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CHAPTER I

INTRODUCTION

The alarming public health issues have made the scientists and researchers to search

knowledge and new wisdom to curtail the problems of non- communicable diseases (NCDS)

in the recent past. The threat to humanity due to environmental hazards and issues awakened

the Agricultural Scientists, Nutritionists and Food Scientists to combat Obesity, Diabetes

mellitus, cardiovascular disorders and cancers all over the globe to work on Green technology

and Green concepts in all areas of natural and basic sciences to curtail the incidences of

mortality and morbidity due to risk factors associated with Public Health issues as stated

above.

Food processing in India is an emerging area of science hence it is essential to

safeguard food from spoilage. It could help millions of humans who are unfed every day. The

industrial revolution brought many technologies together and provided new possibilities for a

healthy society. Since there are more people to be fed, more and more factories are to be

built for mass production of goods in huge number of growing towns and cities for an

extended population (Singh et al., 2013). The traditional food technology methods have been

identified with some modifications to safeguard the preparatory process. Indian traditional

foods have their own medicinal values (Rais et al., 2013). When compared with the modern

food processing technique, traditional food needs lot of energy, manpower and long time for

its process and added preservatives to improve its shelf life.

India is the largest consumer and the second largest producer of sugar in the world.

Sugar industry is the second largest organized industrial sector in our country. In most parts

of the world, sugar is an important part of the human diet, making food more palatable and

providing food energy. After cereals and vegetable oils, sugar derived from sugar cane and

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beet provided more kilocalories per capita per day on an average, than other food groups.

Sugar beet (Beta vulgaris), Family Amaranthaceae, the tuberous root contains a high

proportion of sucrose. Sugarcane (Saccharum spp.), family Poaceae, is cultivated in tropical

and sub-tropical regions for sucrose that is found in its stems. An unbleached and unrefined

sweetener made from sugar cane resembling brown sugar, containing more minerals, golden

or brown in color is Panela.

The multi- dimensional approach to public health and natural resources viability in

specific regions of human habitation and its contribution to good health is the focus to take up

this research on the topic “Innovative Processing method of palm sugar through Traditional

Technology Transfer” – to bring out the ease in preparing “Palm Sugar” a natural resource

from ‘Sap’ obtained from palm trees of Ramnad District. The Researcher is a resident of

Ramanathapuram, taken this research work to support the local palm products producers

families working in the coastal regions of Ramanathapuram District.

The Ramanathapuram District has more than one crore palm trees all around the

district. But the maximum use to tap Sap during seasons starting from February to July end

every year is minimal. It is an “untapped Potential” of this district resource not much

development and research in processing Sap for Palm sugar production is done. Hence the

study was taken to explore the transfer of traditional technology used in producing “palm

candy” to “palm sugar” directly and this is the focused objective in designing the equipment

to produce palm sugar as an organic product as it was not cultivated by farmers or

agriculturists. It is a wild tree grown densely in a natural way. The products of palm tree is

highly valuable and eco- friendly. The entire tree is useful to human race. This natural

resource to be safe guarded and tapped for human living as a food source keeping all these

factors into consideration the study has been taken to help the rural folk involved in palm

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products activities in particular, to initiate the production of palm sugar as a cottage industry

in Ramanathapuram District.

Palm trees usually thrive in tropical and sub-tropical regions. In fact, there is an area

designated as Palm Belt of the world, which extends up to 45° on both sides of the equator.

This belt involves three continents covering 13 countries in Africa, ten in Asia and five in

South America. In India, Palmyrah palm (Borassus flabellifer Lin) is traditionally used for

obtaining various edible and non-edible products. According to the census taken in India in

1995, about 8.59 crores of palmyrah trees present in India and out of which 5.19 crores of

palmyrah trees present in Tamil Nadu. Palm trees thrive on non-agricultural lands, on the banks

of streams, rivers and canals, on undulating hill slopes and sandy lands which are normally unfit

for cultivation. (Central Palm Gur & Palm Products Institute, 2001).

The Palmyra is one of the most valuable and important trees in India. It is not

indigenous to this country but is extensively cultivated as it readily propagates itself in

regions where it is abundant; it is also found growing wild. The uses of various parts of the

tree are innumerable. (Sandhya et al.,2003). The Palm Products Industry is also one of the

major cottage industries under the Village Industries Sector in the State. Tamil Nadu is the

pioneer in development of Palm Products Industry in India. Palmyra is declared as the "State

Tree" of Tamil Nadu. The State earns foreign exchange by exporting Palm products. The

palm tree is present everywhere. Palm trees can last more than 100 years. Palm trees easily

germinate and grow, both in domestic and wild environment.

The Tamil Nadu Palm Products Development Board is functioning since 1995 and is

engaged in the introduction of modern concepts to promote research for the development of

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palm products industry and for the better utilization of palm products with the social

objective of uplifting the economic condition of rural palm gur artisans.

Most of the palms in forest show highly restricted distribution to ecological niches,

except Calamus, Genera Livistona, Hyphaene, Borassus, Nypa, Salaca and Ptychoraphis

which represent single species each in our flora. About 24 species belonging to nine genera

are endemic, including 14 species of Calamus. Most of our present palm species are indicated

by the past history, in which Calamus is possible exception. Most of the Palmyra flora is

present in Andaman–Nicobar islands and the rest of the bio-geographical regions of

distribution of the palms are subjected to extensive habitat loss. Anthropogenic factors like

continued deforestation, change in land use, unscrupulous extraction of wild source, etc. are

the major reason of habitat loss and poses serious threat to our natural palm populations.

(Tamilnadu palm development Board, 2003)

Edible items that could be made from the fruit of palm trees include sap, jaggery,

sugar, syrup, candy, palm fruit jam, chocolates, confectioneries, sherbet as well as non edible

items like palm fiber and palm leaf products, baskets are produced and marketed

(www.tn.gov.in). Palm leaves are traditionally used for making cigarette wrappings. The

leaves which are similar as the coconut leaves are used for thatch, for weaving baskets, band

matting and roofing. The midribs of leaflets are used for making durability brooms, fishing

tools; outer parts of stem used for flooring, furnishing and hand grips of tools; its roots are

useful for medicine and fishing tools; palm sap can be used for indigestion, rashes and

pulmonary irritation

Palm sap is a nutritional drink, which is very popular during the flowering season.

The sap season begins in January, when the palm trees starts budding. In this period, juice is

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obtained only from the male palm trees. The female palm trees start giving sap in the last

week of March or in the first week of April. At this time output from the male palms is on the

downturn and it keeps tapering down till the end of April. Then the female palms alone give

sap till the end of the sap season, which generally lasts till the first-half of June. Sap is

condensed into palm candy and used with hot and cold drinks like paanagam. Fresh palm sap

is boiled shortly to collect palm candy and palm sugar. If this is not done, within few hours

the ‘sweet toddy’ ferments into a sour and potent brew called toddy, which is not fit to drink

the next day.

The white palm sap, at initial stages (when collected) does not ferment (non-

alcoholic) and tastes very sweet. As the time passes the sap gets fermented, intoxicates and

tastes sour. The fermented liquid is known as 'Palm Wine' or Kallu (Tamil). As the palm sap

gets fermented very quickly, people apply lime on the surface of the pot as a preservative.

The lime prevents quick fermentation. (National Research and Development Corporation,

2005)

Toddy is a sweetish, heavy, milky white, vigorously effervescent alcoholic beverage,

possess fermentive odour, contains nutrients and becomes turbid. Fresh toddy has pH 5.5

which on 24 hours storage reduced to pH 4.1.

Palm sugar

Crystalline sugar made from Sap with or without clarification is known as Palm

candy. Sugar produced from the nectar of the palmyra or sugar palm tree. Farmers tap the

palm flower spikes to release the juice, which is kettle-boiled until it thickens into a golden

sugar. Palm sugar found to contain insufficient organic acids like fumaric, malic, oxalic,

sucinic acids and tartaric acid. Asian palms provide significant quantities of food, beverage,

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fiber, rattan, construction material and other products (Sushil et al., 2013). Asia is endowed

with world’s largest palm biodiversity and it is utilized to prepare commercial products, most

of the palm related products were established by local farmers. Chocolates, toffees and

confectionery items are made from Palm Sugar.

Palm Candy

Palm gur, palm candy has also its importance among the products of sap. It is being

produced and used since procuring sweet sap from palmyra has been known. It has got its

various uses in Ayurvedic medicinal preparations. Palm Sap is being fully utilized and

converted as a value added product of Palm Candy by traditional method (45 days; low yield)

which has been modified by a research conducted by Anna University (25 days; high yield).

The technical know-how of the improved method in the production of palm candy has been

provided to the palm gur artisans. (Tamilnadu palm products Development board, 2000)

Palm Jaggery

Jaggery is the most important product made out of pathaneer. It is made directly

by concentrating the pathaneer to a thick consistency. Pathaneer is concentrated without

deliming and the product is generally light brown (almost yellow) in colour. The product

from Thailand is rather soft, unlike the products from India and Sri Lanka. Jaggery has an

intense, earthy and salty taste and reminiscent of chocolates in its taste, darker and richer in

color with cooling effect. And it does not contain deleterious bone meal content, meant for

whitening sugar; make use in the preparation of delicacies like payasams and neyyai appams

and thus it is very popular in Tamil Nadu in the name of “Karuppatti vellam” or “Pana

vellam”.

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Treacle

Pathaneer when concentrated by heating to about 1/6 th of its original volume forms

thick dark syrup called treacle. The temperature should not be raised beyond 107 °C. The

syrup with a brix of 65 % is ready to be removed from the flame, cooled and bottled. In Sri

Lanka it is marketed in 750 ml bottles. Treacle become dark with a disagreeable product if

caramelized (i.e. upon uncontrolled temperature) which can be avoided by concentration

under optimal temperature, giving a golden syrup.

Crystal Sugar Making

The initial process of sugar making is practically the same as that of gur. In this case,

juice is de-limed, filtered and boiled. The juice is poured into the crystallizer at 110 °C. Palm

sugar is a natural sweetener made from the sap of palm trees. It is sold in the form of rounded

cakes, cylinders, and blocks or in large plastic or glass jars. Powdered palm sugar is

completely natural, a healthy sweetener, devoid of chemical additives and a viable alternative

for white sugar.

Sap, sweet sap of the palm otherwise called as sweet toddy or palm nectar, becomes

popular because of its high nutritive value as it contains a number of minerals and salts and is

high in protein. It is a natural and non alcoholic beverage, an instant thirst quencher, sweet,

oyster white, translucent, delicious taste, agreeable flavor and contains acids like ascorbic

acid, nicotinic acid and riboflavin. The chemical percentage composition of sap varies,

depending on various factors viz., place, type of palm, mode and season of its collection.

It is obtained by slicing the spathes of the palmyra, coconut and sago palms and

scraping the tender most part, just below the crown. It requires neither mechanical crushing,

as in the case of cane, nor leaching like that of beet-root. This palm nectar is widely

consumed in India, Sri Lanka, Africa, Malaysia, Indonesia, Thailand and Myanmar.

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(Siddharameswara Swamy et al., 2013). Palm sugar like flavoring (PSLF) with low pH

shows a significant effect, highest anti-oxidant activity on the Maillard reaction.

Panangkalkandu, a sugar in brown colour, when taken with water, will be a very good

medication for throat problems and gastric abnormalities. Palm candy mixed with hot water

will cure cough instantly (Sapjah naveen, 2008). Palm candy has medicinal uses such as

deforming, diuretic and anti inflammatory agent in treatment of inflammation of urethra and

respiratory tract (Mayer, 1995). The sap is given as a tonic to asthma and anaemia patients.

Jaggery is given for anaemia, for diseases characterized by a marked loss of potassium. Palm

candy is used in coughs and pulmonary infections, wheezing and as a laxative for children

(Suresh Babu et al, 2005).

The variations on the quality of sap may be due to genetic and metabolic

characteristics of the tree, environmental factors, collection time, microbial load, personal

hygiene. Microorganisms seem to be the main effect on quality of palm sap because they can

use sugar through the inversion reaction and produce organic acids (Ziadi et al., 2014).

Barh et al., 2005 , reported that In West Bengal fresh sap exudation was collected at

morning between 4 to 6 a.m, from inflorescence of Borassus flavbelifer and Cocos nucifera

and from phloem cutting of Phoenix sylvestris in a sterilized 250 ml conical flask. Collected

sap were brought to laboratory in aseptic, sterile and air tight thermos and then filtered with

Whatman filter paper. Analysis was performed within two hours for fresh sap and after 24

hours fermented sap.

Tapping is an art, percentage of obtained of sap yields depend on the skills of the

tapper (Khieu et al., 1996). Palm trees have to be climbed for tapping as their inflorescences

are located at the summit of their trunk which is often over 10 meters high. Various methods

are used to climb the tree and six methods are recorded (Kovoor et al., 1983), by using

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ankle-loops, aerial ropeways between trees, hoop-belt, riveted bamboo, mobile 4-9 meter

long ladders and fixed ones on the upper part of the trunks, notches in the trunk etc.

There are many techniques for tapping palms viz., i) destructive (incision of stem

apex of felled palm) and is preferred in Ghana; ii) non destructive (excision of male

inflorescence), e.g. in eastern Nigeria (upon economic considerations). The excision of the

terminal bud of standing trees is harmful since tapped palms never resume vigorous growth.

Tapped stems die unless tapping is stopped before the apical meristem is totally destroyed

(Cunningham, 1990). The most advanced method of tapping is that applied to the

inflorescence spadix which guarantees a high yield for long periods without affecting the

well-being of the tree.

Mostly, tapped palm trees provide sap which is very rich in sugar (10 to 20 %

according to species and individual variation). The yields are highly variable according to the

species and its management. When the trees are managed properly, the main tapped palm

species (Arenga pinnata, Borassus flabellifer, Cocos nucifera and Nypa fruticans) can reach

yields of about 20 tonnes of sugar per hectare (Van Die, 1994). Compared to sugarcane

production (5-15 tonnes of sugar/ha/year), the Borassus flabellifer tree can reach 18

tons/hectare/year under rain-fed conditions (Khieu, 1996) and the coconut tree 19

tons/hectare/year (Jeganathan, 2001). Elaeis guineensis produces much less sugar (1.2 tonne

per hectare, Udom, 2000) and also there are good prospects for obtaining much higher yields

in a production system oriented towards sugar production.

Sap is highly susceptible to natural fermentation at ambient temperature within few

hours of extraction from palms. Once fermented, it transforms to toddy with 4 % alcohol.

Using several technologies developed by various research institutes, sap can be processed and

preserved in its natural form to retain the vitamins, sugar, and other nutrients beneficial to

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health. To preserve and extend the shelf life of sap, heat preservation techniques such as

pasteurization is used. A special filtration technique to enhance the shelf life of sap was

developed by the National Chemical Laboratory in Pune, India. (Central Food Technological

Research Institute in Mysore, 2001).

Palm sugar syrup produced by a vacuum evaporator retained desired quality attributes

in syrup better than palm sugar syrup produced by heating with an open pan. The results

obtained from the different treatments suggest that non-enzymatic browning of palm sugar

syrup during storage could be reduced. This could be done by using vacuum evaporator for

the production of palm sugar syrup and storing at low temperatures (Naknean et al., 2013).

Arenga palm sugar block can be transformed successfully into arenga palm sugar granule by

dry granulation method (Iskandar et al., 2014).

Concentration by vacuum evaporation lowers reducing sugar content such as fructose

and glucose, substrates of Maillard’s reaction, than the traditional open pan process, whereas

it retains the sucrose concentration. It could thus be outlined that vacuum evaporation is a

more reliable technique for palm sugar syrup production as it minimizes the loss of quality

through the degradation of products due to the process of heating. It can also be drawn from

the results that heating temperature is the main factor affecting the quality of palm sugar

syrup (Naknean et al., 2009).

Ho et al., 2008, explained the traditional method used for the production of palm

sugar lead to products of inconsistent quality with Maillard compounds of variable proportion

due to the high standard deviation of variables in addition to the quality of age and raw

material.

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Production of palm sugar syrup by traditional method uses both high temperature and

long duration. Non-enzymatic browning reaction and inversion reaction can take place during

heating process which might affect the properties of palm sugar syrup (Naknean et al.,

2009). Some major limitations of this traditional method include the inconsistent quality of

raw palm sap and non-standardized processing methods which lead to inconsistent quality of

the resulting palm sugar.

A large variation in the physical, chemical and microbiological qualities of palm

sugar concentrate produced by traditional method is identified. Literatures quote as samples

with low total soluble solids, contained high total acidity but low pH, low transmittance value

are assured for change of qualities. The palm sap during harvesting – before processing, if

contaminated, its sugar would be used by micro-organisms and resulting in higher acid

content, which synergist with heat and increases the concentration of reducing sugar,

becomes a media for the growth of osmophillic yeast leading to microbial contamination and

poor storage conditions. In order to improve quality of palm sugar concentrate, suitable

temperature and time during evaporating process are also of importance.

The loss of quality of palm sugar syrup due to non enzymatic browning reaction

increased with increases in storage temperature and time (Naknean et al., 2013). The

temperature of 70, 80 and 90 °C give different effect on crystallinity but tend to similar effect

on morphology of granule and microstructure. The dry granulation has the same effect on

functional group comparing with wet granulation and the former at 80 °C is recommended to

produce quality palm granule (Iskandar et al., 2014).

The factors of time and temperature have an influence on the quality of palm sap.

High concentration of Maillard reaction products, caramelisation products and phenolic

content results in increase in antioxidant activity and in the intensity of brown colour, sweet

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taste, thickness and viscosity of palm sugar syrup. In addition, good practices such as

hygiene, sanitary facilities and equipment could greatly contribute to extend this product’s

shelf-life (Naknean et al., 2011).

Paulas et al., 2003, reported that the daily Borassus flabellifer sap yields average

between 6 and 10 liters per tree but can be as low as 1 liter or as high as 20 liters per tree and

this can be explained by genetic and environmental factors. Nypa fruticans produces more

inflorescences (and potentially more sap) when the stands are kept thinned of old leaves.

In the Philippines, Quimbo (2001) was developed a new, highly profitable method of

tapping which increases the sap yield from less than 60,000 liters per hectare to more than

100,000 by wider spacing between trees.

The impact of manuring trees on sap yields is reported to be great. A hybrid between

a tall variety (Typica) and a dwarf one (Pumila) was found to be the best. It is likely that yield

improvement research will produce varieties that will yield more than 100 liters of sap per

palm and more than 14,800 liters per hectare per annum.

Proper timing of harvest reduces incidence and severity of cracking or splitting of

products, excessive dehydration, insect infestation and attack by micro-organisms (Kadar

and Hussein 2009). Moisture should be 20-26 %, with equilibrium relative humidity (ERH)

of not more than 65 % ensure resistance to microbiological factors such as mold, yeast and

bacteria. Transportation under refrigeration (0-2 C and 90-95 % RH) to maintain their

quality; Hydro cooling can be used to effect disinfection of water and removal of excess

surface moisture before packing in the shipping containers. But forced air cooling can be a

better choice than hydro cooling; inspected for quality, fumigated in completely sealed

chambers; shaker for preliminary washing; hot air blast is applied to remove excess water.

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Quality loss resulting from pathological and physiological deterioration increases with

increasing moisture content and storage temperature (Yahia et al., 2004). Storing at low

temperatures is the most important way of maintaining quality; as it minimizes the loss of

color, flavor and textural quality and also delays development of sugar spotting, incidence of

molds and yeasts and insect infestation and prevents development of syrupiness. In order to

reduce moisture loss and improve shelf-life, packaging in moisture-barrier plastic bags or use

of plastic liner in the box is helpful.

Since quality is supremely important in food, deterioration has to be controlled

during production and storage. Non-enzymatic browning may cause unacceptable nutritional

and sensory effects in some stored food products and may be a limiting factor in the shelf-life

of products. Our aim to optimize or design a suitable method to reduce the quality loss of

palm sugar product; concentration by vacuum evaporation is an improvement method for

palm sugar production as this may minimize the loss of quality and degradation due to the

heating process.

During the past five decades though sugarcane production has increased around three-

folds, the sugar recovery has not shown any upward trend. It has always been hovering

around 10 percent. Therefore, the Indian sugar industry presently faces a tough competition

in the international market. The cost of sugar production in India is about 30 % higher than

the international market price. As production of Palm sugar requires limited know-how,

technological barrier to enter the market are relatively low.

Opportunities exist for organic palm sugar in Germany as it is the largest and growing

European market for organic food. From 2006-12, sales of organic food have tripled mainly

coming from imports. In addition, industry sources have indicated that the consumers have

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the impression that the organic sugar is brown. Sugar is the third largest category in the fair

trade market as measured by the Fair Trade Organization (FTO).

Focus of the present study

Authentic food ingredients have a reputation of being healthier and safer than

synthetic ingredients. In addition, the synthetic sweeteners are losing momentum as research

increasingly confirms that they are unhealthy.

The opportunities for sugar palm tree for its palm sugar are still opened widely. The

demand for the commodity never decreases and so far the demand cannot be fulfilled. The

palm sugar that comes from the sap of the sugar palm tree is preferred by consumer and thus

the palm sugar industry is the alternative to improve the people welfare as the process can be

done in a simple way and with small capital (Banten, 2005).

Agro industry is one of industrial branches that relate closely and directly with

agriculture. Agro industry as one of the important sub systems in the agro business has

potentials to support high economic growth because the market share and value added are

high enough. Agricultural sector has important role in the national economy. The agricultural

sector is able to survive and able to grow positively and able to absorb labors hence it

alleviate the risk of economic growth decrease wholly (Djoni and Sukandar et al., 2013).

Tamilnadu palm development board (2003) reported that six lacks artisans, both

men and women, are currently engaged in the Palm Products Industry in the State both

directly and indirectly. This includes 30,000 Scheduled Caste artisans who are directly

engaged in activities related to the Palm Products Industry such as tapping of Sap,

manufacturing of Palm Jaggery. In the existing process of preparing Panaga kalkandu

impurities like thread, sand, dust etc., are present in this product. Considering the deleterious

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effect of consuming this type of palm sugar, a necessity has arisen to develop a process for

preparing palm sugar without using any materials that are not permitted in Food Laws.

The challenges that the scientists, researchers, extension workers and farmers face in

this millennium is to find appropriate and improved ways of utilizing the earth's resources.

Alternate uses of palm sugar particularly in ethnic foods for enhancing their nutritive value

and exploiting the export potential of these products with value addition need an in-depth

study.

In any industrial production particularly in agro-industries the raw material should be

consistent in quality to maintain uniform quality standard in the end product. No study seems

to have been taken to map the variations in the palm sap quality among palm trees, the taping

period and the related preservation techniques for the sap collected from various farms prior

to the preparation of palm sugar. Taking into consideration of these aspects, this study is

under taken.

Due to increasing competition from the fast growing urban economy, poorly paid

activities such as palm sugar collection and processing are under severe economic pressure.

In the end this may lead to an abandoning of palm sugar production and to the extinction of

the palm tree from the farm system. Despite the difficulties involved in sap collection and

sugar production, palm sugar has continued to be a preferred as the source of sweetness in

local communities.

Since quality is supremely important in food, thermal deterioration has to be

controlled during processing and storage. Nonenzymatic browning including Maillard

reaction and caramelisation may cause unacceptable nutritional and sensory effects in sugar

based food products and may be a limiting factor in the shelf life of products. Rangarajan

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(2000) stated about the usage of superphosphate in food industry, mainly in palm products

industry for adjusting pH which resulted in many health effects. Therefore, the study of the

processing method and storage temperature that influence on non enzymatic browning

reactions are very important.

Ramanathapuram District in Tamilnadu is an arid and backward area with thick

unemployment population. The cultivation of palmyra trees is common in this area. Hence

this area has been selected for this study.

The crystal palm sugar is an innovative product from the sugar palm sap processing.

The crystal palm sugar is more practical and ready to be consumed, the water content is lower

so the storability is longer and the crystal palm sugar is packaged into practical package while

the solid palm sugar difficult to store, and more hygiene. The crystal palm sugar is suggested

by the health expert because it has low calorie content when compared with the granulated

sugar.

Contamination of the products may be expected by sources like presence of micro-

organisms in raw material or finished product, during harvesting in open condition or if

stored in traditional earth jars (may be with high load of osmophillic yeast count) which is not

a good practice in sanitary. The best criterion sets to prevent this contamination should

depends on individual production factors such as personal hygiene, sanitary facilities, heating

temperature, heating time and storage conditions. High temperature destroys a substantial

amount of micro-organisms (Phaichamnan et al., 2010).

Hence, we plan to focus on designing an efficient machine along with standardization

of the biochemical and physiological parameters for better and quick extraction of palm

sugar. Physico-chemical properties and nutraceuticals of the collected saps are decided to be

determined to highlight its quality. Comparison of estimated sugars and minerals in palm

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sugar prepared by the conventional and innovative method is planned to be done in the

present study. Suitable temperature and humidity are also to be incorporated in our present

work to account for standardization for bulk storage of palm sugar with following objectives.

OBJECTIVES

1. To assess of physico-chemical and Nutrient properties of Sap collected from

different locations.

2. To conduct a survey on the existing conventional processing methods of

production of palm jaggery and candy.

3. To designing and fabricate an equipment for production of palm sugar.

4. To study the physiochemical and nutritional properties of palm sugar prepared by

using innovative process.

5. To determine the phytochemical composition and Antioxidant activity of palm

sugar prepared by using innovative process.

6. To study the Shelf life analysis of palm sugar assessed by different packaging

materials.

7. To study the Antimicrobial activity of palm sugar prepared by using innovative

process.

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CHAPTER II

METHDOLOGY

The research design pertaining to the study “Innovative Processing Methods of

Palm Sugar Production and its functional properties” is presented under the following

headings.

PHASE I

1.1.Selection of Area and Samples.

1.1.1 Collection of Information from Palm Sap Tappers.

1.1.2 Collection of Palm sap.

1.2.Determination of Physiochemical properties and nutrient composition of the collected

palm sap.

PHASE II

2.1. Understanding the conventional methods used for Palm sugar and Palm candy production

in and around Tamilnadu.

2.1.2. Disadvantages observed in the conventional method of palm candy and palm sugar

production.

2.1.3 Experimental procedure for preparation of palm sugar using innovative process.

PHASE III

3.1. Evaluation of Physiochemical properties of standard and palm sugar produce under

innovative process

3.2. Estimation of Nutrient content of standard and experimental palm sugar

3.3. Determination of phytochemical composition and Antioxidant activity of standard and

experimental palm sugar.

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PHASE IV

4.1. Assessment of Shelf life using different packaging materials of palm sugar prepared by

using innovative process.

4.1.1. Study of Storage conditions of Palm Sugar using in different packaging materials.

4.1.2. Determinate of Shelf life analysis of Palm Sugar prepared by using innovative

process.

PHASE V

5.1. Analysis of Antimicrobial activity of standard and experimental palm sugar

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PHASE I

1.1 SELECTION OF AREA AND SAMPLES

The growth of palm trees will ever be more appreciable in Ramanathapuram district

because of the availability of more number of dry lands in it, which in turn were more

suitable for the cultivation and growth of these palm trees. The hamlets of Ramanathapuram

namely, Kilakarai, Narippayur, Kannirajapuram and Vembar, hosts the highest palmyrah

cultivation. Hence the investigator focused the above mentioned areas in Ramanathapuram

district for sap collection. Moreover, from literature reviews the percentages of availability

of sap in these areas were comparatively higher than that seen elsewhere in Tamil Nadu.

The total Palmyrah Palm Production of the Tamilnadu in the year 2010-2011 was

74475 metric tonnes, out of which, 67876 metric tonnes from cultivated area of 368 acres

(BBSAW – 2009). Ramanathapuram is a district with more number of dry lands with large

number of Palmyra cultivation.

The population of Palmyrah palm tree is found to be tremendously high in the

Eastern coastal line comprising from Kilakarai to Thiruchendur and the occupation of most of

the inhabitants of this area is reported to be palm tapping, which in turn leads to easy and

ready availability of manpower for all processes like sap collection and palm products

processing.

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Figure-1. Coastline of Tamilnadu-Ramanathapuram

1.1.1Collection of Information from Palm Sap Tappers

The selected four villages namely Kilakarai, Narippayur, Kannirajapuram and

Vembar had a total of 1600 palm sap tappers. Twenty five palm sap tappers from each of the

selected four villages (100 numbers) were randomly selected for collecting the information

on palm sap and palm products production. Care was taken to select the palm sap tappers

who were continuously involved and did the production of palm jaggery and palm candy. The

information namely socioeconomic status, method of palm sap collection, economics

involved in palm sap and palm jaggery production was collected using a specially designed

interview schedule. According to Kothari (2011) interview method of collecting data involves

presentation of oral –verbal stimuli and reply in terms of oral- verbal responses.

This information was collected in order to understand usefulness of the developed

innovative processing over the traditional processing technology. The Schedule used is

presented in Appendix I.

47

1.1.2.Collection of Palm sap

The selected four villages namely Kilakarai, Narippayur, Kannirajapuram and

Vembar the sap was collected from the selected palm tappers. The sap for the study was

collectedfrom march to june 2013. Only during these months there is high production of

quality palm sap. Thus this period was selected. The saps from the four villages were

collected for three consecutive days from the same sap tappers of the selected villages. The

method of sap collection from the palmyrah tree is detailed below.

Farmers climbed the Palmyra palm tree mostly twice a day in the morning and

evening with the help of a rope. Both male and female inflorescence is tenderized by gentle

massaging with a massaging horn and was then sliced with a sharp tapping knife. The slices

were less than a millimeter in thickness and the slicing opened up the channels for the sap to

flow. Cutting the older leaves of the tree at the growing point of palm exposed the tender part

at the tip of the stem, which was then punctured and the juice was oozed up from a shallow

depression into a mouth of a fresh sterilized earthen pot hung below. The palm sap was

transferred in 12 hours from mud pots into hages vessels of stainless steel, plastic or

Aluminium vessels.

The mud pots were then coated with lime and kept for further collection of palm sap,

after incision the spike on alternate days twice in the first and third week of every month till

the end of tapping season. During the course of the day, flow of sap decreases as the freshly

incised area turns brown, covered up by tannins. Hence in about 12 hours time, tapping has to

be repeated by incision to increase the flow of palm sap.

The collected palm sap was filtered through a fine muslin cloth or a fine cotton cloth

to give a clear sap. The samples were stored immediately in sterilized bottles in ice box (0-8

°C) and transported to the laboratory for analysis the physico-chemical and nutritional

properties on the same day. Fermentation might be observed if temperature is altered above,

48

resulting in the formation of alcohol an undesirable product. Every time during the process it

becomes necessary to confirm the palm sap is not fermented. The collection of palm sap is

given in Figure II.

49

FIGURE -2. COLLECTION OF PALM SAP

50

1.1.2. DETERMINATION OF PHYSIOCHEMICAL PROPERTIES AND NUTRIENT

COMPOSITION OF THE COLLECTED PALM SAP

The collected palm saps from the four villages were subjected to physiochemical

analysis of properties namely moisture, pH, Acidity, Colour, Brix, viscosity and Boiling

point. The proximate composition namely Carbohydrate, Protein, fat and Calories, Vitamins,

minerals and reducing, non-reducing sugars were analysed. The methods followed for

analysis is presented in Table I. The procedures adapted are given in Appendix II

Table -1 Methods used for Analysis of physical properties in Palm Sap and Sugar

S.No Physical Parameters Method Reference

1. Moisture Oven method

Willits (1951)

2. pH

Digital pH meter

Arnold Orville Beckman (1934)

3. Colour Hunter colour lab

Reader

IS : 3025 (Part 4) (1983)

4. Tittrable acidity Nephrometer

IS 3025{ Part 22} (1983)

5. °Brix Refracto meter IS 3025{ Part 16} (1983)

6. Boiling point

Thiele tube

AACC (1987)

7. Viscosity

Rapid visco analyser

(RVA)

AACC (1987)

8. Glucose, Sucrose,

Fructose, Maltose

HPLC

AOAC ,14.075-14.079, (1984).

51

Table 2 Nutritional Properties of Palm sap and Sugar

S.No Nutrients /100ml of Neera Method of analysis References

1. Protein Kjeldal method AOAC, 976.05,( 2012)

2 Fat Shoxlet method AOAC, 920.39, (2012)

3 Carbohydrate UV Spectrophotometer

Sadasivam, et, al., (2005)

5.

Fat soluble vitamins

(carotene, Cholecalciferol,

Alpha Tocopherol, Vitamin

K)

Water soluble vitamins

(Niacin, Pyridoxine,

Thiamine, Riboflavin)

HPLC -5968-2970E

AOAC (1998),

6. Minerals

Calcium, Iron, Sodium,

Potassium, Magnesium,

Phosphorous, Zinc.

Atomic spectroscopy -

ICP-OES

AOAC (2012)

7. Flavonoids U.V spectrophotometer Da Silva, Pezzini & Soares,

(2015)

8. Antioxidants activity U.V spectrophotometer

DPPH method (BHT

standard)

Sharma & Kumar, (2011)

9. Antimicrobial Activity Kirby- Bauer Disc

Diffusion method

Bauer, Kirby Sherris, Turck.

(1966)

52

Phase II 2.1 UNDERSTANDING CONVENTIONAL METHODS FOR PALM SUGAR, PALM

CANDY PRODUCTION IN AND AROUND TAMILNADU

In order to understand the conventional methods followed for palm sugar and palm

candy preparation. Four units suggested by the Khadi and Village Industries Commission

were contacted and the method of production was observed and the products was collected

for testing the physical and chemical hazards. The following were observed in the four units

for understanding the conventional method of production 1. Materials used 2. pH monitoring

3. Clarification materials used 4. Crystallization methods 5.The type of vessels used 6.

Standardization of production 7. Time duration of production 8. Microbial load of the

product 9. Fermentation process.

2.1.1 Traditional methods of palm candy preparation

In connection with the survey on existing method of palm candy preparation, the

investigator surveyed Tiruchendur, Uthangudi in Thoothukudi District, Marthandam in

Kanyakumari district and Narippaiyur, Sayalkudi in Ramnad District and Central Palm Gur

unit in Chennai, affiliated with Government of India. In these areas villagers engaged in palm

products like Palm Jaggery and preparation of palm candy by conventional method along

with other products using ‘palm sap’ (pathaneer). Palmgur Co-operative Federation provides

the technological support in the processing and production of palm sap and its associated by-

products such as jaggery, sugar and candy.

The physical and chemical hazards were scrutinized from the collected samples

of palm sap in the selected units given in table-3. The physical hazards such as stone, sand,

thread, mud and stick might lead to a severe contamination and finally to a poor quality

product. The physical hazards may be due to the preparation of palm sugar being done in

53

open and using uncleaned vessels, ii) No efforts undertaken for maintaining a clean and

sterilized utensils or premises; iii) No standardization targets either for raw materials or for

finished products of palm sugar; iv) No care for purification of finished products and v) Long

duration usually 40 days required for preparation. The chemical hazards due to addition of

clarifying agents like commercial superphosphate, might cause some neurological problems;

all these might lead to an adverse effect in the quality of the product.

Table-3. Identification of physical/Chemical hazards in Palm sap

S. No

Potential

hazards

Type of hazards

Residues

in palm sap (%)

1 Physical Mud

Sand

Thread

Stone

2

5

3

2

2 Chemical Superphosphate 9

3 Microbial load Bacteria/yeasts ++

Traditionally, palm sap is manually collected from each inflorescence of the Palmyra

palm tree. Palm sugar concentrate was produced by evaporating the palm sap in a large

opened pan (approximately 60-100 liters/pan) and heated using the twigs and palm leaves as

fuel till the required consistency (deep brown colour) was obtained.

54

FLOW CHART FOR PALM CANDY PREPARATION – NARIPPAIURE –

SAYALKUDI

Collection of Neera (Pot Coated With Lime)

Adding Super Phosphate Solution

Boiling (Above 100 ºC)

Transfer into Crystal Box

Poured In Sand (For 40 Days)

Crystal Formation

Storage (Traditionally In Sacks)

2.2 DISADVANTAGES OBSERVED IN THE CONVENTIONAL METHOD OF

PALM CANDY AND SUGAR PRODUCTION

The following observations are recorded on seeing the various methods involved in

palm sugar production, which lead to design and fabricates equipment for production of palm

sugar using a new process. The disadvantages observed in terms of clarification and process

involved in preparation of palm sugar using conventional method.

2.3 EXPERIMENTAL PROCEDURES FOR PREPARATION OF PALM SUGAR

USING INNOVATIVE PROCESS

Experiment I: Modification In Clarification Method

In this study of palm sugar preparation, three types of plant materials were selected as

a natural clarifier instead of synthetic materials to adjust the pH for clarification and

crystallization. Usage of organic extracts in the preparation of palm sugar pave a healthy

track for the future generation in consuming such high and pure quality products. The stem of

selected plants like Ladies finger, Malai Poovarasu and Hibiscus Rosasinensis were collected

from Ramanathapuram district. The stem part of the plants were cut into small pieces, dried,

55

powdered and macerated with glacial acetic acid as solvent for 24 hrs. The plant extracts

were then concentrated by evaporation and used.

PLATE I : TRADITIONAL METHOD OF PALM CANDY PREPARATION

Clarification of Neera

56

This natural clarifier overtakes the property of commercial superphosphate in the

preparation of Neera, as the latter may cause neurological disorders as they are synthetic

based when compared to the former. The Sap collected from palmyra trees from four

different locations namely, Kilakarai, Narippaiure, Kannirajapuram and Vembar in

Ramanathapuram district, were analysed for their nutritional and functional properties

presented in Table 4.On the basis of the analyzed results, the sample of Neera obtained from

Narippayur village was found to be good quality, nutritious and the best for crystal formation.

Table -4 Types of Clarifier used in the process of Palm sugar preparation

Sl.

No.

Clarifier Method of preparation

(Sap – 50 litres)

Quantity of

plant extracts

Final pH

adjusted to

neutrality

1. Synthetic super phosphate Conventional

Innovative process

5 g 6.5

2. Vineger Conventional

Innovative process

6 ml 5.7

3. Hibiscus Rosasinensis Conventional

Innovative process

10 g 7.2

4. Malai Poovarasu Conventional

Innovative process

10 g 6.6

5. Lady’s Finger Conventional

Innovative process

10 g 7.8

Hibiscus Rosasinensis extract used as a clarifier in all methods for preparation.

Clarifiers in different concentrations were used for understanding the best

natural clarifiers to be used for production of palm sugar using innovative process. The

resultant palm syrup was heated up to 106 °C -108 °C for an invariable boiling time ranging

57

from 20-60 minutes depending upon the samples and finally the syrup was cooled for 10

minutes. The Preparation of Palm sugar using the natural clarifier have been compared to the

existing palm sugar (being prepared by using calcium hydroxide) in various aspects like pH,

cleanser, temperature and duration for crystal formation.

PLATE II EXPERIMENTAL PROCEDURES DEVELOPED FOR PALM SUGAR

(A). MALAI POOVARASU AND ITS ACETIC ACID EXTRACT

(B). LADIES FINGER AND ITS ACETIC ACID EXTRACT

58

Conventional method of palm sugar production

Conventional method of palm sugar production consists of a large iron vessel used for

heat treatment. Palm sap was collected, filtered and finally poured into the large vessel

capacity of 15-20 liters. Wood materials or any tree debris were used as fuel for heating up

the iron vessel, ground plan was shown in Fig. 2. Using a long stirrer made up of iron and

agitation was given manually. Stirring was done till the water content present in sap

evaporated and finaly formation of the syrup. The final product will be used for palm sugar

manufacturing.

Fig. 3 Vessel heating system

Disadvantages of conventional method

Air pollution was created during burning lots of fire wood and other types of fuel; Smoke

creates respiratory problem and ophthalmic problems among the workers; temperature cannot

be maintained throughout the process. The procedure was carried at open environment,

interference of dusts and other debris can be found which make the risk of reducing the

product quality.

59

2. Modification of conventional boiling method over electric boiling system (Direct

contact of electric coil)

Palm sap tapped from tree was filtered and fed into the system. The system consists of

20 liters capacity food grade material 304 and inbuilt electrical coil which provides direct

contact with sap and transfers the heat.

Disadvantages of Electric boiling system

Excess of time required for heating up the raw material; No sedimentation was formed

after conducting thermal energy directly to the sap; an unpleasant odour was produced during

the process and owing to the of electric coil with the palm sap, some part of syrup got burnt

(blackening) which will reduce the quality.

3. Modification of conventional boiling method over Steam heating system

The boiler is essentially a closed vessel inside which water is stored. Thermal energy

was generated using electric coil in a furnace and heat was produced. This thermal energy

comes in contact with water vessel where the thermal energy transfer to the water and

consequently steam is produced in the boiler. Then this steam is piped to the container

containing palm sap.

60

Fig. 4 Steam heating system

It includes with thermal efficiency, combustion efficiency & fuel to steam efficiency.

Steam boiler efficiency depends upon the size of boiler used. A typical efficiency of steam

boiler is 80% to 88%. Actually some losses occurred due to incomplete combustion, radiating

loss occurs from steam boiler surrounding wall, defective combustion gas etc.

Disadvantages of Boiler heating system

Inadequate of thermal energy which led to improper formation of sugar from palm sap;

not compact in construction; not economical; size is a difficulty for transportation and

construction; long time required for rising steam at desired pressure, as there is a need for

plenty of water in such boilers; as the water and steam are in same vessel the very high

pressure of steam is not possible and the steam received from boiler.

4. Modification of conventional boiling method over Thermic fluid system

Thermal fluid heating is a type of indirect heating in which a liquid phase heat

transfer medium is heated and circulated to one or more heat energy users within a closed

loop system. Thermal oil, glycol, and water are common heat transfer mediums.

61

Fig. 5 Thermic fluid heater

Heat Transfer fluids

Thermic fluid heaters are popular in industry and are fast replacing steam boilers in

certain applications because of the following advantages :-

� Exemption from Indian Boiler Regulations act and related formalities.

� No need for water treatment.

� No problem of scale deposition on heat transfer tubes.

� Safety from explosion hazards due to low operating pressures.

Heating medium being a liquid, higher efficiency of heat utilisation can be achieved.

Among the process – Thermic fluid system was highly promising thus fabrication of

equipment was carried out.

62

Inventing innovative method for efficient production of palm sugar

Fig. 6 Flow chart displays developing of innovative method of palm sugar production

Experiment II: Modification of Conventional Chula Boiling Method to Electric Boiler

Method:

This Palm sugar extractor was designed with help of technical consultancy from

expert as it is not available in market. This extractor was designed for standardizing the

process and to maintain maintaining uniform quality. Thermostatically controlled heating pan

of food grade stainless steel was used for concentrating the sap. Food grade materials and

plant extracts instead of chemical clarifiers were used for adjusting the pH, clarification and

crystallization. For the evaporation of moisture in the syrup different drying methods were

tried out and the one that was found most efficient has been standardized and utilized.

Traditionally, palm sap was manually collected from each inflorescence of the

Palmyra palm tree. Palm sugar concentrate was produced by evaporating the palm sap by

using wood fired stove and the process ends up by observing the intensity of brown colour,

thickness and viscosity of the product. Overheating process would alter its unique flavour and

63

colour. The total soluble solids with sugar in the finished product should be at least 650 Brix

or above for food safety purpose.

PLATE III PALM SUGAR DEVELOPED BY USING PALM SUGAR EXTRACTOR

Cooling Rotator

CENTRIFUGE METHOD OF SUGAR COLLECTION

DRYING PROCESS OF PALM SUGAR

64

The Equipment design has applied in three steps: 1. Boiler 2. Chiller 3.Centrifuge

1. Boiler:

Boiler is basically a closed vessel in which water or fluid is heated until the liquid is

converted into vapor at required pressure. Mostly, Boiler is operated in vacuum to achieve the

desired temperature at a short duration of time. In this process, a cylindrical shell boiler is

used.

The early proponent of the cylindrical form is a British engineer John Blakey, who

proposed his design in 1774. Another early advocate is the American engineer, Oliver Evans,

who rightly recognized that the cylindrical form is the best, in the view of mechanical

resistance. Normally these boilers are capable of working under 40-50 psi. Here, a cylindrical

boiler made of Stainless Steel (SS-316), is used.

Table 5 Stainless Steel (SS-316) Composition

S.No Element Standard (Max)

1. Carbon 0.08

2. Phosphorus 0.045

3. Silicon 0.75

4. Nickel 10.00 - 14.00

5. Nitrogen 0.10

6. Manganese 2.00

7. Sulfur 0.030

8. Chromium 16.00 - 18.00

9. Molybdenum 2.00 - 3.00

10. UTS 579 MPa at ambience

11. Thermal conductivity 16.2 W/mK at 100 °C

The boiler is cylindrical in shape and it is made up of stainless steel 304. The

stainless steel is used to prevent melting, but copper will melt at this temperature so copper is

65

not used in this boiler. Elements are vertically mounted in the top of the boiler. The elements

in the boilers are easily removable. Some of the elements are illustrated below.

1) Temperature controlling sensor (RTD)

2) Electrical heaters (4)

3) Steam outlet

4) Safety valve

5) Thermic fluid

6) High temperature insulation (Ceramic wool)

7) Motor (pump on, pump off the palm sugar water)

Shell and tube type boilers have adequate steam space above the normal liquid level

of the shell. Shell boilers have dryness fraction up to 98%. It means the moisture content

present in the steam is 2 %. This results in higher heat content of steam thus shorter batch

timings and higher productivity and product quality. Mainly the boiler contains three shells.

Shell Layers

Shell 1:

The innermost shell contains temperature controlling sensor inside the palm water that

undergoes heating. The temperature will be controlled by the sensor named RTD. Resistance

temperature detectors are temperature sensors that contains resistor that changes the

resistance value as its temperature changes. If the sensor detects temperature more than 50-60

degree Celsius in this process, it will automatically stop heating. RTDs have been used

because of its high accuracy, low drift and for its stability.

The first layer forms the wall for the container holding the Palm nectar. The tank is

made up of Stainless Steel (SS-316). Palm nectar is boiled inside the shell. The processing

66

liquid is taken in this 45 liter capacity tank. Shell 1 transfers heat from the heating source to

the dispensation fluid. The working temperature inside the shell is about 150 °C.

Shell 2:

This forms the second layer of the boiler, which contains the heating elements. The

heat energy is generated using a heating coil, which converts electric energy to thermal

energy. Four heating coils of 1kw (1000 Watts) is used. This heating coil can reach up to 800

°C at 100 bar pressure. Electrical energy is a form of energy that occurs as a result of either

stored (potential) or moving (kinetic energy) charged particles.

The faster the atoms or molecules move, the more heat or thermal energy they have.

The heat energy produced by the heating coil needs to be transferred to the processing fluid.

But direct transfer of heat is not possible, as it will spoil the palm nectar. So in order to

provide equal and gradual heat transfer from the coil to the palm nectar, a thermal fluid is

used.

Food grade oil acts as a thermic (thermal) fluid, a heat carrier, which is heated up in

the heater and circulated through the user equipment. In future further improvements can be

done. There it transfers heat for the process through a heat exchanger and the fluid is then

returned to the heater. Electrical heaters are inserted separately in a tube which is of 1.15 inch

diameter in the second shell for heating the thermic fluid. The flow of thermic fluid at the

user end is controlled mostly by a pneumatically operated control valve, based on the

operating temperature. The heater operates on low or high fire depending on the return oil

temperature, which varies with the system load. There is a small tube containing a thermic

fluid for passing on the heat indirectly to the sample just as to prevent the blackening and

thus improvising the quality of food grade palm products.

67

Shell 3:

Exactly the third shell is made up of ceramic wool; therefore the heat will be

maintained in the first two shells. The heat loss will be reduced because of the ceramic wool.

The capacity of the ceramic wool is up to 500 degree Celsius. So instead of glass wool

ceramic wool has been used. If we use other wool dust will mix with the palm water.

In order to avoid heat loss from the thermal fluid and to increase the thermal

efficiency, an insulation layer around the thermic fluid is kept. The insulation material used

here is glass wool. Glass wool insulation is one of the most widely used forms of insulations

world-wide because of its thermal and acoustic properties, light weight, high tensile strength

and exceptional resilience and with service temperatures ranging up to 250 °C.

Glass wool is formed into products with various thickness and densities. It comes in

the form of rolls and slabs with or without Aluminum foil. Types of facings were aluminum

foil, black glass tissue and glass cloth. Density 12 Kg/m3 to 100 Kg/ m3; Thickness 12 mm to

100 mm. Glass wool is suitable for the temperature ranging from -195 °C to +230 °C. For

special applications it can be used up to 450 °C. Aluminum foil facing is suitable for

temperatures up to 120 °C. Glass wool is chemically inert, rot proof and odorless.

Application does not cause or accelerate corrosion.

Glass wool is an insulating material made from fibers of glass arranged using a binder

into a texture similar to wool. The process traps many small pockets of air between the glass,

and these small air pockets result in high thermal insulation properties. Glass wool is

produced in rolls or in slabs, with different thermal and mechanical properties. It may also be

produced as a material that can be sprayed or applied in place, on the surface to be insulated.

68

Shell 4:

Finally, a closing cover is used to enclose the entire boiler, thermic fluid, heating coils

and insulation layer using a stainless steel wall. Stainless Steel (SS-316) is used to in this

wall.

Stirrer:

Here a stirrer is connected to a motor running at constant speed. This entire setup is

mounted on the boiler. The electrical control panel box is fixed at the side of this palm sugar

machine.

2. Chiller

A chiller is a machine that removes heat from a liquid via a vapor-

compression or absorption refrigeration cycle. This liquid can then be circulated through

a heat exchanger to cool air. As a necessary by product, refrigeration creates waste heat that

must be exhausted to ambient or, for greater efficiency, recovered for heating purposes.

Concerns in design and selection of chillers include performance, efficiency, maintenance,

and product life cycle environmental impact. Here, a cylindrical container which is coiled

around with a copper tube is used as chiller. R12 also known as Freon-12 is used as

refrigerant for the chiller.

The construction consists of a stainless steel container with a capacity of 10 liters.

This container receives the semi-solid solution from the boiler output. This container is coiled

around with a copper tube with a thickness of 1mm (OD=12mm). The refrigerant is

circulated with the help of a 1HP compressor, which can be cooled with the help of radiators

or air fins. Similar to the boiler section, a stirrer connected to a motor is mounted on top of

69

the chiller. This helps to provide uniform cooling to the entire semi-solid solution. This has to

be cooled uniformly with continuous stirring, to avoid build-up of crystals.

Figure 7 Inside deign of Chiller

R12 can be prepared by reacting carbon tetrachloride with hydrogen fluoride in the

presence of a catalytic amount of antimony pentachloride. This reaction can also

produce trichlorofluoromethane (CCl3F), chlorotrifluoromethane (CClF3)and tetrafluorometh

ane (CF4).

CCl4 + 2HF → CCl2F2 + 2HCl

The elements and the explanation about the cooing process is given below

1) Copper windings around the vessel

2) Compressor that contains the Freon gas

3) Expansion valve

The cooling effect in this cooler has been achieved by condensation and

vaporization of the Freon gas, the principle is same as the working principle of a refrigerator.

The vessel that contains palm liquid will be wounded by copper wire. So that it will act as a

heat exchanger. There is a compressor that contains the Freon gas. The Freon gas will be

passed through the metal pipe. The insulated compartment of the cooler contains an

70

expansion valve and a heat exchange coil. In this process the Freon is vaporized by absorbing

the heat inside the palm liquid.

In the cooler the electrically run compressor does work Freon gas by increasing the

pressure of the gas instantly the temperature of the gas will increases. This gas enters the coil.

Heat flow from the high temperature gas to the lower temperature surrounding the coil. This

heat loss causes the high pressure gas to condense to liquid, as motion of the Freon molecules

decreases and intermolecular attraction are formed.

3. Centrifuge

A centrifuge is a piece of equipment that puts an object in rotation around a fixed

axis (spins it in a circle), applying a potentially strong force perpendicular to the axis of spin

(outward). The construction is made up of a stainless steel cylinder inside which a mess is

kept. This mess is connected to a motor mounted under the centrifuge cylinder. This motor is

capable of rotating at very high speeds of range 3000 rpm. The mess in which the solution is

poured is a cylindrical section with filter holes of order of 0.01mm to 0.5mm.

Figure 8 Inside view of Centrifuge

71

The centrifugal force can separate a mixture consists of two substances with

different density by continuous rotation. Normally this has been used to separate any

mixtures with having different density. This process has been used here to separate the palm

sugar crystals and its molasses. The main components in this process are:

1) Container

2) Induction motor

3) Controller

The container will be filled with the palm sugar with molasses. The principle of spin

motor and centrifugal force is used in such a way that with the suitable speed of centrifuge

suppresses the loss of crystal sugar in the molasses.

Especially the induction motor which is having nonlinear characteristic whose value

varies with the operating condition, so it changes the load automatically the speed also

changes. The speed cannot be maintained uniformly because of masscults will be different

quality.

The controller has been used to adjust the speed that can maintain the motor speed

despite varying load changes. This results in giving the quality crystal palm sugar within a

short span of time.

The production process commences with the manual harvest of palm nectar, which is

then boiled above 100 °C at the start and gradually increased to a temperature of about 120-

150 °�C. A stirrer is mounted on the boiler head, whose purpose is to supervise uniform

heating of the processing fluid by continuously stirring the solution. The moisture content in

the nectar begins to vaporize, which is then condensed and collected in a collecting tank. The

sugar paste formed is collected and allowed to cool.

72

The palm sap that has been extracted from the palm is diluted. So that the pH level of

the palm water will be neutral. The boiler is then filled with the extracted palm nectar, by

pumping it via an inlet valve. The heating coil is given power, which creates a thermal heat of

about 800 °�C at 100 bar pressure. This is transferred to the processing fluid with the help of a

thermic fluid. A stirrer mechanism is introduced and mounted on the top part of the boiler, for

uniform heating of the nectar. The palm nectar is heated in a boiler with thermic fluid to 50-

60 degree Celsius at which the nectar begins to boil with a simultaneous separation of

calcium from palm toddy water.

During this process the water will be separated from the palm water in the form of

steam. In the top of the boiler there are two valves; Steam valve will collect the steam in a

separate container. The steam water that has been collected can be used as a byproduct

(hospital cleanser). Another valve is used to collect the palm water. Using mesh filter (a high

density cloth), the calcium in the palm water is completely separated. Again after the

separation of palm water from calcium it is refilled in the boiler and heated for 110 degree

Celsius.

After that, heat is gradually increased and water molecules are vaporized. These

vapours are collected through an outlet valve, where it expands, condenses and then removed

as water, leaving a semi-solid solution. The palm nectar reaches a maximum temperature of

120-150 °�C. The entire process takes only one and half to two hours to complete. The paste

like solution obtained is then collected.

The semi-solid solution from the boiler is collected in the chiller’s container. The

temperature of this solution is about 120-150 °C. Now the cooling has to be faster, but

without contamination. So we go for forced convection, using a thin copper tube which is

coiled around the cylinder from top to bottom. Through this copper tube a refrigerant solution

73

(mostly R12 or Freon-12), is circulated continuously with the help of the air compressor. As

R12 absorbs the heat from the hot solution and circulates back it cools down by relieving heat

to the atmosphere via radiator or air fins. A stirrer is used continuously in motion to avoid

settling of the solution for preventing crystallization of solution and also for faster cooling.

As the cooling takes place temperatures drop down from 120-150 °C to 20-25 ° �C. The

solution is not allowed to go below 20 °�C as it may causes solidification of the solution. This

is monitored using micro controllers which closely watches over the temperature and

automatically cuts off the coolant supply when the desired temperature is reached. Mostly

this process takes about half an hour to complete.

The semi-solid solution from the chiller will still have some moisture content in it.

This moisture needs to be removed in order to get fine crystallized sugar. Centrifugal force is

used at this stage to separate palm sugar crystals and molasses or mother liquor. The solution

is poured into the centrifuge’s mess and is rotated at very high speeds of 3000 rpm. With the

help of centrifugal force and sedimentation principle the denser sugar content and water are

separated. Water is removed and is collected in the cylinder outside the mess as it passes

through the small pores in the mess. After this process crystal palm sugar will be separated

from this mother liquor.

74

PHASE III

3.1 EVALUATION OF PHYSIOCHEMICAL PROPERTIES OF STANDARD AND

PALM SUGAR PRODUCED UNDER INNOVATIVE PROCESS

The selected palm sugar sample from the Narippaiure production unit and sample

prepared by our innovative process were subjected to physiochemical analysis of properties

namely moisture, pH, Acidity, Colour, Brix, viscosity and Boiling point. The methods

followed for analysis is presented in Table I & II. The procedures adapted are given in

Appendix II

The Standard used for comparison is the palm candy that is available in the powdered

form and sold as palm sugar.

3.2 DETERMINATION OF NUTRIENT CONTENT OF STANDARD AND PALM

SUGAR DEVELOPED UNDER INNOVATIVE PROCESS

Nutritional properties of standard and developed palm sugar were studied by using

standard procedure. In order to estimate the proximate composition (protein, fat, CHO,

calories), Sugars (Glucose, sucrose, fructose, maltose) and micro nutrients such as Vitamins

(B carotene, Vitamin B1, B2, B6, Vitamin C) minerals (Calcium, Iron, Sodium, Potassium,

Magnesium, Phosphorous, Zinc) . (Methods- Refer table II) The standard procedures are

given in Appendix II.

3.3. DETERMINATION OF PHYTOCHEMICAL COMPOSITION AND

ANTIOXIDANT ACTIVITY OF STANDARD AND EXPERIMENTAL PALM

SUGAR

DPPH Radical-Scavenging Activity

The DPPH assay method is based on reduction of 2, 2-diphenyl-1-picryl hydrzyl

radical (DPPH) ,a stable free radical. The effect of phenolic compounds on the DPPH radical

was used for determination of antioxidant activity of the extracts. When DPPH reacts with an

75

antioxidant compound, it can donate hydrogen, it is also reduced and the colour changes from

deep violet to light yellow.

DPPH (0.1mm) radical solution in 95% ethanol was prepared. DPPH stock solution

(1ml) was added to various concentrations (0.01-1 mg/ml in 60% ethanol) .The control was

prepared as above without any extract. The reaction mixture was allowed to stand in dark for

30 min at room temperature and the discoloration of DPPH was measured against blank at

517.

The inhibition ratio (percent) was calculated according to the following equation:

% Scavenging = [absorbance of control - absorbance of sample)/absorbance of control] X

100

The actual decrease in absorption induced by the tested compounds was compared

with the positive control. The IC50 value was calculated using the dose inhibition curve.

PHASE IV

4.1. DETERMINATE OF SHELF LIFE USING DIFFERENT PACKAGING

MATERIALS OF PALM SUGAR

4.1.1. Storage of Palm Sugar using different packaging materials:

Different packaging materials were used to pack the standard and developed palm

sugar and palm sugar. To find out the proper packaging material this enables the complete

protection. Four different packaging materials were used namely, 150 gauge High Density

Polyethylene (HDPE) · 80 gauge Low Density Polyethylene (LDPE) · Aluminium foil,

Laminated Aluminium Pouches. About 1.5 kg of palm candy and about 1.5 kg of palm sugar

were packed by using above packing materials as 60 packs and sealed.

After packaging to observe the physical changes occurring in the product during the

storage period, the palm candy was stored at room temperature, refrigeration temperature and

three different relative humidity conditions. These packs were kept 90 days in different

76

temperatures and sensory attributes of sugar namely appearance, texture, colour, taste and

odour were evaluated. . Palm Sugar was stored at room temperature. After six months to

observe the physical changes in the palm Sugar. Finally the standard palm Sugar and

compare to prepare palm Sugar is prepared through innovative process.

PLATE IV VACCUM PACKING

4.2. ANALYSIS ON ANTIMICROBIAL ACTIVITY OF STANDARD AND

EXPERIMENTAL SUGAR

To find the possibility of developed palm sugar and standard sugar the inhibitory

activity of the sugar for bacteria and fungi was carried out. Antibacterial analysis was

conducted using standard Ethanol.

Antibacterial tests were evaluated by measuring the zone of inhibition against the test

microorganisms namely Shigella flexneri, Escherichia coli, Pseudomonas aeruginosa. These

micoorganism were tested as they were commonly found in sugar. Ethanol was used as

solvent for extraction. Nalidixic acid (30mg) disc was used as reference antibacterial agent.

The tests were carried out in triplicates. The detailed procedure is given in Appendix _

The search for antimicrobials from natural sources has received much attention and

efforts have been put in to identify compounds that can act as suitable antimicrobials agent to

77

replace synthetic ones. Phytochemicals derived from plant products serve as a prototype to

develop less toxic and more effective medicines in controlling the growth of microorganism.

(Kelmanson JE et, al., 2000)

PLATE V ANTIMICROBIAL ACTIVITY OF EXPERIMENTAL PALM SUGAR

78

The minimal inhibitory concentration:

The minimal inhibitory concentration (MIC) was estimated using the broth dilution

method (1991, vander bergle) for the above microorganisms. Dilutions of extract from 0.075

to 2.0mg /ml were used. Test bacterial culture was used at the concentration of 10 5 Colony

forming units for 2mg/ml preparation. The lowest sugars extract concentration that

prevented visible bacterial growth after 24 hours of incubation at 370 c was taken as minimal

inhibitory concentration values and experiments were triplicated.

Determination of Total bacterial count in standard and palm sugar prepared by using

innovative process

About 1 g of the sample was serially diluted in sterile distilled water up to 10-8

dilutions. A suitable dilution of this sample was spread plated on the nutrient agar plates. The

plates were incubated at 37oC and the number of the colonies was counted after 24 hours of

incubation.

DATA ANALYSIS

Statisticalanalysis All data were expressed as Mean±SD. Statistical analysis was performed b

y Oneway ANOVA using Origin version 6.0 software andp<0.05 was considered as statistical

ly significant. Formula is presented in Appendix IV

79

CHAPTER III

RESULTS AND DISCUSSION

The results of the study pertaining to “Innovative Processing Methods of Palm Sugar

Production and its functional properties” are presented under the following heads:

4.1 Phase I

4.1.1 Socio economic status of palm sap Tappers

4.1.2 Physiochemical properties of selected palm sap samples

4.1.2.1 Physical properties of selected palm sap samples

4.1.2.2 Proximate composition of selected palm sap samples

4.1.2.3 Mineral sand vitamins composition of selected palm sap samples

4.1.2.4 Composition of sugar present in the palm sap samples

4.2 Phase II

4.2.1 Materials used for fabrication of the palm sugar extractors

4.2.2Advantages Observed in different Innovative Process against conventional Method for

Production of palm sugar

4.2.3 Construction of the palm sugar extractor involving the innovative process

4.3 Phase III

4.3.2 Comparison of Physico chemical Characteristics of the Palm Sugar produced by

conventional and Innovative Process

4.3.3 Comparison of the Nutrient content , flavonoids and antioxidant property of the palm

sugar produced by conventional and Innovative Process

PHASE IV

4.3 Shelf life analysis of palm sugar prepared by innovative process

PHASE V

5.1 Antimicrobial study on standard and palm sugar prepared by innovative process

80

PHASE I

4.1.1 SOCIO-ECONOMIC STATUS OF PALM SAP TAPPERS

Our research work of palm sap (Neera) collection from palmyrah trees has been

planned to be originating coastal line locations of Ramanathapuram district namely,

Kilakarai, Narippaiure, Kannirajapuram and Vembar in Ramanathapuram district. Hence, the

quality of palm sugar can be assuredly expected if and only if the palm sap is obtained from

seashore palm trees as they usually show an increased Brix value owing to the presence of

more sugar contents compared to those located in the interior part of the District. Moreover,

one can find numerous palmyra tree grown villages, tremendous number of palmyrah trees

population and more number of tappers being found prevalently in these areas of seashore

locations of Gulf of Mannar. The inhabitants of these locations, have their occupation as”

Palm Neera tapping” during the season and do fishing during the off seasons. Since large

number of tappers can be hired for palm Neera collection, one can be so sure about in the

minimization of cost of production of palm sugar.

The tappers in these areas usually depend upon the Palmyra market association for

their economical support even before the season commences. Their economic conditions are

poor and also lack in knowledge of processing techniques, preservation methods and storage

process etc., they are unable to carry out direct marketing of palm gur and palm candy

products. The agents fix a very high value for the low-income people’s products and were

very much greedy enough to sell at a hiked margin. Owing to all the above aspects, the price

of palm gur and candy available in the market is found to be very high compared to that of

white sugar.

81

Table-6 Socioeconomic Status of Palm sap Tappers

S.No Particulars Number of respondent

n=50

Percentage (%)

I Age Distribution

1 20-40 22 44

2 40-60 25 50

3 60-80 3 6

II Sex

Male 35 70

Female 15 30

III Level of Education

Primary 2 4

Secondary 20 40

Higher secondary 10 10

Graduate 3 6

Illiterate 15 30

IV Types of Occupation

Fishing/ Neera Tapper 26 52

Daily wages 14 28

Working in shops 10 20

V Family Income / month

Low income (<4500) 13 26

Middle income (4500 – 7500) 28 56

High income (>7500) 9 18

82

The socio-economic status of palm sap tappers indicates that 50 % of the tappers

were engaged persons for tapping occupation were found to be in the age group of 40-

60range and to the next level of tapping profession, the age group lie in the range 20-40 as

they frame 44 percentage of the total community of that area. People fewer than60 or above

80 in age were not generally seen in such occupations as the former class don’t prefer this

and the latter one are not young and energetic to undergo such works.

Of all the classes of consideration for employed status, the fishing /Sap tapping

category of people (52 %) dominates the other two, the daily labour (28 %) and working in

shops (20 %). This because during the non-palm juice season (August -December), the self-

employing palm worker family groups can find a surplus percentage of profits by processing

of edible products like palm Nongu, palm fruit and palm tubers etc., and non-edible products

like palm fibre and palm leaf articles meant for manufacturing plates, mat or baskets etc.,

which in turn could even be exported. Apart from this, every family gets benefitted by

having a business share with the processing units; indulging their family women and heirs in

processing, preservation, packing and marketing and all such sorts of palmyrah works so as to

empower and sustain their livelihoods throughout the year. The percentage of people under

labor categorieswas less (34 %) as they are paid less amount for Neera tapping (Rathiha et

al., 2009).

A sum of Rs. 400-450 per day (middle income group) has been fixed as pay for Neera

tappers (almost 56 % of total respondent) as the nature of tapping work is very hard and

heavy task demanding; also to attract the professional tappers and to make them not to quit

and alleviate such professions as they are a boon to the workers in the sector. This fix of high

pay has become possible by some of the schemes announced by Government as for disbursal

of working capital to jaggery manufacturers and loans to members of various societies

83

manufacturing palm products. If the tappers were charged with less pay like Rs. 200 or

250/day, (low income) then on analysis, it was confirmed as only very less percentage (only

6 %) of such daily income were seen in tapping process and also that no tappers were usually

paid with high income group (Rs. 500/ day) as it covers only 18 %.

Palm sugar is known in Indonesia as the sweetener for food and beverage that can be

used as the substitute for granulated sugar. The sugar palm can be shaped become solid palm

sugar and crystal palm sugar. The solid palm sugar is obtained by cooking the sugar palm sap

up to be thickened like taffy, then pour it into mould. Crystal palm sugar, the cooking is

longer, up to the sugar become crystal, then be dried or put in oven up to the water content

under three percentage.

Palm Neera was collected from different spikes of the same tree and at randomly

selected trees in the same Farm to find out the variations in the properties. The palm products

producers in Narippaiure were largely involved in the production of palm gur and palm

candy.

84

4.1.2 PHYSIOCHEMICAL PROPERTIES OF SELECTED NEERA SAMPLES

Table-7

Fresh Neera

samples

Parameters

pH (Normal 6.7 to

7.2)

Ash (gm) 0Brix (%) Viscosity Titratable

Acidity (gl-1)

Boiling Point °C

KS1 11.50±2.00 0.17±0.05 16.2±3.00

0.69±0.45 1.00±0.14 107.80±5.22

NS2 10.92±1.24 0.21±0.05 17.5±3.04

1.04±0.04 0.38±0.38 109.00±5.57

KS3 10.80±1.96 0.23±0.06 15.4±2.02

0.89±0.44 1.17±0.50 109.80±1.79

VS4 10.50±1.00 0.14±0.03 14.2±2.06

0.55±0.59 0.69±0.52 109.00±2.24

Mean ± standard deviation (n= 5)

KS1-Kilakkarai sample; NS2-Narippayur sample; KS3-Kanirajapuram sample; VS4-Vembar sample

85

The Physio-chemical properties of Neeraare presented in Table-7. The nominal colour

and appearance of the quality of Neera was as pale white compared to oyster white or that of

creamy yellow which in turn refers to an undesirable sap that is turbid with a fermentative

odour. The pH value measured at ambient temperature with a pH meter (Meenune et al.,

2011).pH value gives a measure of the acidity or alkalinity of the product and to ensure the

quality of the same. These turbid results also showed that Sap contained a pH value ranging

from 10.92±1.24 indicating that it was strong basic in nature at the time of collection.

Titratable acidity gives a measure of the amount of acid present in the product. As

there was an increased alkaline pH, one could expect for titrable acidity values of fresh Neera

to range from 0.38± 0.38%(gl-1). If on contrary, a higher value in Titrable acidity is observed

which might be due to the traditional methods of production which are non-standardized in

terms of raw materials, equipment and finished products quality and handling (Wonang and

Opoefe, 1999). High percentage of total acidity indicated the initial spoilage or fermentation

of fresh palm sap as a raw material used for palm sugar concentrate production.

The fresh Sap, as a clear liquid will never be viscous or turbid in nature and thus, the

analyzed viscosity results were almost nil or negligible (0.54±0.53). The determined turbidity

parameter values of sap indicated its clarity and thereby its purity for a healthy drink. Ash

content of palm sap was in the range of 0.14±0.03.The physio-chemical properties of

traditional local drink of palm sap showed that the fresh sap contains 17.5±3.04 % of total

soluble solids (%) 0Brix(TSS) as a suspension of soluble solids.

The boiling point required for conversion of fresh sap to a palm candy was found to

be as 108-110 °C. Excess boiling temperature might result in the maillard reaction, an

untoward effect, and then the brown color of the palm sugar concentrate sample will be

86

produced during heating. Low temperature from the observed nominal boiling point might

not lead to crystal formation from palm sap. The microorganism like yeast and lactic acid

bacteria observed in the palm sap (being present naturally) or in collecting mud pots (may be

retained during previous collection of sap) and serves as an inoculums. It is also believed that

the lactic acid bacteria increased the acidity and ascorbic acid content. It was also reported

that the fermentation caused the increase in alcohol content. The increase in protein content

might be because of the yeast cells itself.

Proximate nutrient composition

The proximate nutrient composition of the selected samples are shown in table 9 and figure

Table–8. Proximate composition of Fresh palm Neera

S.No Sample (Sap ) Protein

(gm/100ml)

Carbohydrate

(gm/100ml)

Fat

(gm/100 ml)

Calories

(Kcal/100ml)

1. KS1 12.8 28.3 0.03 109

2. NS2 17.5 29.5 0.06 108

3. KS3 12.31 23.2 0.07 114.9

4. VS4 17.2 20.5 0.05 117.5

KS1-Kilakkarai sample, NS2-Narippayur sample, KS3-Kanirajapuram sample,

VS4-Vembar sample

87

Figure 9 Proximate composition of palm Neera

Table–10 Sugar content of fresh Palm Neera

S.No Samples

(Fresh Sap)

Parameters

Total sugar

(gm/100ml)

Glucose

(gm/100ml)

Fructose

(gm/100ml)

Sucrose

(gm/100ml)

1. KS1 14.66±2.07 0.08±0.46 0.14±0.05 154.72±27.46

2. NS2 26.48±1.80 1.28±0.23 0.14±0.03 149.79±39.05

3. KS3 16.22±1.62 1.17±0.59 0.12±0.07 167.45±82.91

4. VS4 13.04±0.95 1.28±0.07 0.28±0.30 119.82±8.97

KS1-Kilakkarai sample; NS2-Narippayur sample; KS3-Kanirajapuram sample; VS4-Vembar

sample

The total sugar content of health drinks of particular food types might vary

considerably with variety, soil, climatic conditions, socio-economic factors, methods of

production and raw materials or containers being used. The concentration of fructose and

glucose was analyzed to be less than that of sucrose, a less calorific sugar so as to prevent the

browning effect of the formed syrup. When once the probability of maillard reaction is

88

controlled by having a reduced heating temperature and heating time during the production

process, then the inversion of sucrose i.e. the conversion of sucrose into their individual

monosaccharides, fructose and glucose also does not occur. Owing to the above mentioned

reaction and reason, the less calorie sucrose was present in comparatively higher than the

diabetic causing glucose content and thus the palm sugar and its precursor material, palm Sap

become most essential as sugar free food supplement.

Palm sugar syrup heated by vacuum evaporator can reduce the loss of sucrose more

than palm sugar syrup heated by open pan. This is probably due to this process using a lower

temperature and a shorter time. Additionally, this process can also minimize sucrose

inversion, therefore lower reducing sugar contents of fructose and glucose were obtained. The

reducing sugar content is an important parameter that affects the properties of palm sugar

syrup during storage since it can act as a substrate for maillard reaction.

Table–10. Estimation of vitamins in Fresh Neera

S.No Samples

(Fresh Sap)

Vitamin

A (IU)

Niacin

(IU)

Pyridoxine Thiamine

(mg)

Riboflavin

(mg)

1. Market sample 2.351 0.110 NQ NQ NQ

2. KS1 1.657 0.000 NQ NQ NQ

3. NS2 2.346 0.132 NQ NQ NQ

4. KS3 1.214 - NQ NQ NQ

5. VS4 2.438 0.002 NQ NQ NQ

KS1-Kilakkarai sample, NS2-Narippayur sample, KS3-Kanirajapuram sample,VS4-Vembar

sample,NQ-Negligible quantity.

89

Only β-carotenes (2.3-2.4 IU) were found to be present in appreciable quantities

comparing to all other vitamins like Niacin (just 0.110 NU) and Pyridoxin, Thiamine and

Riboflavin (very negligible or almost nil in quantities). Protein, carbohydrate, fat, calories

and ash contents were determined by dry weight basis. The fat content observed was very less

and negligible in the fresh toddy. The protein content was found to be 17.5 gm/100 ml

matching to most of the standard nutritional health drinks and thereby assuring its role as a

dietary material.

The determination of calorific contents of palm Sap led to a fact of obtainable energy

source as around 114.9-117.5 Kcals and thus it acts as a very good energy provider and a rich

energy supplements in food items.

Figure 10 Analysis of Vitamin A

90

Table-11. Estimation of Minerals in Sap

S.No Samples

(Fresh Sap)

Parameters

Ca

(µg/gm)

Fe

(µg/gm)

P

(µg/gm)

Na

(µg/gm)

K

(µg/gm)

Zn

(µg/gm)

Mg

(µg/gm)

Mn

(µg/gm)

1. KS1 17.4 0.212 2.234 3.213 21.43 1.231 0.246 0.213

2. NS2 14.2 0.343 2.318 3.428 25.42 1.245 0.342 0.124

3. KS3 16.5 0.322 2.110 3.183 18.56 0.333 1.247 0.117

4. VS4 15.5 0.257 2.414 2.124 22.43 0.236 1.213 0.011

KS1-Kilakkarai sample; NS2-Narippayur sample; KS3-Kanirajapuram sample; VS4-Vembar sample

All these nutritional and functional characteristics can ensure the quality and purpose of palm sap as a rich food supplements.

The quantities of minerals present in different samples of Sap from different places of Ramanathapuram district in tabulated -9. In

most of the determination of minerals like Ca, Fe, P, Na, K, Zn, Mg and Mn, the Naripayyur samples was found to have the

maximum concentration for almost all of the minerals and the results were 17.4 µg/gm of Ca, 0.343 µg/gm of Fe, 2.318 µg/gm of P,

.428 µg/gm of Na, 25.42 µg/gm of K, 1.245 µg/gm of Zn, 0.342 µg/gm of Mg and 0.213 µg/gm of Mg. All these results

confirmed the nutritional importance of Naripayyur Sap sample in terms of minerals and vitamins. All these results confirmed the

nutritional importance and enriches of Naripaiure Neera sample in term of minerals and vitamins. The composition of mineral

contents would in turn be reflected by that of ash content.

91

Figure 11 Comparison of phosphorus and calcium content in Neera

92

PHASE II

4.2.1.1 STUDY ON EXISTING METHODS OF PALM SUGAR PREPARATION

AROUND TAMIL NADU

Table–12. Survey on Palm Neera Process in various parts of Tamilnadu

S.

No.

Areas of study Products being

prepared by mentioned

area

Type of

Neera

Quantity

(liter)

Production

time (days)

Yield

(kg)

1. Palm society of Ramnad,

Narippayur

Palm Gur,

Palm Candy

Pal

m N

eera

(P

athan

eer)

100 40 12-13

2. Central Palm Gur Unit,

Madhavaram

Palm Gur,

Palm Candy, Palm taffy,

Neera Preservation

100 30 30-33

3. Private Small Scale

Industry, Thiruchendure

Palm Gur,

Palm Candy 100 40 10-12

4. Small scale unit, under

self-help group of

Women, Sayalkudi in

Ramnad District

Palm Gur,

Palm Candy 100 40 13-14

The results of a survey on palm Neera process in various parts of Tamilnadu were

tabulated in table-10. Palm products like palm gur, palm candy, palm taffy and Neera

preservation carried out by Central Palm Gur Unit, Madhavaram has produced a very high

percentage yield of 33 % in just 30 days. Whereas, the other areas though were able to produce

the same palm products, their percentage yield and the duration were found to be less favorable

93

as they were just 10-14 % yield and in only 40 days respectively. Also the quantities being

produced in case of Madhavaram was 300 liters whereas, for others, it was just 100 liters. This

because, Palm product workers in Naripayyur, Thiruchendur and Sayalkudi areas are not trained

professionally about palm work processing; usually carry out such processes as in traditional,

unhygienic processing environment and with no care of quality of products; their general aim of

expectation would usually to sell the palm jaggery, obtained by just a one day process instead of

a long term production of palm candy i.e. 45 days as the latter just yields only a very narrow

differences in profits in spite of lot of investments for the same. The wholesaler usually sets a

very low price for the palm products obtained from palm processing family workers as a

marketing strategy and also as the products obtained from them would generally be spurious and

less standard.

The palm workers in above said areas were not able to manufacture a very high

percentage yield for the above mentioned reasons, whereas, those in Madhavaram area are very

professionally trained by central palm gur unit for palm cookies or taffy or Neera preservation

and do care for both quality and for profits of the process. A Central Training School was

established in Madhavaram to train the tappers in tapping, preservation and sale of Neera,

distributing improved tools and equipment and arranging demonstrations and exhibitions for

propagating Neera and Gur as main facets of development programme. The reason for such

success by central unit is that they have many workers to be working on more than 100 trees

simultaneously for Neera collection and thus both the weaker section of the society as well as the

central unit are mutually benefitted.

94

Figure 12 pH variations in Palm Neera

Table-13. Identification of hazards in Palm candy and Palm jaggery

S. No

Potential

hazards

Type of hazards

Residues

in candy (%)

Residues

in Jaggery (%)

1 Physical Mud

Sand

Thread

Stone

1

3

4

5

2

5

3

2

2 Chemical Superphosphate 10 9

3 Microbial load Bacteria/yeasts + ++

95

The contaminants in Jaggery are more comparing to that in candy irrespective of the

types of hazards. Jaggery deteriorates faster and becomes watery within 1 or 2 weeks due to its

hygroscopic nature and thus deteriorates its quality through microbial fermentation. The different

types of hazards that the palm candy or jaggery producers usually come across during their

traditional manufacturing processes can be aimed to be alleviated in this innovative method

involving a natural organic clarifier or a modern machine, a palm sugar extractor. As there is a

rich demand for palm products in society and through which, a huge employment scope can be

raised in these palm products processing, we focus to plan for a high quality and a hazard free

methods for palm sugar production.

Raw materials and ingredients used in the processing should be obtained from certified

vendors. Raw materials should be maintained at proper storage conditions, the production should

follow HACCP principles and standard operating procedures to minimize risk of contamination

and quality defects.

Table-14. Raw materials for Palm candy/sugar preparation

S.No Area Raw material Actually added

quantity of

Superphosphate

Acceptable level of

Superphosphate

1 Naripaiyur • Neera

• Superphosphate

solution

10 g in 1/4 liter of

Neera

5-7 g in 100 liters of

Neera

2 Madavaram • Neera

• Superphosphate

solution

8 g in 1/2 liters of

Neera

5-7 g in 100 liters of

Neera

96

Though the acceptable level of superphosphate to be added in palm candy/sugar

preparation permits only 5-7 g in 100 liters of Neera but in actual, the palm candy producers of

Naripayyur or the palm sugar producers of Madhavaram do utilize the quantities of

superphosphate for production as 10 g or 8 g just for ¼ liters or ½ liters of Neera so as to

improve the percentage yield of production inspite of realizing the hazardous facts caused by

such superphosphate solution. According to Thomson Linda (2002), superphosphate is a

chemical used in food industry, excess consumption of superphosphate will lead to cancer and

neurological disorders. We thus planned to avoid or replace the role of this hazardous chemical

by a natural organic clarifier.

97

Table-15. Types of clarifier used in Palm sugar preparation

NS2 – Narippayur sample of Neera

On the basis of the review of literatures, the stem extracts of plants viz., Hibiscus, Ladies

finger and Malai Poovarasu were found to possess a large quantities of clarifying property and it

was shown in Table-15. In Standard method, superphosphate was used as a clarifier as a

traditional method existing in village pockets, Clarification of palm Neera is very important for

making light yellow colored, crystallized and impurities free a gur, suitable for storage. The

purpose of clarifier in such preparation is to clarify the collected Neera from their adjunct dusts

or debris and also to promote the crystal formation along with the use of vinegar. Clarification of

palm Neera is called Deliming process is done by using commercial superphosphate solution and

thus the neutral reaction is brought out by pH adjustment with vinegar. The dissolved impurities

in the Neera are removed with the help of vegetative clarificants. Instead of 5 g quantity of the

chemical clarifier, superphosphate, all the natural clarifiers were taken in 10 g quantities in 250

S.

No Palm

Neera

Neera

quantity

(ml)

Clarifier Quantity

(g)

Initial pH

of Plant

extracted

Method of

preparation of

extract

1. Standard 250 Super phosphate

solution

5 6.5 -

2. NS2

250 Hibiscus leaves

(extract)

10 7.2

Soaked in water for

about 2-4 hrs,

ground and crushed.

Added this

mucilaginous liquid

250 Ladies finger

(extract)

10 6.6

do

250 Malai Poovarasu

Stem (extract)

10 7.8

do

98

ml Neera in order to achieve the most preferable crystallization of palm sugar with maximum

concentration.

Table–16. Difference between the existing palm candy and organic palm candy

S. No. Parameters Existing Palm Candy Organic Palm Candy

1. Container

Calcium Hydroxide

coated pot, U -

Shaped metal chamber

Calcium Hydroxide coated,

sterilized mud pot

2. pH maintainer and

cleanser Superphosphate

Hibiscus leave extract, Ladis

Finger stem extract, Malai

poovarasu extract

3. Temperature 110 0C 108 0C

4 Cooling condition Upon Soil In rooms

6 Duration of Storage

(for crystal formation) 45 days 12 days

Neera at the time of collection do usually contain the value of pH as around 11, a strong

alkaline nature which to be decreased to a low basic pH like around 6.5-7.5, which is best

achieved by Malai Poovarasu stem extracts. The purpose of coating the containers with calcium

hydroxide is to prevent the process of fermentation. Though the temperature condition for both

existing and organic palm sugar preparation did not differ much, but there was a big deal of

variation in the duration of crystal formation i.e almost 25-30 days had been saved in the

production process and indeed it is a huge point of consideration in profit point of view.

99

Table-17. Preparation of Palm syrup

S.No Sample Initial pH of

Neera

Final pH of

Neera

Temperature

( o

C)

Boiling

time

(min)

Cooling

time

(min)

1. Standard 12 8 106 – 108 60 10

2. KS1 10.2 8 106 – 108 30 10

3. NS2 9.8 8.3 109 – 110 45 10

4. KS3 11 7.8 107 – 108 40 10

5. VS4 11.8 8 106 – 108 25 10

KS1-Kilakkaraisample,NS2-Narippayursample,KS3-Kanirajapuramsample, VS4-Vembar sample.

Different samples of Neera, obtained from various villages of Ramnad district, were

subjected for the preparation of palm syrup and the observed the reaction parameters were shown

in the Table-14. Strong alkaline pH of Neera (10-12) at the time of collection has been decreased

to neutrality i.e. to weak alkaline pH (7.8-8) using apple vinegar before boiling. The optimum

boiling temperature of the process was found to be 109-110 o C, given out by Naripayyur sample.

As boiling proceeds, the froth and foam coming up to the surface is removed by means of a

perforated laddle and the same was stirred at intervals to facilitate mixing and rapid evaporation.

The optimum boiling and cooling time, after comparing all the four samples, were found to be as

45 and 10 minutes respectively.

100

The results of a survey on palm sap process in various parts of Tamilnadu were

tabulated in table-10. Palm products like palm jaggery, palm candy, palm taffy and sap

preservation carried out by Central Palm Gur Unit, Madhavaram has produced a very high

percentage yield of 33 % in just 30 days. Whereas, in the other areas though they were able to

produce the same palm products, their percentage yield and the duration was found to be less

favorable as they were just 10-14 % yield and in only 40 days respectively. Also the quantities

being produced in case of Madhavaram was 300 liters whereas, for others, it was just 100 liters.

This because, Palm product workers in Naripayyur, Thiruchendur and Sayalkudi areas are not

trained professionally about palm work processing; usually carry out such processes as in

traditional, unhygienic processing environment and with no care of quality of products; their

general aim of expectation would usually to sell the palm jaggery, obtained by just a one day

process instead of a long term production of palm candy i.e. 45 days as the latter just yields only

a very narrow differences in profits in spite of lot of investments for the same. The wholesaler

usually set a very low price for the palm products obtained from palm processing family workers

as a marketing strategy and also as the products obtained from them would generally be spurious

and less standard.

The palm workers in above said areas were not able to manufacture a very high

percentage yield for the above mentioned reasons, whereas, those in Madhavaram area are very

professionally trained by central palm gur unit for palm cookies or taffy or Sap preservation and

do care for both quality and for profits of the process. A Central Training School was established

in Madhavaram to train the tappers in tapping, preservation and sale of Sap, distributing

improved tools and equipment and arranging demonstrations and exhibitions for propagating Sap

and Gur as main facets of development programme. The reason for such success by central unit

101

is that they have many workers to be working on more than 100 trees simultaneously for Sap

collection and thus both the weaker section of the society as well as the central unit are mutually

benefited.

The contaminants in Jaggery are more comparing to that in candy irrespective of

the types of hazards. Jaggery deteriorates faster and becomes watery within 1 or 2 weeks due to

its hygroscopic nature and thus deteriorates its quality through microbial fermentation. The

different types of hazards that the palm candy or jaggery producers usually come across during

their traditional manufacturing processes can be aimed to be alleviated in this innovative method

involving a natural organic clarifier or a modern machine, a palm sugar extractor. As there is a

rich demand for palm products in society and through which, a huge employment scope can be

raised in these palm products processing, we focus to plan for a high quality and a hazard free

methods for palm sugar production.

Raw materials and ingredients used in the processing should be obtained from certified

vendors. Raw materials should be maintained at proper storage conditions, the production should

follow HACCP principles and standard operating procedures to minimize risk of contamination

and quality defects.

102

Table 18

Difference between the Conventional and Innovative method of palm sugar production

S.No Particulars Conventional method Innovative method

1 Raw material used Palm sap 50 litre Palm sap 50

pH monitoring - pH meter

Clarifying agent superphosphate Hibiscus extract

Type of boiler Aluminium vessel Food grade electronic boiler

Boiling time 3 hours 1.5 hrs

Crystallization method

Manual Chiller

Crystallization time

24hrs/ 50 litre 6hrs/50 litre

Time duration for production

37 days 24 hours

Type of Fuel

Wooden Chulas

Power operated

4 Centrifugation No Centrifuge used

5 Drying time 24 hr/ 5 kg 1 hr/5 kg

6 Storage period 1 year 1 year

Though the acceptable level of superphosphate to be added in palm candy/sugar

preparation permits only 5-7 g in 100liters of Sap but in actual, the palm candy producers of

Naripayyur or the palm sugar producers of Madhavaram do utilize the quantities of

superphosphate for production as 10 g or 8 g just for ¼ liters or ½ liters of sap so as to improve

the percentage yield of production in spite of realizing the hazardous facts caused by such

103

superphosphate solution. According to Thomson Linda (2002), superphosphate is a chemical

used in food industry, excess consumption of superphosphate will lead to cancer and

neurological disorders. thus planned to avoid or replace the role of this hazardous chemical by a

natural organic clarifier.

104

FABRICATION OF PALM SUGAR EXTRACTOR

Based on the primary and secondary data gathered through this study, the researcher tenured

to design the equipment for the preparation of palm sugar. Newly designed and fabricated palm

sugar extractor has the following components

1. Boiler with four shell layers

2. Chiller

3. Centrifuge

This has been fabricated with the help of a mechanical engineer working in Research and

Development, SITRA, Coimbatore. The whole process consists of three units. Each unit is

designed in a manner to reach maximum quality and quantity, as follows:

Fig-15.1Flow chart for new concept of palm sugar preparation

Boiling unit

Cooling unit

Centrifuge unit

Dried under sun light

Collection of Sap (Pot Coated With Lime)

Storage

105

CONSTRUCTION OF PALM SUGAR MANUFACTURING MACHINE

This machine can hold a capacity of 20liters of Sap and can produce approximately 3kg

of palm sugar. The construction of palm sugar machine is shown in figure .4.1.

It has three units and they are,

1. Boiling unit,

2. Cooling unit,

3. Centrifuge unit.

Palm sugar machine is constructed using steel frame section. In left side of the steel frame

section, boiler is located which is used to boil the palm water under 120°C and it consist of

temperature controller unit and stirred motor. Palm syrup is fed through the cooler unit that is

connected with the stirrer motor. Centrifuge is connected next to the cooler unit for further

process.

106

Fig-16 Schematic diagram of palm sugar manufacturing machine

107

4.1 Boiling unit

Fig-17 Boiling unit

108

The boiler used to remove the water content and calcium. The elements of the boiler are

illustrated below.

1. Frame

2. Boiler

3. Heating coil

4. Outer cover

5. High temperature insulation

6. Temperature controlling sensor

7. Stirrer

1. Frame

A frame is a structural system that supports other components of a construction. It is

made of mild steel and has a dimensions 25mm square and 3mm thickness.

2. Boiler

Boiler is used to boil the Sap .The capacity of the boiler is 20 liters and made by

AISI304L (food grade stainless steel). The thickness of the boiler drum is 1.6mm; the rationale

behind using less thickness is the fact that it is open to the atmosphere. Steam outlet pipe is

provided in the top of the boiler to flush out the steam from the system.

3. Heating coil

Heating coil is placed directly under the bottom outer surface of the boiler. Heating coil

has Ø190mm , Voltage of 220V, xx Watts and xx Ampere. It is used to raise the temperature of

the boiler to remove the water content in the Sap.

109

4. Outer Cover

The outer cover acts as a second layer insulation over the boiler. Heatfrom the insulation

wool is transferred to the outer cover this ensures minimal heat loss in the process. The main

advantage of using the outer cover is it acts as a support for the insulation wool; hence there is no

need of support strips for the insulation wool. The outer cover is made of Mild steel; its

dimensions are Ø 300(mm)x 300 (mm) length.

5. High temperature insulation

At the time of startup, it is essential that heat does not escape through conduction and

convection, Insulation plays a critical role in maintaining the temperature in the system, Ceramic

wool is used as insulation for this system, the low values of thermal conductivity of ceramic

wool aids in retaining the heat in the boiler. A thickness of 25mm is provided to optimize heat

transfer rates.

6. Temperature controlling sensor

A temperature sensor is fixed at the bottom of the boiler; it displays the temperature of

the system at any given time. It also acts as a feedback to the system, if in a given case there is a

temperature rise above 120ºC. The sensor triggers the heating coil and switch off the system.

7. Stirrer

The stirrer assists in mixing of the contents in the boiler. It essentially consists of a

stainless steel shaft, which is connected to a motor at one end and rotary blade at the other end.

Its rpm range is between 80-100 rpm. This ensures good coagulation and easy evaporation of

water in the Sap.

110

4.2 Cooling unit:

Figure 18 Cooling unit

The semi-solid palm extract which is obtained from the boiler unit has to be cooled to

room temperature; this is handled by the cooling unit at the exit of the boiler unit. The main

elements of the cooling unit are illustrated below-

111

1. Inner Vessel

2. Water storage vessel

3. Stirrer

1.Inner Vessel

The material of construction for the inner vessel is stainless steel; Stainless helps in cooling the

semi-solid extract, owing to its high thermal conductivity. The capacity of the inner vessel is

10L.

2. Water storage vessel

This module of the cooling unit is responsible for holding the coolant which is

instrumental in heat transfer from the inner vessel, which is alsoessential in reducing the

temperature of the extract. The material used for this component is stainless steel. The idea of

using stainless steel is to ensure that there is minimal corrosion involved in the process as the

coolant used in this process is water, which has a tendency to cause corrosion over a period of

time.

3. Stirrer

The stirrer assists in mixing of the contents in the vessel. It essentially consists of a

stainless steel shaft, which is connected to a motor at one end and rotary blade at the other end.

Its rpm range is between 80-100 rpm. This ensures uniform cooling in this process.

112

Figure 19 Centrifuge unit

113

Fig-4.4 Centrifuge unit

Thepurpose of this unit is to separate palm sugar crystals from molasses or mother liquor using

centrifugal force. This system constitutes the following parts.

1. Basket

2. Outer Case

3. Bottom plate

4. Filter

5. Power unit

6. Funnel

1. Basket

The basket receives input from the power unit causing it to rotate and separate the water from the

extract, It acts as a perforated cylinder which ensures that water which exits through the filter is

separated out. It also acts as reinforcement for the filter. The cylinder is made of stainless steel

and has dimensions of Ø 280mm x 300 mm length. Inside the basket there is a cone helps in

obliterating the molasses which finally aids in separating the sugar crystals.

2. Outer Case

The outer case remains stationary while the basket rotates. It ensures that the water which is

being separated get contained within the unit. It is welded to the bottom plate. It is made of

stainless steel and has dimensions of Ø 400 mm x300mm length.

3. Bottom plate

The bottom plate is stationary and is welded on to the frame; it contains bearings which are used

to couple the shaft and the pulley. The bottom plate ensures the stability when the centrifuge is on

operation

114

4. Filter

Filter element is used in the inside of the basket to filter the palm sugar crystal from

molasses. It is made of stainless steel and has dimensions of 200mm diameter x 250mm length.

5. Funnel

Funnel is used to pour the semi-solid palm extract exactly to cone. It is welded to the top

of the outer case. It is made of stainless steel and has dimensions of Ø 80mm x 150mm length.

6. Power unit

It comprises of a motor, driven pulley and belt. It is the source of the centrifuge’s power.

To have a higher rpm in the centrifuge we use a smaller driven pulley, the motor pulley

arrangement is such that it increases the rpm, and the driver pulley has a higher speed ratio to the

driven pulley.

115

Phase III: PHYSICAL PROPERTIES OF STANDARD AND DEVELOPED PALM

SUGAR

Table 19 Physical properties of standard and developed palm sugar

Sample

pH (Normal 6.7

to 7.2)

Ash(mg) Total soluble solids (°Brix %)

Colour Titratable

Acidity %

(gl-1)

Standard sugar 7.9

0.03 9.5 Acceptable 74mg/kg

Developed

palm sugar

7.2 0.04 10.5 Acceptable 60mg/kg

Since composition of physical parameters of palm sugar is found in various quantities,

above table present data for the evaluation of pH, Total acidity, and °Brix during the storage of

palm sugar. The pH of the sugar nearly neutral around (pH 6.8), this value was measured at

ambient temperature with a pH- meter (Inlab) which calibrated with pH 4.0 and 7.0.No

significant variation was noted for pH in sugar and pH values oscillate around a value of 7.6.

The acidity was estimated by titrating against 0.1 N sodium hydroxide using phenolphthalein as

the indicator. Acidity was expressed as a percentage of acetic acid, the Titratable acidity varies

between standard and developed palm sugar 74mg/kg and 60mg/kg. Moreover an increase in

Titratable acidity and decrease in pH is also responsible for the inversion reaction (Naknean et

al., 2010). The total soluble solids of palm sugar were determined as °Brix using hand

Refractometer (Reichert, Model 10430).

116

Figure 20 Total soluble solids in developed Palm sugar

Table 20. Rapid Visco Analyzer (RVA) analysis of the sample

Sample

P H C

BD SB

P.T

(cP) (cP) (cP) min

Palm Sugar -Developed 5 -28 33 -30 -2 1.07

Palm Sugar - Standard 4 -22 26 -19 3 1.47

Parameters tested are not covered under the scope of NABL accreditation\

Where , P – Peak Viscosity, H – Hot Paste Viscosity, C – Cold Paste Viscosity, BD –

Breakdown, SB – Setback, P.T(min) – Pasting time, cP – Centipoises (Viscosity unit)

117

Table- 21 Comparative analytical data on Nutritional properties of standard and developed

palm sugar

Samples

Nutritional parameters

CHO Protein

g/100gm

Fat

g/100gm

Calories

kcals/100gm

Glucose

mg/100gm

Fructose

mg/100gm

Sucrose

mg/100gm

Standard 58.25 1.08 0.24 220.50 0.032 0.004 1.015

Developed 66.56

2.09 0.36 227.84 0.094 0.007 2.621

The above table indicates the proximate composition tested existing palm sugar

(standard) and developed sugar prepared by using new process .The Carbohydrate, protein, fat

and calories contents of the standard sugar was 58.25g, 1.08g, 0.24g and 220.50 Kcals

respectively. Concerning sucrose content of sugar was comparatively high in other quality from

other sugars. It is apparent from these data that, sucrose content in both palm sugar samples

varied between 1.015 to 2.621mg. However, reducing sugar and protein contents were higher in

palmyrah palm sugar compared to standard and sugar developed by new process.

The crystal palm sugar is suggested by the health expert because low calorie content if

compared with the granulated sugar. The palm sugar has Glycemic Index lower about 35 while at

the granulated sugar about 58(Nenania, 2011). The Glycemic index will impact to pancreas

fatigue index, the higher Glycemic Index the higher the pancreas fatigue Index, so the palm

sugar is more suggested for diabetic sufferer compared with the granulated sugar.

118

Table -22 Fat soluble vitamins analysis of standard and developed palm sugar

Sample Vitamin A

mg/100gm

Vitamin C

mg/100gm

Alpha -

Tocopherol (E)

Vitamin K Cholecalciferol (D3)

Standard

0.120 489 0.690 0.332 0.010

Developed

palm sugar

0.436 712 0.877 0.638 0.023

Quantitative analysis of vitamins was analysed on the basis of 100g of standard and

developed palm sugar, the data was presented in Table 22. Comparison study was made on the

amount of vitamin A, Vit C, Alpha Tocopherol and Vit K, Choleclciferol found in the standard

sugar and developed sugar samples to those presented in table. The vitamin Acontent 0.120 and

0.436, found in both standard and developed sugar at moderate amount, comparatively other

sugars these sugars contains vitamins content two times greater than that found in palm sugar.

Developed sugar was also considered to be rich in vitamin E with moderate amount of vitamin

K,vitamin D3 and vit E. HPLC method was used to vitamin analysis of the palm sugar.

119

Table 23 Water soluble vitamins analysis of standard and developed palm sugar

Sample Niacin (mg/ml)

Pyridoxine (mg/ml)

Thiamine (mg/ml)

Riboflavin (mg/ml)

Standard

0.021 0.011 0.235 0.012

Developed palm sugar

0.025 0.016 0.467 0.001

Table 24 Analysis of ICP- OES of Standard and developed Palm Sugar

Sample Calcium(317.933) (mg/kg)

Iron (238.204)(mg/kg)

Sodium(589.592) (mg/kg)

Pottasium (766.490) (mg/kg)

Zinc(206.200) (mg/kg)

Standard

8.54 0.47 0.92 Below

detection

limit

1.05

Developed palm sugar

9.66 0.50 0.98 Below

detection

limit

2.10

The composition of minerals of palm sugar samples is shown in table 24. Calcium, Iron,

and Sodium, potassium, Zinc contents are high compared to other minerals for the standard

samples. These five elements called Macro-minerals are distinguished from the micro-minerals

by their occurrence in the body, as they required in amounts greater than100 mg per day.

Pottasium presented the below detection limit in the two samples. The calcium content was

abundant in both palm sugar samples. All the mentioned macro-minerals have vital physiological

and biochemical functions in human body. Only Sodium were found in fair amount and zinc

content was good in developed sugar (2.10mg/kg) . The greatest biological significance of zinc

in the organism is associated with its occurrence in active sites of many enzymes and proteins.

120

Table 25. Flavonoids compounds of standard and developed palm sugar

The beneficial effects derived from phenolic compounds have been attributed to their

antioxidant activity and studies have suggested the role of phenolic compounds as the major

sources natural antioxidants in foods of plant origin. The results of (table 25) showed lower than

palm sugar (Galic acid 0.013 and 0.010 mg/ml, caffeic 0.015 and 0.014). Ferulic acid was found

in standard sugar 0.062mg, developed sugar 0.085mg. The total phenolic contents of dried palm

sugar decreased with the increased temperature of drying.

The influence of different drying processes on the concentration of phenolic compounds

can be attributed to the varying stability of different phenolic compounds under the drying

conditions (Joshi et al., 2011).

Sample Gallic acid (mg/ml)

Caffeic(mg/ml) Rutin(mg/ml) Quercetin(mg/ml)

Ferulic acid (mg/ml)

Standard

0.013 0.015 0.013

0.001

0.062

Developed palm sugar

0.010 0.014 0.002 0.011 0.085

121

Table 26. Antioxidant activity assay in standard and developed Palm Sugar

The scavenging of the DPPH radical by hydrogen donating antioxidants (AH, equation 1)

is characterized by a rapid decline in the absorbance at 515 nm, followed by a slow step where

the absorbance depreciates more gradually. The above table shows the total phenolic content of

standard palm sugar possessed higher antioxidant content, while the lowest antioxidant activity

observed in ethanolic extract shows that there exists higher anitioxidant activity in the developed

sugar .The free radical scavenging activity of ethonolic standard sugar and developed palm sugar

extract against total antioxidant activity is (32.57,20.98, 31.05)( 48.34, 57.21, 49.13)

respectively. The inhibition of ethanolic extract (10,20,30).

I n this study, DPPH residual scavenging activity % was plotted against the sample

extract concentration and a linear regression curve was established in order to calculateIC50

which is the amount of sample required to decrease the absorbance of DPPH free radical by

S.No

Concentration

mg/m

% Free radical scavenging activity ( IC50 values)

% of inhibition of

ethanolic extract

% of inhibition of

Ascorbic extract

% of inhibition of

BHA

Sample Standard

palm

Sugar

Developed

Palm

sugar

Standard

palm

Sugar

Developed

Palm

sugar

Standard

palm

Sugar

Developed

Palm

sugar

1. 10 mg 32.57 48.34 22.38 19.05 25.69 50.04

2. 20mg 20.98 57.21 29.45 22.15 57.01 69.05

3.

30mg 31.05 49.13 16.30 24.02 84.79 76.05

122

50%. IC50 values of ascorbic acid for both sugar were 10,20 and 30mg/ml, respectively. Ascorbic

extract has the lowestIC50 value compared to the two samples. In DPPH assay, the lower theIC50,

the better it is ability to scavenge the radicals.

The DPPH radical scavenging activity of gallic acid, ascorbic acid ,crude and ethanol

extracts increase in a dose-dependent manner. Gallic acid exhibits higher DPPH radical

scavenging activity than either ascorbic acid or palm sugar extracts when tested at concentrations

of 0.2-1.0 Mm GAE. For example, at a concentration of 1.0 Mm, the DPPH radical

scavenging activity of gallic acid (94.5+0.35) was more than 6 times that of ascorbic

acid(14.6+1.1%),crude extract (15.4+0.4%),and ethanol extract (14.2+0.7%).On the other hand

,the radical scavenging activities of the extracts are comparable to that of ascorbic acid.

117

Phase: IV SHELF LIFE ANALYSIS OF DEVELOPED PALM SUGAR STORED IN

DIFFERENT PACKAGING MATERIALS

Table 27 Impact of packaging and storage conditions on Brix and moisture content of

palm sugar

AFTER 30 DAYS

BRIX MOISTURE

LDPE

%

HDPE

%

AF

%

LAP

%

LDPE

%

HDPE

%

AF

%

LAP

%

Room

Temperature

1.04 1.03 1.02 1.02 2.9 2.8 2.7 2.5

Refrigeration 1.03 1.02 1.02 1.02 2.7 2.6 2.5 2.5

Humidity

11%

1.00 1.03 1.01 1.02 2.5 2.6 2.6 2.5

Humidity 75%

1.06 1.04 1.02 1.02 2.9 2.8 2.6 2.5

Humidity 86%

1.07 1.06 1.03 1.02 3.1 2.9 2.7 2.6

AFTER 60 DAYS

BRIX MOISTURE

LDPE

%

HDPE

%

AF

%

LAP

%

LDPE

%

HDPE

%

AF

%

LAP

%

Room

Temperature

1.10 1.08 1.04 1.05 3.2 3.1 2.9 2.6

Refrigeration 1.08 1.06 1.04 1.04 2.9 2.7 2.6 2.6

Humidity

11%

1.06 1.05 1.04 1.04 2.6 2.7 2.6 2.6

Humidity

75%

1.09 1.08 1.04 1.04 3.1 2.8 2.7 2.6

Humidity 86%

1.12 1.09 1.05 1.04 3.4 2.9 2.7 2.6

AFTER 90 DAYS

BRIX MOISTURE

LDPE

%

HDPE

%

AF

%

LAP

%

LDPE

%

HDPE

%

AF

%

LAP

%

Room

Temperature

1.16 1.13 1.10 1.09 3.4 3.2 2.9 2.7

Refrigeration 1.11 1.09 1.09 1.08 3.1 3.0 2.8 2.8

Humidity

11%

1.10 1.09 1.08 1.08 2.9 2.7 2.7 2.7

Humidity 75%

1.11 1.10 1.09 1.08 3.2 2.9 2.7 2.7

Humidity 86%

1.13 1.11 1.10 1.09 3.5 3.3 2.8 2.7

It becomes necessary to undertake the study of impact of packaging materials for the

prepared palm sugar as the shelf life of the palm candy is very short and also the tapping of

118

palm juice and the preparation of palm candy is just a seasonal process. The problem can be

overcome by developing an economic packaging and working out a suitable environmental

condition so as to make this product available at affordable price throughout the year. In any

industrial production particularly in agro-industries the raw material should be consistent

enough in quality to ensure the uniform quality and standard in the finished product.

Keeping all the very important therapeutic uses of palm candy in mind and its storage

difficulties, introduction of a suitable method of appropriate packaging technology becomes

essential to promote their product quality, to increase the shelf life, to prevent undesirable

physical changes during storage period due to the environment factors and other factors, to

evaluate the impact of packaging and storage methods and to map the variations in the palm

sap quality and also for marketing strategy.

Different packaging materialsviz., 150 guage High Density Polyethylene (HDPE), 80

guage Low Density Polyethylene (LDPE), Aluminium Foil (AF) and Laminated Aluminium

Pouches (LAP) were used to pack the freshly prepared palm candy in order to protect the

prepared products. After packaging, the products were subjected for checking various shelf-

life parameters like storing at room temperature, refrigeration temperature and three different

relative humidity conditions (11%, 75% and 85%) to observe for any physical/chemical

changes during their storage period. Saturated aqueous solution of lithium chloride, sodium

chloride and potassium chloride were taken in three different desiccators so as to achieve the

desired humidity conditions.

The parameters Brix and Moisture contents of palm candy were checked out for every

10 days, 20 days and 30 days to observe for any undesirable property changes in the prepared

palm candy. Brix had been checked out by Refractrometer and the moisture content had been

determined by infra red absorption by moisture meter. In samples which were packed in

119

LDPE and HDPE packages, both brix and moisture content were increased as the days of

storage increased and fluctuations also observed in the determined values. Whereas, in the

samples packed in aluminium foil and laminated aluminium pouches, very slight increase in

brix and moisture content was found.

From the above study, it was suggested that laminated aluminium pouches with

storage conditions at refrigeration condition and with lower RH were better suited for

maintaining palm candy than other packagings and storage conditions. No much differences

were found in the properties of palm candy when they were packed using laminated

Aluminium pouches and kept at refrigeration condition and lower humitidies.

PHASE V

ANTIMICROBIAL STUDY OF DEVELOPED PALM SUGAR

Table - 28 Antimicrobial activity of palm sugar standard and developed palm sugar

against bacterial pathogens

S.No Test Organisms Zone of inhibition in millimeter (in diameter)

Standard

palm sugar

(30 µg/ml)

Developed

Palm sugar

(30 µg/ml)

Solvent

control

Standard

Nalidixic acid

(30 µg/ml)

1. Shigellaflexneri 13mm 14mm 6mm

20

2. Escherichia coli 10mm

- 9mm 16

3. Pseudomonas

Aeruginosa

- - - 16

Solvent used: Ethanol, Standard used: Nalidixic acid 30 µg/ml

The above table showed that all Ethanol extracts of palm sugar were active against the

locally isolated human pathogens like Shigella flexneri, Escherichia coli and Pseudomonas

aeruginosa. The organic extracts provided more powerful antimicrobial activity as compared

to aqueous extracts. This observation clearly indicates that the existence of non-polar residues

120

in the extracts which have higher both bactericidal and bacteristatic abilities. Shigella

flexneri reflects higher amount of zone of inhibition in the range of 14mm in developed

palm sugar with the concentration in (30mg/ml), when compare to other two species.

Jaggery deteriorates faster and becomes watery within 1 or 2 weeks due to its

hygroscopic nature and thus deteriorates its quality through microbial fermentation. The

quality of the stored jiggery mostly depends upon the moisture content which is favorable for

inversion and development of different types of fungi and bacteria in the jiggery resulting in

changes in tastes and colours because of the organic acid and decomposition of complex

decomposition of products (Tiwari et al., 2004).

Table -29 Total Bactorial count from standard and experimental palm sugar

S.No

Standard of Serial

dilution (10-3

,10-4

, 10-

5, 10

-6, 10

-7)

Number of colonies / plate

(experimental sugar)- cfu/gm

Number of colonies / plate

(Standard palm sugar) -

cfu/gm

1. T1 99.00±97.78 101.80±103.26

2. T2 99.00±80.52 104.80±87.71

3. T3 98.60±98.28 123.80±140.58

4. T4 102.20±96.17 109.00±112.23

5. T5 94.40±91.69 104.80±93.55

(T1 – T5 : Dilution 103 to 10

7) TLTC = Too Low To Count

The microorganisms found in the standard and developed palm sugar were counted

through TLTC method. No significant difference was recorded in both the bacterial and

fungal counts. The pour plate method was used to cultivate serially diluted portions of the

sugar samples under investigation. The mean heterotrophic bacterial and fungal counts of the

different sugar samples ranged from 94.40±91.69 to102.20±96.17 cfu/g. This might be due

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to lack of proper storage facilities and sales infrastructure within the markets visited, hence

the standard palm sugar failed to resist contamination. The moisture content of the palm

sugar should always be maintained at minimal levels to reduce the rate of microbial

proliferation.

Inadvertent contamination by microbial or chemical agents during processing could

also caused deterioration, thereby compromising safety and quality, and rendering the plant

material less effective and possibly harmful to the consumer.(WHO, 2003)

The presence of the fungal contaminant shows the possibility of poor storage

conditions. This is a serious contaminant since some common species of fungi produce toxins

like Aflatoxins. According to the WHO , aflatoxins in herbal drugs can be dangerous to

health even if they are absorbed in minute amounts. The limits of microbial contamination

are total aerobic bacteria 105 CFU/g yeast and mould 103 CFU/g. However, none of the

herbal suspensions exceeded the recommended total aerobic counts. The absence of

contaminants may be due to hygienic packing or presence of bacteriostatic substance that

would have killed possible microbial contaminants. Investigation of possible antimicrobial

adulterants in the herbal suspensions is suggested.

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SUMMARY AND CONCLUSION

Palm sugar is a delicious natural sweetener used traditionally by south Indians. Palm

Sugar is rich in Nutraceuticals and functional properties. In the traditional process of

preparing Panamkalkandu (Tamil equivalent for palm sugar) with the presence of impurities

like thread, sand and dust the researcher attempted to remove such deleterious materials in

the preparation of palm sugar, so a necessity has arisen to develop an alternative, new

processing technology to remove the materials. The final outcome the study has been taken

up for not only improving the quality of palm sugar available in the domestic market but also

for facilitating the entry of this product into foreign market as purity and consistency in

quality is assured.

Ramanathapuram district, a coastal area in Tamilnadu, India has been selected for this

study taking into consideration the following facts. The review of literature indicates the

existence Palmyra trees are enormous in this district. The Brix value of Neera is found to be

high in these areas when compared to the available Neera in other parts of the State. This

district is an arid and backward area with thick unemployed population and literacy rate is

low when compared with other districts. The study also reveals the tappers’ (persons

collecting the sap from trees) families do not like to climb the palm trees for tapping Neera

and selling the same at low price. More over it is a seasonal job of the locals. If better Neera

preservation and processing techniques are evinced, sizable proportion of the unemployed

youths can get an assured employment potential in palm industry, by engaging them in palm

sugar production and packaging for export market, which is a challenging outcome to meet

the international market of this region. Cultivation of more palm trees for income generation

activities is the need of the hour. The cultivation of palm trees does not require much water

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resources when compared with other plantations. It is also an important factor in maintaining

the eco-system of this region too.

The population of Palmyrah palm tree is found to be tremendously high in the Eastern

coastal line comprising from Kilakarai to Thiruchendur and most of the inhabitants of this

area do have their mainly focused occupation as palm tapping, which in turn leads to easy

and ready availability of manpower for all processes like sap collection, palm products

processing.

The selected four villages had a total of 1600 palm sap tappers. For the study purpose

one hundred palm sap tappers from the 4 villages at randomly were selected for collection of

information. Care was taken to select palm sap tappers who were continuously involved and

did the production of palm jaggery and palm candy. The information viz socioeconomic

status, method of palm sap collection, economics involved in palm sap and palm jaggery

production was collected using a specially designed interview schedule. The selected four

villages viz Kilakarai, Narippayur, Kannirajapuram and Vembar the sap was collected from

the palm tappers. The collected palm sap was filtered through a fine muslin cloth or a fine

cotton cloth to give a clear sap. The samples were stored immediately in a sterilized bottles

an ice box (0-8 °C) and transported to the laboratory for analysis the physico-chemical and

nutritional properties on the same day. Fermentation might be observed if temperature is

altered above, resulting in the formation of alcohol, undesirable product. Every time during

the process it becomes necessary to confirm the palm sap is not fermented.

The collected palm saps from the four villages were subjected to physiochemical and

nutritional properties. The physio chemical properties viz Moisture, pH, Acidity, Colour,

Brix, viscosity, Boiling point were analysed. The nutrient composition viz proximate

composition, Vitamins, minerals were analysed.

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Four units suggested by the Khadi and Village Industries Commission was contacted

and the method of production was observed and the products was collected for testing the

physical and chemical hazards. The following were observed in the four units for

understanding the conventional method of production 1. Materials used 2. pH monitoring 3.

Clarification materials used 4. Crystallization methods 5.The type of vessels used 6.

Standardazation of production 7.Time duration of production 8. Microbial load of the

product 9.Fermentation process.

Traditionally, palm sap is manually collected from each inflorescence of the Palmyra

palm tree. Palm sugar concentrate was produced by evaporating the palm sap in a large

opened pan (approximately 60-100 liters/pan) and heated using the twigs and palm leaves as

fuel till the required consistency (deep brown colour) was obtained. Inorder to overcome all

these disadvantages modified new process was carried out and new equipment was designed

and fabricated.

This natural clarifier overtakes the property of commercial superphosphate in the

preparation of Neera, as the latter may cause neurological disorders as they are synthetic

based comparing to the former organic. The Sap collected from palmyra trees from four

different locations viz., Kilakarai, Narippayur, Kannirajapuram and Vembar in

Ramanathapuram district, were analysed for their nutritional and functional properties. On

the basis of the analyzed results, the sample of Neera obtained from Narippayur village was

found to be of more quality, nutritious and the best for crystal formation.

Traditionally, palm sap is manually collected from each inflorescence of the Palmyra

palm tree. Palm sugar concentrate is produced by evaporating the palm sap by using wood

fired stove and the process ends up by observing the intensity of brown colour thickness and

viscosity of the on-going product. Overheating process would alter its unique flavour and

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colour and the total soluble solids with sugar in the finished product should be at least 650

Brix or above for food safety purpose.

CONCLUSION

This study is an eye-opener to all food scientists, nutritionists and policy maker throw

open a new vista of knowledge to promote this palm industry is particular-production of palm

sugar is all areas of our nation, which are wide spread is particular in Tamilnadu. Which can

promote this industry with the combination of traditional skills with the emergency

technology to nature this is a commercial way to install the machine developed by the

researcher is all pockets of palm trees regions in Tamilnadu. To produce palm sugar which

is a real natural replacement of synthetic low calories sugar and other white sugar / brown

sugar available is the market for obesity and diabetes mellitus.

The district rural development authority can initiate to have an exclusive cooperative

society to promote Neera collection during the seasonal months by having chilling vans to

collect Neera from the rural population engaged in this activity to promote the production of

palm sugar, in these belts of Ramanathapuram district. The palm sugar, an organic product

having low glycemic index, rich in minerals and other micro nutrients is a boon for health

conscious population. Which the world is looking around for replacement of white sugar

which has brought out serious health concerns and awareness to prevent the usage of white

sugar is India.

This study has brought out are insight to native people to refurbish this traditional

food and to grow more palm trees which are diminishing at a faster rate due to the non

availability of manpower to climb large huge trees. This is also are big challenges to review

the palm industry and the conservation of these trees, a treasure of Indian food industry. We

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need to bring out new strategies to train our rural folk in this palm industry, assure confidence

to review this industry, is a big way. The MSME, Govt of India, shall focus on this issue, to

review our traditional cottage industry near future.

AKNOWLEDGEMENT

All praise goes to the Almighty for his manifold to carry out my research work

successfully. I gratefully acknowledge UGC, New Delhi for their financial support in this

major research project. The investigator records her gratitude and sincere thanks to

Alhaj.B.S. Abdur Rahman, Founder, the Dr. Rahmathnisha Rahman, Correspondent,

for encouraging the research work in the area of palm sugar processing and providing me an

opportunity to work in this esteemed institute.

I would like to express my deep sense of gratitude to my Professor Dr. S. Sumayaa,

Head & Principal, Department of Home science and Research Center for her inspiring

guidance and unstinted help throughout my Research work and for extending all possible

help towards completion of this research.