clean, sanitary surfaces and tools, free of debris, chemicals,
standing liquids, and other food types can help reduce the chance of all forms of
contamination. However, even if all precautions have been taken and the food has been
safely prepared and stored, bacteria can still form over time during storage. Food should
be consumed within one to seven (1-7) days while it has been stored in a cold
environment, or one to twelve (1-12) months if it was in a frozen environment (if it was
frozen immediately after preparation).
ISO 22000
ISO 22000 is a standard developed by the International Organization for

Standardization dealing with food safety. ISO 22000 standard: The ISO 22000
international standard specifies the requirements for a food safety management system
that involves interactive communication, system management, prerequisite programs,
and HACCP principles.
HAZARD ANALYSIS CRITICAL CONTROL POINT
HACCP is a management system in which food safety is addressed through the

analysis and control of biological, chemical, and physical hazards from raw material
production, procurement and handling, to manufacturing, distribution and consumption
of the finished product. The Seven Principles of HACCP
APPLICATION OF THE PRINCIPLES OF HACCP
Principle 1 - Conduct a Hazard Analysis
The application of this principle involves listing the steps in the process and
identifying where significant hazards are likely to occur. The HACCP team will focus on
hazards that can be prevented, eliminated or controlled by the HACCP plan. A
justification for including or excluding the hazard is reported and possible control
measures are identified.
Principle 2 - Identify the Critical Control Points
A critical control point (CCP) is a point, step or procedure at which control can be
applied and a food safety hazard can be prevented, eliminated or reduced to acceptable
levels. The HACCP team will use a CCP decision tree to help identify the critical control
points in the process. A critical control point may control more that one food safety
hazard or in some cases more than one CCP is needed to control a single hazard. The
number of CCP's needed depends on the processing steps and the control needed to
assure food safety.
Principle 3 - Establish Critical Limits
A critical limit (CL) is the maximum and/or minimum value to which a biological,
chemical, or physical parameter must be controlled at a CCP to prevent, eliminate, or
reduce to an acceptable level the occurrence of a food safety hazard. The critical limit is
usually a measure such as time, temperature, water activity (Aw), pH, weight, or some
other measure that is based on scientific literature and/or regulatory standards.
Principle 4- Monitor CCP
The HACCP team will describe monitoring procedures for the measurement of
the critical limit at each critical control point. Monitoring procedures should describe
how the measurement will be taken, when the measurement is taken, who is responsible
for the measurement and how frequently the measurement is taken during production.
Principle 5 - Establish Corrective Action
Corrective actions are the procedures that are followed when a deviation in a
critical limit occurs. The HACCP team will identify the steps that will be taken to prevent
potentially hazardous food from entering the food chain and the steps that are needed
to correct the process. This usually includes identification of the problems and the steps
taken to assure that the problem will not occur again.
Principle 6 - Verification
Those activities, other than monitoring, that determine the validity of the HACCP
plan and that the system is operating according to the plan. The HACCP team may
identify activities such as auditing of CCP's, record review, prior shipment review,
instrument calibration and product testing as part of the verification activities.
Principle 7 – Record keeping
A key component of the HACCP plan is recording information that can be used to
prove that the food was produced safely. The records also need to include information
about the HACCP plan. Record should include information on the HACCP Team, product
description, flow diagrams, the hazard analysis, the CCP's identified, Critical Limits,
Monitoring System, Corrective Actions, Recordkeeping Procedures, and Verification
Procedures.
HACCP Does not stand Alone
The application of HACCP does not stand alone in a food processing facility. The
plan must be built on other food safety programs. Good Manufacturing Practices (GMP)
that are practiced by the processing facility will support HACCP plan and will address
food safety and food quality issues that are not critical for the reduction of food safety
hazards. Sanitation Standard Operating Procedures (SSOP's) are required in federally
inspected meat and poultry operations and address procedures for clean facilities,
equipment and personnel that are necessary for all products produced in a facility.
FOOD SAFETY AND STANDARDS REGULATIONS (FSSAI) 2006
1. Food Safety and Standards (Licensing and Registration of Food Businesses)

Regulation, 2011
2. Food Safety and Standards (Food Product Standards and Food Additives)
Regulation, 2011
3. Food Safety and Standards (Prohibition and Restriction on Sales) Regulation,
2011
4. Food Safety and Standards (Packaging and Labelling) Regulation, 2011
5. Food Safety and Standards (Contaminants, Toxins and Residues) Regulation, 2011
6. Food Safety and Standards (Laboratory and Sampling Analysis) Regulation, 2011
7. Food Safety and Standards (Food or Health Supplements, Nutraceuticals, Foods
for Special Dietary Uses, Foods for Special Medical Purpose, Functional Foods and
Novel Food) Regulations, 2016
8. Food Safety and Standards (Food Recall Procedure) Regulation, 2017 Guidelines
for Food Recall (PDF, 355 KB). (Uploaded on: 28.11.2017)
9. Food Safety and Standards (Import) Regulation, 2017
10.Food Safety and Standards (Approval for Non-Specified Food and Food
Ingredients) Regulations, 2017.
11.Food Safety and Standards (Organic Food) Regulation, 2017.
12.Food Safety and Standards (Alcoholic Beverages) Regulations, 2018
13.Food Safety and Standards (Fortification of Foods) Regulations, 2018
14.Compendium of Food Safety and Standards (Fortification of Foods) Regulation
15.Food Safety and Standards (Food Safety Auditing) Regulations, 2018
16.Food Safety and Standards (Recognition and Notification of Laboratories)
Regulations 2018.
17.Food Safety and Standards (Advertising and Claims) Regulations, 2018.
Experiment – 3
Objective
1. To know about Wheat and its value-added products
2. Development of value-added products from wheat Date__/__/____
3. Calculation of Nutritive value, cost and………. of developed products.
W
Wheat and its value-added products
heat is one of the first cereals known to have been domesticated, and
wheat's ability to self-pollinate greatly facilitated the selection of many
distinct domesticated varieties. In 2007 world production of wheat was
607 million tons, making it the third most-produced cereal after maize (784 million tons)
and rice (651 million tons). Globally, wheat is the leading source of vegetable protein in
human food, having a higher protein content than either maize (corn) or rice, the other
major cereals.
Nutritional composition of wheat
Nutrients Amount (per 100 grams)
Carbohydras 71
Protein 12.6
Fat 1.5
Dietary Fibre 12.2
Wheat is a major ingredient in foods such as bread, porridge, crackers, biscuits,

pancakes, pies, pastries, cakes, cookies, muffins, rolls, doughnuts, gravy, boza(a
fermented beverage), and breakfast cereals (e.g. Wheatena, Cream of Wheat, Shredded
Wheat, and Wheaties).Much of the carbohydrate fraction of wheat is starch. Wheat
starch is an important commercial product of wheat, but second in economic value to
wheat gluten. The principal parts of wheat flour are gluten and starch. These can be
separated in a kind of home experiment, by mixing flour and water to form a small ball
of dough, and kneading it gently while rinsing it in a bowl of water. The starch falls out
of the dough and sinks to the bottom of the bowl, leaving behind a ball of gluten.
3.1 Butter Biscuit
Ingredients
Maida 200 g
Icing sugar 100 g
Vanaspati 120 g
Cardamom flavour few drops
Soda ¼ tsp
Procedure
 Cream Vanaspati and sugar with soda till light and fluffy.
 Add sieved Maida and flavour and make a smooth and soft dough.
 Make small round balls from the dough and arrange on greased baking sheet
one inch apart.
 Bake at 3000F for about 20 minutes
Nutritive value per 100 gm of ingredients
Ingredients Qty. Protei CHO Fat Fibre Ca Fe Energy Cost
n (g) (g) (g) (g) (mg) (mg (Kcal) (Rs.)

)
Maida
Icing sugar
Vanaspati
Cardamom flavor
Soda
Nutritive value of product per 100 gm

Ingredients Qty. Protein CHO Fat Fiber Ca Fe Energy Cost
(g) (g) (g) (g) (mg) (mg) (Kcal) (Rs.)
Maida
Icing sugar
Vanaspati
Cardamom flavour
Soda
Observations:
Total yield:
……………………………………………………………………………….
Cost of production:
……………………………………………………………………………….
Selling price per unit:

……………………………………………………………………………….
Labelling:
……………………………………………………………………………….
Remarks:
…………………………………………………………………………….
Evaluation
3.2 Coconut Cookies
Ingredients
Maida 60 g
Vanaspati 60 g
Coconut Powder 30 g
Vanilla flavour few drops
Sugar 30 g
Grain sugar 1 tsp
Cherry (for topping) 5 nos.
Procedure
 Mix all the ingredients in a clean bowl and knead till they are soft and smooth
(except cherries).
 Make round small balls from the dough and arrange 1/2’ apart on the baking
tray.
 Cut each cherry into eight parts and press on each part of the cookies.
 Bake at 160oC. for 15 to 20 min.
Nutritive value per 100 grams of ingredients
Ingredients Qty. Protein CHO Fat Fibre Ca Fe Energy Cost

(g) (g) (g) (g) (mg) (mg) (Kcal) (Rs.)
Maida
Vanaspati
Coconut
Powder
Vanilla flavour
Sugar
Grain sugar
Cherry
Nutritive value of product per 100 grams
Ingredients Qty. Protei CHO Fa Fibre Ca Fe Energy Cost

n (g) (g) t (g) (mg (mg (Kcal) (Rs.)
(g) ) )
Maida
Vanaspati
Coconut
Powder
Vanilla flavour
Sugar
Grain sugar
Cherry
Observations:
Total yield:
……………………………………………………………………………….
Cost of production:
……………………………………………………………………………….

……………………………………………………………………………….
Labelling:
……………………………………………………………………………….
Remarks:
…………………………………………………………………………….
Evaluation
3.3 Masala / Sweet Doughnuts
Ingredients
Masala doughnut Sweet Doughnut

Flour 1000 g 1000 g
Baking powder 15 g 15 g
Yeast 30 g 30 g
Water 150 ml 150 ml
Milk powder 40 g 40 g
Sugar 50 g 200 g
Vanaspati 150 g 150 g
Salt 25 g 5g
Eggs 4 nos. 4 nos.
Oil for frying
Green Masala 300 g (Onion, Coriander leaves, Curry leaves,
Green chilies, Ginger)
Sugar powder for sweet doughnut.
Procedure
 Sieve the flour with baking powder and milk powder twice.
 Dissolve yeast in 100 ml, luke warm water.
 Rub half of the fat in flour, add sugar and mix.
 Add eggs, ferment to the flour, add sugar and salt water, and knead to a smooth
dough with remaining fat.
 Rest the dough for 30 minutes. Add green masala and roll the dough to ¼ inch
thickness, cut with doughnut cutter. Again rest for 15 minutes.
 Gradually deep fry the doughnut till they acquire golden brown color.
 Roll the sweet doughnuts in sugar powder.
Nutritive value per 100 gms of ingredients

(g) (g) (g) (g) (mg) (mg) (Kcal) (Rs.)
Nutritive value of product per 100 gms

(g) (g) (g) (g) (mg) (mg) (Kcal) (Rs.)
Observations:
Total yield:
……………………………………………………………………………….
Cost of production:
……………………………………………………………………………….

……………………………………………………………………………….
Labelling:
……………………………………………………………………………….
Remarks:
…………………………………………………………………………….
Evaluation
3.4 Sponge cake
Ingredients Required
Ingredients Quantity
Maida 200 gm
Sugar 200 gm
Fat 200 gm
Baking Powder ½ t. Sp.
Egg 4 Nos.
Salt a pinch
Milk To mix
Vanilla flavor Few drops
Procedure
 Sieve Maida, baking powder and salt twice.

 Cream fat and sugar till light and (fluffy).
 Beat the egg with vanilla flavour.
 Add beaten eggs to the creaming mixture little by little all the time.
 Fold in Maida gently.
 Add sufficient milk to bring the mixture into dropping consistency.
 Put the mixture in the greased and dusted tin and level it uniformly.
 Bake at180oC for about 15-20 minutes.
 Cool the hot cake on the cooling rack.

(g) (g) (g) (g) (mg) (mg) (Kcal) (Rs.)

(g) (g) (g) (g) (mg) (mg) (Kcal) (Rs.)
Observations:
Total yield:
……………………………………………………………………………….
Cost of production:
……………………………………………………………………………….

……………………………………………………………………………….
Labelling:
……………………………………………………………………………….
Remarks:
…………………………………………………………………………….
Evaluation of the product

3.5 Instant Rava Idli Mix
Ingredients for Rava Idli mix
Rava 100 g
Salt 1g
Soda 1g
Oil 10 g / 2 tsp
Bengalgram dhal 1 tsp
Mustard ¼ tsp
Curry leaves few
Sour butter milk
Procedure
 Roast the rava in a pan, heat the oil, fry dal, mustard and curry leaves, add the
roasted rava, salt and soda, mix well.
 Roast rava in a pan, mix it with sour butter milk and then heat oil and fry the
dhal, mustard and curry leaves.
 Put the mixture on greased plate, steam for 10 minutes, after the time limit
reached remove the idli from the greased plate, instant rava idli will be ready.

(g) (g) (g) (g) (mg) (mg) (Kcal) (Rs.)

(g) (g) (g) (g) (mg) (mg) (Kcal) (Rs.)
Observations:
Total yield:
……………………………………………………………………………….
Cost of production:
……………………………………………………………………………….

……………………………………………………………………………….
Labelling:
……………………………………………………………………………….
Remarks:
…………………………………………………………………………….

3.6 Maida Chakli
Ingredients
Maida 100 g
Oil to fry (Approx. 20 g in the oil absorption)
Salt to taste
Chilli powder to taste
Ajvain ¼ tsp
Procedure
 Sieve maida in the siever. Tie it in a white thin cloth and steam it for about 20
minutes. It is done mainly to inactivate the gluten content.
 On cooling just press the lumps with your hands powder it and sieve it.
 Mix the heated oil, add salt and chilly powder though roughly and make a dough.
 Insert the dough into chakli mold such that it fits tight in the mold.
 Set the mold and roll out chakli of required size in circular form on a thick plastic
sheet.
 The oil should be heated and when it is heated fry the chaklies to light brown on
both the sides.
 After that allow it cool in a plate and store it in air tight containers and will remain a
fresh for more than a month, if fresh cooking oil is used.
Nutritional composition for the recipe
Ingredients Qty. Protei CHO Fat Fibre Ca P Energy Cost

n (g) (g) (g) (g) (mg) (mg) (Kcal) (Rs.)
Nutritional composition (per 100 g)

Observations:
Total yield:
……………………………………………………………………………….
Cost of production:
……………………………………………………………………………….

……………………………………………………………………………….
Labelling:
……………………………………………………………………………….
Remarks:
…………………………………………………………………………….

Experiment – 4
Objective
1. To know about Ragi and its value-added products
2. Development of value-added products from ragi Date__/__/____
Introduction
F inger millet (Elcusina coracona) ranks third in importance among millets in the
country after sorghum and pearl millet. It can be grown in poor water holding
capacity soils. The crop occupies an area of 1.75 mha and contributes 2.6 mt of
grain in India. The average productivity of finger millet in the country is 1550 kg / ha
(Anon 2009).
Nutritional composition of Ragi
Nutrients Amount (per 100 grams)
Carbohydras gm 72.2
Protein gm 7.3
Fat gm 1.3
Dietary Fibre 3.6

gm
Energy Kcal. 328
Calcium mg 344
Phosphorus mg 283
Iron mg 3.9
Ragi is a staple food for hundreds of millions of the poor who live on starchy
staples such as cassava, polished rice and or maize meal. Finger millet can be grown and
ground or cooked into flakes, cakes, dumplings or porridge. The grain is made into
fermented drink in some countries.
The finger millet grains are rich in calcium, iron, and proteins. It is also good food
for persons suffering from diabetes. The processed foods like malt, biscuits and cakes
are delicious for all age group of people.
Nutritional Value of Finger millet: Finger millet is often ground to a fine powder and
sold. It is depicted that in a 100 grams of Finger millet flour that major portion is
carbohydrate (72%), followed by protein and fiber. It has the least amount of fat in them
which is good. Protein (7.3g) and Fiber (3.6g) content is relatively good with an average
of 328 KCal of energy.
4.1 Ragi Hurihittu
Ingredients
Ragi 500 gms
Roasted Bengal gram 50 gms
Sugar 500 gms
Cardamom 4-6 units
The other ingredients used are coriander leaves, jeera, chopped chilli, chopped
onion, butter milk etc.
Preparation of Ragi Hurihittu

For preparation of ragi hurihittu, we need to prepare ragi hurihittu, soak ragi in
buttermilk for 1-2 hrs. and pop it and mill it.
Procedure
Ragi hurihittu majigae is prepared in the following way:
Ragi hurihittu
Mixing of all the curds/spices and condiments
Addition of sugar and salt in little quantity for taste
Mixing up thoroughly all the ingredients
Allow it for some time
Nutritive value per 100 gems of ingredients
Ingredients Protein CHO Fat Fibre Energy Ca Fe Cost

(g) (g) (g) (g) (Kcal) (mg) (mg) (Rs.)
Ragi
Sugar
Roasted
Bengal gram
Cardamom
Nutritive value of product per 100 gums
Ingredients Qty. Protei CH Fa Fibr Energ Ca Fe Cost

n (g) O t e (g) y (mg) (mg) (Rs.)
(g) (g) (Kcal)
Ragi
Sugar
Roasted
Bengal gram
Cardamom
Observations:
Total yield:
……………………………………………………………………………….
Cost of production:
……………………………………………………………………………….

……………………………………………………………………………….
Labelling:
……………………………………………………………………………….
Remarks:
…………………………………………………………………………….

4.2 Ragi laddu
Ingredients
Ragi hurihittu (Popped ragi mix) 200 gms
Jaggery 200 gms
Ground nut (peanut) 200 gms
Cardamom 2 units
Method
 Roast groundnut (peanut) till the raw flavor is gone completely. Allow it to cool
and remove the outer seed coat.
 Grind together all the ingredients like Ragi hurihittu, Jaggery, roasted groundnut
along with Cardamom to a fine powder. Mix nicely and shape it in the form of
laddu with hands.
 Serve this ragi laddu as a nutri-snack.

(g) (g) (g) (g) (Kcal) (mg) (mg) (Rs.)
Ragi hurihittu
(Popped ragi
mix)
Jaggery
Ground
nut(peanut)
Cardamom
Ingredients Qty. Protein CHO Fat Fibre Energy Ca Fe Cost

(g) (g) (g) (g) (Kcal) (mg) (mg) (Rs.)
Ragi
hurihittu
(Popped ragi
mix)
Jaggery
Ground
nut(peanut)
Cardamom
Observations:
Total yield:
……………………………………………………………………………….
Cost of production:
……………………………………………………………………………….

……………………………………………………………………………….
Labelling:
……………………………………………………………………………….
Remarks:
…………………………………………………………………………….

4.3 Ragi Shavige Mixture
Ingredients
Ragi 1000 gm
Water 400 ml
Bengal gram 100 gms
Groundnut 100 gms
Avalakki 100 gms
Coconut powder 150 gms
Chilli powder
Curry leaves 10 gm
Oil to roast
Tools
Shavige hollu
Noodles press with small holes
Pan
Spoon
Method
 Wash and soak ragi in water overnight (let the water be one inch above the ragi).
 Grind ragi.
 Dough preparation: Ragi flour 200 gms added to boiling water of 400 ml. Mix it
well and cook for 4 – 5 minutes.
 Pass dough through the vermicelli press, spreads it over on butter paper on a
tray.
 Dry it at 600C in a hot air oven. Weigh the final product after dry then cut into
small pieces.
 Add 2-3 spoon of oil to pan and roast the vermicelli. Then add ingredients like
curry leaves, avalakki, bengal gram, groundnut, coconut powder, chilli powder,
groundnut and Bengal gram (pre roasted separately). Cool the product, then pack
in a suitable container.

(g) (g) (g) (g) (Kcal) (mg) (mg) (Rs.)
Ragi
Water
Bengalgram
Groundnut
Avalakki
Coconut
powder
Chilli powder
Curry leaves
Oil

(g) (g) (g) (g) (Kcal) (mg) (mg) (Rs.)
Ragi
Water
Bengalgram
Groundnut
Avalakki
Coconut
powder
Chilli powder
Curry leaves
Oil
Observations:
Total yield:
……………………………………………………………………………….
Cost of production:
……………………………………………………………………………….

……………………………………………………………………………….
Labelling:
……………………………………………………………………………….
Remarks:
…………………………………………………………………………….

4.4 Ragi malt
Ragi 1kg
Wheat 250gm
Green gram 250gm
Cardamom 5gms
Equipment’s required
Flour mill
Roaster
Utensils
Sieve
Packaging and sealer
Procedure
 Soak ragi, wheat and green gram separately overnight (12 hours)
 Germinate ragi for 2 days (48 hours) and green gram, wheat for one day (24
hours)
 Dry in sunlight or drying oven at 700C for 8 hours
 Roast separately till it attains malt flavour (10-12 minutes) rub with hand, remove
vegetative parts by winnowing.
 Sprinkle ¼ cup water to ragi and rub well to moisten the surface (tempering).
Mill it separately
 Mill wheat, green gram and cardamom
 Sift with 60 mesh sieves
 Store in air tight containers.
Preparation of Beverage
 Boil 1 cup of water (100 ml) and 1 cup of milk (100 ml)
 Add sugar to taste 2 teaspoons
 Make a slurry of 2 teaspoon (10 g) Ragi malt powder
 Add it to the boiling milk and boil for 2 minutes
 Serve hot

(g) (g) (g) (g) (Kcal) (mg) (mg) (Rs.)
Ragi
Wheat
Green gram
Cardamom
Cost (Rs.)
Ingredients
Energy
Qty.
Protein (g)
CHO (g)
Fat (g)
Fe (mg)
Fiber (g)
Ca (mg)
(Kcal)
Ragi
Wheat
Green gram
Cardamom
Observations:
Total yield:
……………………………………………………………………………….
Cost of production:
……………………………………………………………………………….

……………………………………………………………………………….
Labelling:
……………………………………………………………………………….
Remarks:
…………………………………………………………………………….

4.5 Millet dosa mix
Ragi 200gm
Navane 100gm
Urad dal 75gm
Methi seeds 5gm
Salt 5 gm
Equipments required
Flour mill
Mixer
Utensils
Sieve
Packaging and sealer
Dosa Tava and Laddle
Method
 Soak ragi, navane, methi seeds for 2 hours and dry completely
 Mill all the ingredients and sieve
 Store in airtight container.
Dosa making directions
 Mix the flour with required amount of water and bring it to dosa batter
consistency.
 Keep it for one hour.
 Add salt to taste and make dosa like other dosas.

(g) (g) (g) (g) (Kcal) (mg) (mg) (Rs.)
Ragi
Navane
Urad dal
Methi seeds
Salt

(g) (g) (g) (g) (Kcal) (mg) (mg) (Rs.)
Ragi
Navane
Urad dal
Methi seeds
Salt
Observations:
Total yield:
……………………………………………………………………………….
Cost of production:
……………………………………………………………………………….

……………………………………………………………………………….
Labelling:
……………………………………………………………………………….
Remarks:
…………………………………………………………………………….

Experiment – 5
Objective
1. To know about Maize and its value-added products
2. Development of value-added products from Maize
3. Calculation of Nutritive value, cost and………. of developed products. Date__/__/___
Processing and Value-Added Products of Maize
Maize (Zea mays) kernel is the largest of all the cereals. It also has a relatively larger
germ than other cereals and contributes to 10-14 per cent of the kernel weight. Most of
the oil (81-86%) is present in the germ. Total carbohydrates accounts for as much as 60-
70 per cent of the seed weight. Protein ranges from 8-14 per cent. Maize is used to
produce corn starch, corn oil and various animal feed products. However, partly it is
used for food products and alcoholic beverages.
Nutritive value of Maize
Moisture 14.9
Protein (g) 11.1
Carbohydrate (g) 66.2
Fat (g) 3.60
Energy (Kcal) 342
Fiber 2.7
Calcium (mg) 10.0
Iron (mg) 2.0
β-carotene 90.0
Processing of Maize (Lime treatment)
Maize
Soak 500 g grains in 1% lime for 5 mins.
Heat treatment at simmering temperature for 30 mins.
Remove vessels, leave it overnight
Wash 3-4 time to remove lime
Dry in sunlight (moisture – 9 -10%)
Store in air tight container

5.1 Maize Uppittu
Ingredients
Maize rava 100 g

Oil 30 ml
Mustard 2g
Redgram dhal 5g
Onion 50 g
Curry leaves few
Green chillies 5g
Water 300 ml
Method
 Roast rava till good aroma
 Heat oil, add seasoning ingredients
 Fry onions till golden brown colour
 Add water to the above and heat it to boiling temperature
 Add roasted maize rava and stir it smoothly and leave it for 5-10 minutes in
simmering temperature.
Ingredients Qty. Protein CHO Fat Fibre Ca P Energy Cost

(g) (g) (g) (g) (mg) (mg) (Kcal) (Rs.)

(g) (g) (g) (g) (mg) (mg) (Kcal) (Rs.)
Observations:
Total yield:
……………………………………………………………………………….
Cost of production:
……………………………………………………………………………….

……………………………………………………………………………….
Labelling:
……………………………………………………………………………….
Remarks:
…………………………………………………………………………….
5.2 Maize sweet

Ingredients
Maize Rava 100 g
Fat 60 g
Sugar 75 g
Cardamom 5g
Water 350 ml
Method
 Roast rava oil good aroma
 Heat fat, cashew nuts and resins
 Add water to the above and heat to it to boiling temperature and leave it for 10-
15 mins. in simmering temperature.

(g) (g) (g) (g) (mg) (mg) (Kcal) (Rs.)

(g) (g) (g) (g) (mg) (mg) (Kcal) (Rs.)
Observations:
Total yield:
……………………………………………………………………………….
Cost of production:
……………………………………………………………………………….

……………………………………………………………………………….
Labelling:
……………………………………………………………………………….
Remarks:
…………………………………………………………………………….

5.3 Maize Nutri Pakoda
Ingredients
Maize flour 20 g
Basan flour 20 g
Ragi flour 20 g
Wheat flour 20 g
Rice flour 20 g
Onions 50 g
Green chillies 5 in no.
Grated carrot 20 g
Grated potato 20 g
Green leafy vegetables* 20 g
Curry leaves few
Ginger 10 g
Jeera 5g
*drumstic leaves, anne soppu, sabsige soppu
Method
 Mix all the flours and vegetables with 100 ml water and required amount of salt.
 Heat oil in frying fan.
 Deep fry the pakodas.
 Serve hot.

Nutritional composition of products (per 100 g)

Observations:
Total yield:
……………………………………………………………………………….
Cost of production:
……………………………………………………………………………….

……………………………………………………………………………….
Labelling:
……………………………………………………………………………….
Remarks:
…………………………………………………………………………….
Experiment – 6
Date __/__/___
Objective
1. To know about Green Leafy Vegetables and its value-added products
G
GREEN LEAFY VEGETABLES AND ITS VALUE-ADDED PRODUCTS
reen leafy vegetables are vital for growth and good health as they contain all
important nutrients. In India, a wide range of greens are consumed. The most
popular ones being Spinach, Amaranth, Gogu, Fenugreek, Drumstick leaves,
Mint etc. Leafy vegetables are particularly rich in mineral nutrient and iron. Iron
deficiency leads to anemia, a common health problem among pregnant and lactating
women and also children. Inclusion of greens in daily diet would help prevent anemia
and promote good health. Green leafy vegetables are also a rich source of Calcium, Beta
carotene and Vitamin C.
In India, nearly 30,000 children under five years of age go blind every year due
to Vitamin A deficiency. Carotene in greens gets converted in the body to form Vitamin
A which prevents blindness. To preserve Vitamin C content in greens, prolonged
cooking should be avoided, as this nutrient, which keeps gums in good condition is lost
on overcooking.
Greens also contain some of the B-Complex Vitamins. The recommended dietary
allowance of green leafy vegetables for an adult woman is 100g/day, adult man
40g/day, preschool children (4-6 yrs) and for boys and girls beyond 10 yrs of age it is
50g/day.
Leafy vegetables are ideal for weight management as they are typically low in
calories. They are useful in reducing the risk of cancer and heart disease since they are
low in fat, high in dietary fiber, and rich in folic acid, vitamin C, potassium and
magnesium, as well as containing a host of phytochemicals, such as lutein, beta-
cryptoxanthin, zeaxanthin, and beta-carotene. One study showed that an increment of
one daily serving of green leafy vegetables, lowered the risk of cardiovascular disease by
11 percent. In the Adventist health study, the frequent consumption of green salads by
African-Americans was associated with a substantially lower risk of mortality.
Because of their high magnesium content and low glycemic index, green leafy
vegetables are also valuable for persons with type 2 diabetes. An increase of 1
serving/day of green leafy vegetables was associated with a 9 percent lower risk of
diabetes. The high level of vitamin K in greens makes them important for the production
of osteocalcin, a protein essential for bone health. The risk of hip fracture in middle-
aged women was decreased 45% for one or more servings/day of green, leafy
vegetables compared to fewer servings.
6.1 Composite flour of Green Leafy Vegetables
Ingredients
Wheat flour = 750 g
Bengal gram = 200g
Soya flour = 50 g
Spinach powder = 20 g
Green powder = 20 g
Procedure
 Spinach powder is prepared by taking a bundle of spinach leaves and wash, then
dry the leaves in oven upto 5-10 minutes, dried leaves are grind thoroughly to
get the spinach powder.
 Bengal gram of about 200 g should be powdered.
 Wheat flour 750 g, soya flour 50 g, Bengal gram powder 200 g and spinach
powder 20 g. Mix all the flours to get a composite flour.


Observations:
Total yield:
……………………………………………………………………………….
Cost of production:
……………………………………………………………………………….

……………………………………………………………………………….
Labelling:
……………………………………………………………………………….
Remarks:
…………………………………………………………………………….
6.2 Composite Flour of Carrot Powder

Principle Nutrient value of percentage of RDA
Energy 41 Kcal 2%
CHO 9.58 g 7%
Protein 0.93 g 1.5%
Fat 0.24 g 1%
Cholesterol 0 mg 0g
Dietary fiber 2.8 g 7%
Minerals: Ca 3%, Cu 5%, Iron 4%, Mg 6%, Mn 3%, P 5%, Zn 2%, Na 4.5% and K 6.5%.
Ingredients
Dry carrot powder 20 g
Wheat flour 750 g
Soya flour 50 g
Bengal gram 200 g
Methods
 For carrot powder preparation
i) Wash the carrot with the fresh water and remove soil and dust particles.
ii) Grate the carrot using crater and put into the tray.
iii) Keep the tray in hot air oven at 600C for 20-24 hours.
iv) Grind the dry carrot powder using grinder.
v) One kg of carrot yields about 100-150 g of dry carrot powder.
 Carrot powder + Composite flour
i) Mix the all the ingredients i.e., dry carrot powder 20 g + 750 g of wheat flour
+ 50 g of soya flour + 200 g of bengal gram powder


Observations:
Total yield:
……………………………………………………………………………….
Cost of production:
……………………………………………………………………………….

……………………………………………………………………………….
Labelling:
……………………………………………………………………………….
Remarks:
…………………………………………………………………………….
6.3 Preparation of Nippattu from composite flours
Ingredients
Composite flour 50 g
Oil 50 g
Chopped onions 100 g
Coarsely grind groundnut 50 g
Gingelly seeds 10 g
Coriander and curry leaves 5g
Roasted fenugreek seed powder Pinch
Hing or Aspoetida ¼ ts
Cumin seeds ½ ts
Salt 1 ts
Method of Preparation
 Sieve the flour together along with salt
 Rub in oil, mix remaining ingredients
 Prepare soft dough with little water
 Divide dough into small balls
 Flatten these on plastic paper
 Place on the greased baking plate
 Bake in pre-heated oven
 Cool and pack in HDPE pouches
Nutritional composition for the Ingredients

Observations:
Total yield:
……………………………………………………………………………….
Cost of production:
……………………………………………………………………………….

……………………………………………………………………………….
Labelling:
……………………………………………………………………………….
Remarks:
…………………………………………………………………………….

6.4 Carrot Composite Flour Laddu
Ingredients
Carrot composite flour* 125 g
Sugar powder 75 g
Ghee 50 g
Cardamum 1 pinch
Cashewnut 10 g
Resins 10 g
Milk 20 ml
*Combination of carrot based composite flour
Dry carrot powder 20 g
Wheat flour 750 g
Soya flour 50 g
Bengal flour 200 g
Methods
 Mix carrot composite flour with cardamom, cashewnut powder and resin
thoroughly.
 Fry the flour with ghee
 Mix the fried flour with sugar powder
 Then make it small balls by using heated milk


Observations:
Total yield:
……………………………………………………………………………….
Cost of production:
……………………………………………………………………………….

……………………………………………………………………………….
Labelling:
……………………………………………………………………………….
Remarks:
…………………………………………………………………………….

6.5 Multi Grain Sattu
Ingredients
Wheat 1 kg
Ragi 1 kg
Bengal gram or dhal ½ kg
Green gram or dhal ½ kg
Sugar 2 kg
Dry coconut 200 g (Optional)
Cardamom few
Method
 Roast all the grains till they are golden brown
 By droping small quantity at a time and using slow fire
 Mix roasted grain with sugar, dry coconut and cardamom and grind to fine
powder and pack
 Calculate the energy, protein, calcium, iron and fibre


Observations:
Total yield:
……………………………………………………………………………….
Cost of production:
……………………………………………………………………………….

……………………………………………………………………………….
Labelling:
……………………………………………………………………………….
Remarks:
…………………………………………………………………………….

Experiment – 7
Date__/__/____
Objective
3. Calculation of Nutritive value, cost and………. of developed product
G
GRAIN AMARANTHUS AND ITS VALUE-ADDED PRODUCTS
rain amaranth, a pseudo cereal is being grown in Kolar, Tumkur Bangalore
districts; Suvarna variety was developed at University of Agricultural Sciences,
Bangalore, which is resistant to lodging, high yielding and matures in 90-95
days. It yields 12-15 quintals per hectare. It is a ‘lysine’ rich crop; it contains 17-18 per
cent protein which is nearly 2 ½ times higher than conventional cereals. It could be used
both for grains and greens; leaves are rich in vitamin-A, calcium and iron content.
Nutrient composition of Grain Amaranth (per 100g)
Moisture 9.39 g
Protein 16.5 g
Fat 5.3 g
Carbohydrates 62.7 g
Minerals 3.5 g
Fibre 2.79 g
Energy 364 K.cal
Calcium 223 mg
Iron 17.6 mg
Lysine 7-8%
Amaranth is an extremely nutritious grain that is also called ‘Pseudo cereal’ or ‘Pseudo-
grain’. It’s high in protein, particularly in the amino acid, lysine, which is low in the cereal
grains. In fact, amaranth has the highest lysine content of all the grains. It is also highest
in fibre content 24%. This makes amaranth an effective agent against cancer and heart
diseases. Fat 8%, Fe 17.3%, lysine (gm) 0.74 and methionine in grams 0.22. It is very
higher content in amaranth compare to all other cereals. But this grain is not consume
as a whole it should be supplemented with other food stuffs like with wheat flour for
chapathi making etc. This amaranth popped grain is good for children and also adults
Amaranth Chikki is combination of ingredients such as jaggery (a sweetner material),
popped amaranthus seeds, groundnuts and ghee. The preparation of chikki is very
simple. Jaggery is very popular sweet item in both rural and urban, South Asia (Sparring
India, Pakistan, Bangladesh, Nepal and Sri Lanka).
Most popular chikki are sourced from the Indian towns of Lonavla, Matheran and
Karjat near Mumbai. Special chikki are made out of cashews, almonds and pistachios.
Though jaggery is the usual sweetner material, sugar is used as the base in certain types
of chikki.
But today there are many with a larger different exotic flavours available in the
market. Similar preparations are made in the market of South India, but with a larger
proportion of nuts to sugar and the mixture is formed into balls rather than slabs. The
most common versions are kadalai urundai (peanut balls), ellu urundai (sesame balls)
and pori urundi (puffed rice balls).
7.1. Popped Grain Amaranth
Ingredients
Amaranth grains (which showed be free from other impurities)
Method of Preparation
Take 1 kg of amaranth grains (dried grains)
The pan should be heated for 5 min. So that it has enough
Heat to popp the grains
Put the amaranth grains in the hot pan at little quantity
Take cloth and stir over the seeds so, that the grains get popped
uniformly
Nutritional composition for the Ingredients per 100 gm

Observations:
Total yield:
……………………………………………………………………………….
Cost of production:
……………………………………………………………………………….

……………………………………………………………………………….
Labelling:
……………………………………………………………………………….
Remarks:
…………………………………………………………………………….
7.2 Popped Grain Amaranth Sweet Mixture
Ingredients
Popped amaranthus 250 gm
Roasted Bengal gram 250 gm
Puffede rice (Puree) 100 gm
Bella 100 gm
Roasted groundnut 100 gm
Copra grating 50 gm
Method
 Roasted groundnut
 Greating the dry coconut
 Mix with popped amaranthus
 Mix with roasted Bengal gram


Observations:
Total yield:
……………………………………………………………………………….
Cost of production:
……………………………………………………………………………….

……………………………………………………………………………….
Labelling:
……………………………………………………………………………….
Remarks:
…………………………………………………………………………….
7.3 Popped Grain Amaranth Mixture Savoury

Ingredients
Popped amaranthus 250 gm
Avalaki 250 gm
Groundnut 150 gm
Roasted Bengal gram 150 gm
Curry leaves, Oil & Jeera – little amount
Chilli Powder – to taste
Salt – to taste
Method
 Fry Avalaki
 Roast Groundnut in oil
 Mixed with popped amaranthus
 In a Pan, take little oil & season with curry leaves
 Add the above Mixture to the seasoning, stir well
 Sprinkle salt & chilli powder

Observations:
Total yield:
……………………………………………………………………………….
Cost of production:
……………………………………………………………………………….
……………………………………………………………………………….
Labelling:
……………………………………………………………………………….
Remarks:
…………………………………………………………………………….
7.4 Amaranthus Laddu

Ingredients
Amaranth seeds 300 g
Bengal gram 50 g
Groundnut 100 g
Jaggery 200 g
Ghee 12 g
Procedure
 Make a jaggery syrup to hard ball consistently.
 Roasted Bengal gram roasted
 Amaranth seeds should be roasted without oil.
 Totally mix all the ingredients and look for 3 to 4 min. and put of the heat.
 Mix with a jaggery syrup and make laddus of appropriate size.
Note: To test syrup consistency, drop a little quantity of syrup into water. It comes out as
hard ball, then the right syrup consistency is reached.

Observations:
Total yield:
……………………………………………………………………………….
Cost of production:
……………………………………………………………………………….

……………………………………………………………………………….
Labelling:
……………………………………………………………………………….
Remarks:
…………………………………………………………………………….

7.5 Amaranthus Chikki
Ingredients
Popped grain amaranthus 50 g
Roasted Bengal gram 25 g
Roasted groundnut 25 g
Jaggery 200 g
Ghee 5g
Methods
 In a pan, boil ¼ cup of water, add jaggery and boil the jaggery till hard ball
consistency. Add ghee and then boil.
 Add the roasted Bengal gram, groundnuts and popped grain amaranthus. Mix
them well in the boiling jaggery.
 Transfer the solid on to a greased plate and cut into required shape

Observations:
Total yield:
……………………………………………………………………………….
Cost of production:
……………………………………………………………………………….

……………………………………………………………………………….
Labelling:
……………………………………………………………………………….
Remarks:
…………………………………………………………………………….
7.6 Amaranthus Paustic Chapathi
Ingredients
Amaranthus (flour) 250 g
Wheat flour 500 g
Grated carrot 100 g
Salt to taste
Oil 5g
Coconut powder 50 g
Method
 Mix throughly all the ingredients like amaranthus, wheat flour, grated carrot, salt
and coconut powder.
 Add little water to make desired dough
 After the dough is ready, take required dough for the roll.
 Roll the dough by using roller.
 Roast the rolled dough with little oil for few minutes.

Observations:
Total yield:
……………………………………………………………………………….
Cost of production:
……………………………………………………………………………….

……………………………………………………………………………….
Labelling:
……………………………………………………………………………….
Remarks:
…………………………………………………………………………….

Experiment – 8
Objective
3. Calculation of Nutritive value, cost and………. of developed products.Date__/__/____
S
SOYBEAN AND ITS VALUE-ADDED PRODUCTS
oybeans or soya beans (Glycine max) are a type of legume native to eastern
Asia. They are an important component of Asian diets and have been consumed
for thousands of years. Today, they are mainly grown in Asia and South and
North America. In Asia, soybeans are often eaten whole, but heavily processed soy
products are much more common in Western countries. Various soy products are
available, including soy flour, soy protein, tofu, soy milk, soy sauce, and soybean oil.
Soybeans contain antioxidants and phytonutrients that are linked to various health
benefits. However, concerns have been raised about potential adverse effects. Soybeans
are among the best sources of plant-based protein.
The protein content of soybeans is 36–56% of the dry weight. The nutritional
value of soy protein is good, although the quality is not quite as high as animal protein.
The main types of protein in soybeans are glycinin and conglycinin, which make up
approximately 80% of the total protein content. These proteins may trigger allergic
reactions in some people.
Consumption of soy protein has been linked with a modest decrease in cholesterol
levels Soybeans are classified as oilseeds and used to make soybean oil. The fat content
is approximately 18% of the dry weight — mainly polyunsaturated and
monounsaturated fatty acids, with small amounts of saturated fat. The predominant
type of fat in soybeans is linoleic acid, accounting for approximately 50% of the total fat
content. Being low in carbohydrates, whole soybeans are very low on the glycemic index
(GI), which is a measure of how foods affect the rise in blood sugar after a meal.This low
GI makes soybeans suitable for people with diabetes.
Soybeans contain a fair amount of both soluble and insoluble fiber. The insoluble
fibers are mainly alpha-galactosides, which may cause flatulence and diarrhea in
sensitive individuals .Despite causing unpleasant side effects in some people, soluble
fibers in soybeans are generally considered healthy.They are fermented by bacteria in
your colon, leading to the formation of short-chain fatty acids (SCFAs), which may
improve gut health and reduce your risk of colon cancer .
Nutritional quality of Soybean
 Soybean with 40 per cent of protein

 Soybean with 20 per cent of oil
 Great potential to slove problem of PEM which exixts in India
 Quality of protein is judged with its essential amino acids make up (8 e.a.a.)
 Soya oil contains 80 per cent of unsaturated fatty acids
 Soya and Bone health Asteoporosis in bone density and strength in women
(Menopause)
Increase Soya Improves
Calcium content in the body Bone minerals content
Bone mineral loss Bone mineral density
Importance of value of soya in human diet
Soybean has been variously called:
 The miracle golden bean
 Nuggest of nutrition
 Cow of China
 Gold from soil
 Wonder bean etc
Indicating it value and importance in different parts of the world over several
thousands of years. China is using since 4000 years.
Currently soya utilization 10-15 per cent is used has consumption ................ for oil
extraction and soya meals to animal feed.
The soybean is considered a complete food because it contains protein,

carbohydrate and fat, as well as impressive .......... of vitamins and minerals including iron,
phosphorus, magnesium, thiamine, riboflavin and niacin.
It is a richer source of protein compared to an equivalent amount of cheese, milk,
eggs or even fish. It is natural source of fibre.
It is very versible and can be used as a base for a variety of products such as .....,
soups, drinks, sauces, dressings, mayonnaise, yoghurts, ice creams and cheese, chutney
puri, etc.
Chutney puri can be making by addition of soya powder and other ingredients
and are good in test and higher protein content.
8.1 Soya Chutney Pudi
Ingredients
Soyadal 200 g
Groundnut 100 g
Roasted Bengal gram 100 g
Dry coconut 100 g
Dry chilli 50 g
Tamarind 25 g
Garlic 25 g
Curry leaves 5g
Sugar 10 g
Salt to taste
Total
Method
 Roast soya, groundnut, chillies and curry leaves without oil.
 Grind dry coconut then mix all ingredients together and grind them.

Observations:
Total yield:
……………………………………………………………………………….
Cost of production:
……………………………………………………………………………….

……………………………………………………………………………….
Labelling:
……………………………………………………………………………….
Remarks:
…………………………………………………………………………….
8.1 Soya nuts
Ingredients
Soybean 200g
Salt to taste
Sodium bicarbonate few grams
Oil for fry
Methods
 Soak soybean in H2O containing 5% table salt and 3% sodium bicarbonate for
3 hrs.
 Drained water and remove surface moisture.
 Then deep fat fry and add salt and chilli powder for taste.

Observations:
Total yield:
……………………………………………………………………………….
Cost of production:
……………………………………………………………………………….

……………………………………………………………………………….
Labelling:
……………………………………………………………………………….
Remarks:
…………………………………………………………………………….

8.2 Soya Milk and Paneer
Ingredients
Soya Milk 1 litre
NaCo3 1gm
Cows Milk 250 ml
Citric acid 10 gm
Procedure
Cleaning and soaking of soybeans
Washing and grinding
Cooking of slurry
Filtration
Pressing & packing

Observations:
Total yield:
……………………………………………………………………………….
Cost of production:
……………………………………………………………………………….

……………………………………………………………………………….
Labelling:
……………………………………………………………………………….
Remarks:
…………………………………………………………………………….

Experiment – 9 Objective
1. Development of value-added products from Flax Seed
2. Calculation of Nutritive value, cost and………. of developed product
Date__/__/____
9.1 Flax Seed Chutney Powder
Ingredients
Flax seeds 250 gm

Ground nuts 250gm
Fried gram 100gm
Red chilly powder 25gm
Jaggery 25 gm
Tamarind Marble size
Curry leaves few
Salt to taste
* Tsp-Table spoon and tsp- tea spoon
Method:
 Roast the ingredients.
 Mix them and grind into powder.
Blended powder may be used as a side dish for chapatti or dosa. Also eaten with
boiled rice and ghee. The powder can be stored in dry container for 15 to 20 days.


Observations:
Total yield:
……………………………………………………………………………….
Cost of production:
……………………………………………………………………………….

……………………………………………………………………………….
Labelling:
……………………………………………………………………………….
Remarks:
…………………………………………………………………………….

Experiment – 10
(1) Processing of turmeric powder
Objective
T
PROCESSING OF TURMERIC POWDER
Date__/__/____
he turmeric (Curcuma longa ) is made of the ground rhizomes of the plant. The
bright yellow color of processed turmeric has inspired many cultures to use it as
a dye. Ground turmeric is also a major ingredient in curries. Capsules, teas,
powders, and extracts are some of the turmeric products available commercially.
Curcumin is the active ingredient in turmeric, and it has powerful biological properties.
Ayurvedic medicine, a traditional Indian system of treatment, recommends
turmeric for a variety of health conditions. These include chronic pain and inflammation.
Western medicine has begun to study turmeric as a pain reliever and healing agent.
While turmeric is a flavorsome spice that is nutritious to consume, it has also
traditionally been used in Ayurvedic and Chinese medicine to treat inflammatory
conditions, skin diseases, wounds, digestive ailments, and liver conditions.
Some of the health benefits of turmeric are as follows:
Anti-inflammatory properties: The Arthritis Foundation cites several studies in which
turmeric has reduced inflammation. This anti-inflammatory ability might reduce the
aggravation that people with arthritis feel in their joints.
Pain relief: Turmeric is thought of as a pain reliever. The spice is reputed to relieve
arthritis pain as well .Studies seem to support turmeric for pain relief, with one
study noting that it seemed to work as well as ibuprofen (Advil) in people with arthritis
in their knees.
Improving liver function: Turmeric has been getting attention recently because of
its antioxidant abilities. The antioxidant effect of turmeric appears to be so powerful that
it may stop your liver from being damaged by toxins. This could be good news for
people who take strong drugs for diabetes or other health conditions that might hurt
their liver with long-term use.
Possibly reducing the risk of cancer: Curcumin shows promise as cancer treatment.
Studies suggest it has protective effects against pancreatic cancer, prostate cancer, and
multiple myeloma.
Digestion: Turmeric can help digestion. Turmeric adds flavor to food, which explains its
presence in curry powder. However, turmeric can also play an important role in
digesting that food. The spice can contribute to healthy digestion as a result of its
antioxidant and anti-inflammatory properties. The spice is even being explored as a
treatment for irritable bowel syndrome (IBS).
Including turmeric in the diet: Turmeric is a highly versatile spice that can be added to
meals in a range of ways, including adding turmeric into spice mixtures such as curry or
barbecue rub. Making a homemade dressing using part oil, part vinegar, and seasonings
including turmeric
Flowchart for processing of turmeric powder
Turmeric rhizomes
Boiling at 100 0 C for 45 to 50 min
Break turmeric into small pieces
Oven dry at 650C for 48 hrs or sun dry for 3 days
Milling
Turmeric powder (60-80 mesh)
Packing


Observations:
Total yield:
……………………………………………………………………………….
Cost of production:
……………………………………………………………………………….

……………………………………………………………………………….
Labelling:
……………………………………………………………………………….
Remarks:
…………………………………………………………………………….

Experiment – 11
To know about Preparation of Pickles
Objective
T
Preparation of Pickles
Date__/__/____
he history of pickles began long years back, when the journey used to be long
and the travellers comes back home after months of voyages and travels, that
time when it was thought of preserving food and vegetables and preparing
long lasting food which could retain its taste as well as freshness.
Salt is a condiment which enables to keep everything fresh and avoid excess
moisture of the food item like salad and vegetables, to be fresh for many days. Another
idea behind this was to preserve the vegetables and fruits even after their season were
over
Today every part of world process its own fundamental ideas regarding pickles.
Not even a single vegetable is left that could escape the pickle experimentation.
Although there were several other methods to preserve the food items like canning,
drying, fermentation, smoking and sugaring etc. However, pickling that could take as
many experiment as were possible. And the spiced-up version became extraordinary
popular than other methods of preserving food
Pickling
Pickling is also known as brining or curing, the process of preserving food by an

aerobic fermentation on brine (a solution of salt in water) to produce lactic acid or
marinating and storing it in an acid solution, usually vinegar (acetic acid). The resulting
food is called a pickle. This procedure gives the food a salty or sour taste. Edible oils are
used as the pickling medium instead of vinegar
Methods of pickling
Pickling is a method of preserving food in an edible anti-microbial liquid. Pickling
can be broadly categorized as chemical pickling (for example, brining) and fermentation
pickling (for example, making saurkrant)
In chemical pickling
The food is placed in an edible liquid that inhibits or kills bacteria and other
micro-organisms. Typical pickling agents include brine (high in salt), vinegar, alcohol
and vegetable oil, especially olive oil but also many other oils.
In fermentation pickling
The food itself produces the preservation agent, typically by a process that
produces lactic acid, fermented pickle include saurkrant, and pickled cucumbers are also
fermented.
In commercial pickles, a preservative like sodium benzonte or EDTA may also be
added to enhance shelf life.
11.1 Bitter gourd pickle (South Indian)
Ingredients
Bitter gourd (small variety) ¼ kg
Tamarind / lime 65 g
Red chilli powder 65 g
Salt 65 g
Garlic 10 g (1tbsp)
Ginger 10 g
Oil 125 g
Method
 Peal and apply turmeric and salt to bitter gourds.
 Keep aside for ½ hour.
 Put tamarind in hot water and grind with salt, chilly powder, garlic to a
course paste.
 Heat the oil add all the seasoning materials and season
 After cooling add bitter gourd and ground paste.
 Mix well.
 Store in a glass jar or pickle jar.
For seasoning
Bengal gram dal 10 g
Urad dal 10 g
Mustard 10 g
Garlic 10 g
Jeera 5g
Curry leaves 3g
Red chillies 5g

Observations:
Total yield:
……………………………………………………………………………….
Cost of production:
……………………………………………………………………………….

……………………………………………………………………………….
Labelling:
……………………………………………………………………………….
Remarks:
…………………………………………………………………………….
11.2 Carrot Pickles
Ingredients
Carrot 250 g
Red chilli powder 100 g
Salt 100 g
Turmeric 1 + tsp
Methi powder 1t sp
Mustard 1 tsp
Garlic 20 g
Oil 50 g
2 lime juice
Method
 Cut carrot into small pieces, add salt, turmeric, chilli powder, methi powder,
mustard powder and lemon juice then mix well.
 Heat oil, add garlic and cool it then add other ingredients.
 Fill it in bottle and cover in oil.


Observations:
Total yield:
……………………………………………………………………………….
Cost of production:
……………………………………………………………………………….

……………………………………………………………………………….
Labelling:
……………………………………………………………………………….
Remarks:
…………………………………………………………………………….

Experiment - 12
Objective
To know about Tomato and Its Value-Added Products
TOMATO AND ITS VALUE-ADDED PRODUCTS
T
he tomato fruit is consumed in diverse ways, including raw, as an ingredient in
many dishes and sauces, and in drinks. While it is botanically a fruit, it is
considered as a vegetable for culinary purposes. The fruit is rich in lycopene,
which has beneficial health effects.
Nutrition
Tomatoes are now eaten freely throughout the world, and their consumption is
believed to benefit the heart, among other organs. They contain the carotene lycopene,
one of the most powerful natural antioxidants. In some studies, lycopene, especially in
cooked tomatoes, has been found to help prevent prostate cancer, but other research
contradicts this claim. Lycopene has also been shown to improve the skin's ability to
protect against harmful UV rays. Natural genetic variation in tomatoes and their wild
relatives has given a genetic plethora of genes that produce lycopene, carotene,
anthocyanin, and other antioxidants. Tomato varieties are available with double the
normal vitamin C (Doublerich), 40 times normal vitamin A (97L97), high levels of
anthocyanin (resulting in blue tomatoes), and two to four times the normal amount of
lycopene (numerous available cultivars with the high crimson gene).
Medicinal properties
Lycopene has also been shown to protect against oxidative damage in many
epidemiological and experimental studies. In addition to its antioxidant activity, other
metabolic effects of lycopene have also been demonstrated. The richest source of
lycopene in the diet is tomato and tomato derived products. Tomato consumption has
been associated with decreased risk of breast cancer, head and neck cancers and might
be strongly protective against neurodegenerative diseases. Tomatoes and tomato
sauces and puree are said to help lower urinary tract symptoms (BPH) and may have
anticancer properties.
12.1 Tomato Ketchup
Ingredients
Tomato juice - 1 kg
Sugar - 80 gm
Salt - 10 gm
Acetic acid - 4 ml.
Red chilli powder - 1tsp
Ginger - 1 inch
Onion - 10 gm
Cloves - 2-3nos.
Cinnamon - 1small piece
Cardamom - 2-3nos.
Jeera - 1/2 tsp
Pepper - 1/2 tsp
Sodium Benzoate - 30 mg
* tsp-teaspoon
Method
 Cut tomatoes into small pieces and boil for five minutes to get pulp
 Boil tomato pulp adding chilli powder, half sugar on a medium flame for two minutes
then add spice bag (spices, onion, ginger should be tied loosely in a muslin cloth bag).
Then add remaining sugar.
 Acetic acid should be added towards end of boiling.
 Boil the juice till 1/3rd of the original volume.

Observations:
Total yield:
……………………………………………………………………………….
Cost of production:
……………………………………………………………………………….

……………………………………………………………………………….
Labelling:
……………………………………………………………………………….
Remarks:
…………………………………………………………………………….

12.2 Tomato Thokku
Ingredients
Tomato 450 gms

Chilli powder 1 tsp
Methi powder ¼ tsp
Salt ½ tsp
Mustard ¼ tsp
Asafoetida ¼ tsp
Tamarind paste ½ tsp
Oil 6 Tsp
Method
 Blend tomatoes and let it boil until it becomes a thick paste.

 Fry mustard, asafoetida, chilli powder, and roasted methi powder in 6 tsp of oil,
and add this to the boiling tomato paste.
 Put salt and tamarind paste and allow it to cook for a few minutes


Observations:
Total yield:
……………………………………………………………………………….
Cost of production:
……………………………………………………………………………….

……………………………………………………………………………….
Labelling:
……………………………………………………………………………….
Remarks:
…………………………………………………………………………….

12.3 Tomato Carrot Soup
Ingredients
Tomatoes -1/2 kg
Carrot -200 g
Salt -2 tsp, or to taste
Powdered black pepper -1/4 tsp water
Sugar (optional) -1 tsp
Onion (Chopped) -1 tsp
Corn Starch -½ tsp
Grated carrot -for garnishing
Cream/butter -for garnishing
Method
 Chop the tomatoes and carrots. Put them to boil partially covered with one cup
water and salt.
 When it comes to a boil, lower the heat and simmer till the vegetables are
completely cooked through. Cool and pass through a soup strainer or blend in a
blender and then strain. Add water to make up to 4 1/2 cups of liquid. If required
add corn starch.
 Put on the fire and bring to a boil and simmer. Add sugar, salt and pepper. Simmer
for about 10 minutes.
 Serve garnished with the cream/butter and carrots.

Observations:
Total yield:
……………………………………………………………………………….
Cost of production:
……………………………………………………………………………….

……………………………………………………………………………….
Labelling:
……………………………………………………………………………….
Remarks:
…………………………………………………………………………….
Experiment – 13
Date__/__/___
Visit to Krishimela
Experiment –
Experiment –14
Date__/__/___
Visit to international trade fair

Experiment – 15
Date__/__/___
Visit to bakery training unit
Experiment – 16
Date__/__/___
Commercial processing and marketing

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UNIVERSITY OF AGRICULTURAL

DEPARTMENT OF FOOD SCIENCE AND NUTRITION

HANDS ON TRAINING (HOT)

Course Title : Commercial Food Processing and

DEPARTMENT OF FOOD SCIENCE AND NUTRITION

Introduction - Commercial Food Processing and

1. Introduction to Food Processing Equipment’s

Wheat and its value-added products

Ragi and its value-added products

5. Processing and Value-Added Products of Maize

Green Leafy Vegetables and its Value-Added

Grain Amaranthus and its Value-Added Products

Soybean and its Value-Added Products

8.  Soya Chutney Pudi

Flax Seed and its Value-Added Products

10. Processing of Turmeric Powder

Tomato and its value-added products

University of Agricultural Sciences, Bangalore

satisfactorily completed the course experiments in PHT-402,

Commercial Food Processing and Value Addition (0+5)

Agriculture, University of Agricultural Sciences, GKVK, Bangalore for IV

B.Sc. (Agri.) during the year 2018-19

Date ……………….. Signature of the Student

Signature of the Teachers

Signature of Head of the Department

Food processing is the conversion of agricultural product to substances

Primary processing is the conversion of raw materials to food commodities. Milling is an

Secondary processing is the conversion of ingredients into edible products – this

Product Development for Commercial Processing

Product development is the process of making new or modified food products.

2. Test ideas on a small scale: Research is carried out to form a number of

3. Sensory evaluation: Sensory evaluation is carried out at many stages of the

7. Perform consumer testing

9. Produce product on a large scale: The manufacturing process is sometimes

Stages in Practical Product Development

 Small scale bench work i.e., one off production – prototype

Storage of ingredients e.g., in hoppers, bins, etc.

Weigh and mix ingredients - formulation

Packaged and Labelled

Stored usually on pallets

Dispatched for transportation

Benefit of Processing and Preservation

Food Processing and Preservation Technologies

Introduction to Food Processing Equipment’s

Preparation and cooking equipment include conveyor systems, ovens, dispensing

 Cleaning, Grading and Milling

The five key principles of food hygiene, according to WHO, are:

 Prevent contaminating food with pathogens spreading from people, pets, and

SAFE food handling (from market to consumers)

ISO 22000 is a standard developed by the International Organization for

HAZARD ANALYSIS CRITICAL CONTROL POINT

HACCP is a management system in which food safety is addressed through the

APPLICATION OF THE PRINCIPLES OF HACCP

Principle 1 - Conduct a Hazard Analysis

Principle 2 - Identify the Critical Control Points

Principle 3 - Establish Critical Limits

Principle 4- Monitor CCP

Principle 5 - Establish Corrective Action

Principle 7 – Record keeping

FOOD SAFETY AND STANDARDS REGULATIONS (FSSAI) 2006

1. Food Safety and Standards (Licensing and Registration of Food Businesses)

Nutritional composition of wheat

Nutrients Amount (per 100 grams)

Dietary Fibre 12.2