technology of sweets (mithai) namkeen and snacks food with formulae

TECHNOLOGY OF

SWEETS (MITHAI),NAMKEEN ANDSNACKS FOOD

WITH FORMULAE

TECHNOLOGY OF

SWEETS (MITHAI),NAMKEEN ANDSNACKS FOOD

WITH FORMULAE

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© Copyrights Reserved by Sudhir Gupta, Delhi

ISBN: 9789380772196

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EIRI BOARD OF CONSULTANTS & ENGINEERS

iv vTechnology of Sweets, Namkeen and Snacks Food with Formulae Contents

Preface

Sweets are part of any Indian celebration or festivity of anykind. They are prepared in Indian households not only for specialfeasts and occasions, but also for simple celebrations likebirthdays, anniversaries, graduations or even any other concoctedreason. Every event big or small, calls for the sharing sweetswith the whole neighborhood even simply because he/she is theproud owner of a new car.

There are several categories of Indian sweets like its varieties.They can be classified as: Kheer And Payasams, Laddu OrLadoos, Halwas, Burfis, Kulfis, Sugar Syrup Based Sweets etc.

Snacks, namkins and pappads are popular food items in Indiandiet. Pappad is essentially a thin wafer-like product, circular inshape, rolled from dough made from flour of pulses with salt,chilli and spices added to it. It is easy to digest and nutritiousas well. There are many farsan items popular throughout thecountry and minor changes are made in some ingredients to suitthe local tastes and preferences. Items like masala puffed rice,chevda, fried peas, dal-muth, roasted masala peanuts etc. fallunder the category of farsan. Papad is eaten along with the maincourse as taste enricher, while farsan is a snack. Quality standardsspecified by BIS are available. Certification under PFA Act iscompulsory.

Indians seem to be snacking on ethnic foods with avengeance. This is good news for the corporate sector, given thatthe past few years have seen a perceptible shift towards thebranded sector at the cost of the unbranded segment.

vi viiTechnology of Sweets, Namkeen and Snacks Food with Formulae Contents

Product is the most important part of the marketing mix. Itsignifies what you are going to sell to the consumer. Acomprehensive analysis of the Industry and Our Market Surveyhas given us a platform on which our product can be built. Ourproduct will be built for the masses, and expansion shall begradual, to cater to the entire country’s needs. Namkeen is aproduct, which needs three important things:

1. Taste,

2. Quality and

3. Variation.

In the same order of significance we need to provide all threeto our consumers. Ours is a Company whose Product shall standfor something every Indian craves for. We are entering a marketalready dominated by a number of branded and unbranded players.Customers are extremely loyal to the namkeen they consume.

So we thought about what would make these customers cometo us? Initially housewives in India used to make Namkeen athome, but with changing times this is gradually fading away andpeople have started thinking that it is easier to buy Namkeen thanmake it at home.

The book “Technology of Sweets (Mithai), Namkeen andSnacks Food with Formulae” contains following chapters: Detailsof Raw Materials used for Sweets Manufacture, Making of Milk-based Sweets, Manufacture of Bengali Sweets, ShrikhandManufacture, Chakka Powder, Shrikhand Wadi, KheerManufacture, Dried Kheer Mix Manufacture, PayasamManufacture, Phirni Manufacture, Sevian Manufacture, SohanHalwa, Gajar-ka-Halwa, Kaju Burfi Manufacture, GhevarPreparation, Rasogolla, Kheer and Pal Payasam, Preparation ofLassi, Shrikhand Preparation, Technology of Khoa Manufactureand Storage, Peda, Khoa-based Sweet - Kalakand, Khoa-basedSweet - Gulab Jamun, Milk-based Sweet - Burfi, Chhana-basedSweet - Rasogolla, Preparation of Kulfi, Yoghurt, Production ofSandesh, Manufacture of Shrikhand by Ultrafiltration Process,Preparation of Traditional Sweets, Gulab Jamun/Rasogullas, WinterProducts, Some Selected Recipes of Traditional Foods, DessertPowders & Puddings, Extruded Snacks, Potato-based Textured

Snacks, Snacks and Namkeen Recipies, Snack Food Preservation& Packaging, Details of Plant, Machinery and Equipments forSnacks Food, Namkeen and Sweets, Processed Products fromPotato, Pappad and Bariyan Plant, Potato Chips/Waffers, PotatoChips (Automatic Plant) with Imported Machinery, Rice Puff, RiceFlakes, Corn flakes and Wheat flakes (integrated unit), SnackFood, and Packaging of Snack Foods

Director

Nai Sarak, New Delhi (INDIA)*Website: www.eiriindia.org, www.eiribooksandprojectreports.com

iContents-cum-Index

Chapter 1

Details of Raw Materialsused for SweetsManufacture........... 1-52

Sweeteners: gur (jaggery),khandsari, bura, andchini .................................. 1

Gur (jaggery) ............................ 2

Regulatory Status .................... 2

Technology ............................... 4

Khandsari (Khand) ................... 4


Technology ............................... 5

Bura ......................................... 5


Technology ............................... 6

Chini (Refined Sugar) .............. 6

Technology ............................... 7

Storage ..................................... 7

Packaging ................................ 8

Grains: Chawal (Rice),Maida, Suji, Rava ............. 9

Rice (Chawal) .......................... 9

Quality Characteristics ............. 9

Packaging .............................. 10

Maida and Suji or Rava(Wheat Flours) ................ 10

Maida (Refined WheatFlour) .............................. 11

Characteristics ....................... 11

Microscopic appearance ........ 11

Grades ................................... 11

Packaging .............................. 12

Suji or Rava (Semolina) ........ 12


Microscopic Appearance ....... 13

Grading .................................. 13

Large Particle Grade ............. 13

Small Particle Grade ............. 14

Packaging .............................. 14

Storage................................... 14

Dry Fruits And Other Nuts:Badam, Kaju, Copra,Pista, Khaskhas,Akhrot, Kishmish ............ 14

Almonds (Badam) .................. 14

Description ............................. 15

Quality Characteristics ........... 15

Shelf Life ................................ 16

Nutritive Value ........................ 17

Applications ........................... 17

Contents

ii iiiTechnology of Sweets, Namkeen and Snacks Food with Formulae Contents-cum-Index

Almond Oil ............................. 19

Kaju (Cashew) ....................... 19


Preservation ........................... 22

Packaging and Storage ......... 22

Copra (Dried Coconut Kernel)23

Description ............................. 23


Microbiological Quality ........... 24

Grades ................................... 24


Pistachio (Pista) ..................... 25

Processing ............................. 25

Regulatory status ................... 26

Shelf Life ................................ 26

Nutritive Value ........................ 27

Application ............................. 27

Khaskhas (Poppy Seeds) ...... 27

Application ............................. 28

Akhrot (Walnuts) .................... 28

Quality characteristics ........... 29

Inshell Walnuts ...................... 29

Shelled Walnuts ..................... 29

Applications ........................... 29

Kishmish (Raisins) ................. 29

Processing ............................. 32

Sulphur Fumigation ............... 32

Drying and Postdryingprocesses ....................... 32


Flavourings And Colourings:Chhoti Elaichi(Cardamom), GulabJal (Rose Essence),

Kesar (Saffron), Cocoa .......... 33

Chhoti Elaichi (Cardamom) ... 33


Grading .................................. 35

Packaging .............................. 35

Gulab Jal (Rose Essence) .... 35

Chemical Composition ........... 38

Imitation Rose Flavours ......... 38

Application ............................. 38

Kesar (Saffron) ...................... 39

Packaging .............................. 39

Grading .................................. 40

Flavour ................................... 40

Freedom from moulds,insects etc. ...................... 40

Saffron in Filament ................ 40

Saffron in Cut Filaments ........ 41

Yellow Filaments .................... 41

Floral Waste .......................... 41

Extraneous Matter ................. 41

Saffron Powder ...................... 41

Chemical Requirements ........ 41

Cocoa (Cocoa, CocoaPowder & Coatings) ....... 41

Cocoa Coatings ..................... 44



Miscellaneous ........................ 45

Makhana (Gorgon Fruit) ........ 45

Harvesting and Processing ... 46

Roasting and Popping ........... 47

Polishing, Grading andPackaging ....................... 47

Uses ....................................... 47

Sabudana (Sago) .................. 47


Gelatinization ......................... 48

Applications ........................... 49

Packaging .............................. 49

Water ..................................... 49

Chapter 2

Making of Milk-based Sweets .... 53-127

Khoa/Mawa ............................ 54

Product Description ............... 55

Technology ............................. 58

Process Mechanization ......... 59

Innovations............................. 60

Continuous KhoaMachine .......................... 61

Packaging of Khoa ................ 66

Packaging Study .................... 66

Recommended Packaging .... 67

Physico-chemical Aspects ..... 67

Water Activity of Khoa ........... 71

Rheology of Khoa .................. 71

Microbiological Quality ........... 71

Preservation of Khoa ............. 72

Nutritive Value of Khoa .......... 73

Khoa Powder ......................... 73

Reverse Osmosis (RO) ......... 75

Tray Drying at AtmosphericPressure ......................... 75

Spray Drying Process ............ 75

Fluidized Bed Drying ............. 75

Roller Drying Process ............ 75

Gulabjamun ............................ 78

Product Description ............... 78

Technology ............................. 78

Composition ........................... 79

Rheological Properties .......... 79

Potential ProcessModifications ................... 80

Shelf Life ................................ 82

Dry Gulabjamun Mix .............. 82

Skim Milk Powder-basedGulabjamun Mix .............. 82

Whole Milk Powder-basedGulabjamun Mix .............. 83

Kalajamun .............................. 83

Technology ............................. 84

Pantua .................................... 84

Product description ................ 84

Technology ............................. 84

Physico-chemical aspects ..... 85

Lalmohan ............................... 86

Technology ............................. 86

Burfi ........................................ 86

Technology ............................. 86

Industrial manufacture ........... 87

Quality factors ........................ 88

Fat content ............................. 89

Stage of sugar addition ......... 89

Effect of additives .................. 89

Corn syrup addition ............... 90

Desiccation temperature ........ 90

Physico-chemicalcharacteristics ................. 90

Flavour ................................... 90

Colour .................................... 90

Body ....................................... 90

Texture ................................... 91

Equilibrium relativehumidity (ERH) of burfi ... 91

Free fatty acids ...................... 91

Hydroxy methyl furfural(HMF) content ................. 92

Microbiological quality ........... 92

Shelf-life ................................. 93

iv vTechnology of Sweets, Namkeen and Snacks Food with Formulae Contents-cum-Index

Rancidity ................................ 93

Acid development .................. 93

Browning ................................ 94

Packaging .............................. 94

Kalakand ................................ 95

Product description ................ 95

Size of industry ...................... 96

Technology ............................. 96

Sensory quality ...................... 97

Fat ........................................ 97

Sugar ..................................... 97

Strength and type ofcoagulant ........................ 98

Microbiological quality ........... 98

Biochemical quality ................ 98

Sensory quality ...................... 99

Packaging and storage.......... 99

Milk cake .............................. 100

Technology ........................... 100

Peda ..................................... 101

Product description .............. 102

Technology ........................... 102

Current status ...................... 103

Quality factors ...................... 104

Packaging ............................ 105

Shelf-life ............................... 105

Dharwad peda ..................... 106

Size of industry .................... 106

Technology ........................... 106

Thirattupal ............................ 106

Technology ........................... 107

Prospects of mechanization 107

Rabri .................................... 108


Technology ........................... 108

Physico-chemicalaspects ......................... 108

Current status ...................... 110

Khurchan .............................. 110


Technology ........................... 111

Basundi ................................ 112


Size of industry .................... 113

Technology ........................... 113


Innovations ........................... 114

Kulfi and frozen desserts ..... 115


Technology ........................... 116

Innovations ........................... 118

Formulation of kulfi .............. 118

Sweet fresh cream andfresh milk ...................... 119

Frozen cream....................... 120

Fluid whole and skimmilk ............................... 120

Plain condensed skimmilk ............................... 120

Plain condensed wholemilk ............................... 121

Super-heated condensedskim or whole milk ........ 121

Sweetened condensedwhole or skim milk ........ 121

Packaging ............................ 121


Shelf-life ............................... 122

Malai-ka-baraf ...................... 122

Falooda ................................ 122


Technology ........................... 123

Innovations........................... 124

Kunda ................................... 124


Technology ........................... 125


Shelf-life ............................... 126

Bal mithai ............................. 126


Technology ........................... 127

Chapter 3

Manufacture ofBengaliSweets .............. 128-144

Rasogolla ............................. 128


Size of industry .................... 129

Technology ........................... 130

Sugar syrup ......................... 131

Mechanized production ....... 132

Use of milk powder .............. 132

Dried rasogolla mix .............. 133

Yield ..................................... 133

Packaging ............................ 133

Rasomalai ............................ 133


Technology ........................... 134

Rajbhog................................ 134

Technology ........................... 134

Khirmohan............................ 135

Sandesh ............................... 135


Technology ........................... 136

Physico-chemical aspects ... 137

Chhana-murki ...................... 138


Technology ........................... 139

Prospects formechanization .............. 139

Cham-cham ......................... 139

Technology ........................... 139

Prospects formechanization .............. 140

Chhana podo ....................... 140

Surti paneer ......................... 140

Technology ........................... 141

Bandel cheese ..................... 142


Technology ........................... 142

Regional products ................ 142

Ksheer sagar ....................... 142

Sita bhog .............................. 142

Chhana gaja ........................ 143

Chhana jhele ....................... 143

Chhana kheer ...................... 143

Chhana pakora .................... 143

Rasaballi .............................. 143

Shosim ................................. 144

Kalari .................................... 144

Chapter 4

ShrikhandManufacture ..... 145-150


Technology ........................... 146

Traditional method ............... 146

Innovations ........................... 147

vi viiTechnology of Sweets, Namkeen and Snacks Food with Formulae Contents-cum-Index

Preparation of curd .............. 147

Preparation of chakka ......... 147

Preparation of shrikhandfrom chakka .................. 148

Starter cultures ..................... 148

Separation of wheyfrom curd ...................... 149

Mixing of chakka withcream and sugar .......... 149

Packaging of shrikhand ....... 149

Shelf-life ............................... 149


Chapter 5

Chakka Powder ...... 151-152

Chapter 6

Shrikhand Wadi ..... 153-156

Approximate composition .... 153

Lassi ..................................... 153

Manufacturing process ........ 154

Innovations........................... 156


Chapter 7

KheerManufacture..... 157-166

Rice kheer ............................ 157


Mango coconut rice kheer ... 158

Size of industry .................... 159

Technology ........................... 159

Process upgradation ............ 160

Selection of rice ................... 161

Cooking characteristicsof rice ............................ 161

Long-life kheer ..................... 162

Physico-chemicalcharacteristics ............... 164

Shelf-life ............................... 165

Chapter 8

Dried Kheer MixManufacture ..... 167-172

Nutritional propertiesof kheer ........................ 168

Advantages .......................... 168

Process ................................ 168

Manufacturing method ......... 169


Shelf-life ............................... 171

Plant parameters ................. 172

Manpower ............................ 172

Raw material ........................ 172

Utilities ................................. 172

Plant & machinery ............. 172

Chapter 9

PayasamManufacture ..... 173-183


Classification ........................ 174

Pulse-based payasams ....... 174

Cereal-based payasams ...... 176

Vermicelli payasams ............ 176

Rice suji-based payasam .... 177

Wheat suji-basedpayasam ....................... 177

Avalakki (beaten rice-based) payasam ........... 177

Ada-based payasam ............ 177

Tuber crop-basedpayasams ..................... 178

Fruit-based payasams ......... 179

Seed-based payasams ........ 179


Chapter 10

PhirniManufacture..... 184-185

Ingredients ........................... 184

Technology ........................... 184

Chapter 11

SevianManufacture..... 186-187


Technology ........................... 186

Chapter 12

Sohan Halwa .......... 188-189


Technology ........................... 188

Chapter 13

Gajar-ka-Halwa ...... 190-192


Technology ........................... 191

Innovations........................... 191

Quality factors ...................... 192

Packaging ............................ 192

Chapter 14

Kaju BurfiManufacture ..... 193-196


Technology ........................... 193

Chapter 15

GhevarPreparation ...... 197-200


Technology ........................... 198

Lauki halwa .......................... 198

Padusha (makkhan bada) ... 198

South indian sweet .............. 199

Technology ........................... 199

Mohandas ............................ 200

Chapter 16

Rasogolla, Kheerand PalPayasam .......... 201-204

Chapter 17

Preparation ofLassi ................. 205-207

Introduction .......................... 205

Composition ......................... 205

Method of preparation ......... 206

Materials required ................ 206

Preparation of sugarsyrup ............................. 206

Preparation of lassi .............. 206

Microflora of lassi ................. 207

viii ixTechnology of Sweets, Namkeen and Snacks Food with Formulae Contents-cum-Index

Chapter 18

ShrikhandPreparation .......208-211

Introduction .......................... 208

Material required .................. 208


Traditional method ............... 210

Industrial method ................. 210

Chapter 19

Technology of KhoaManufacture andStorage............. 212-218

Introduction .......................... 212

Definition .............................. 213

Varieties and grades

of khoa ................................. 213

Chemical compositionof khoa .......................... 213

Microbiological qualityof khoa .......................... 213

Methods ofmanufacture .................. 214

Small scale preparationof khoa .......................... 215

Equipment ............................ 215

Quality of milk ...................... 215

Traditional process .............. 216

Improved batch method forkhoa preparation ........... 216

Packaging and storageof khoa .......................... 217

Chapter 20

Peda........................ 219-220

Introduction .......................... 219

Composition ......................... 219

Method of manufactureof peda .......................... 219

Chapter 21

Khoa-based Sweet -Kalakand .......... 221-222

Introduction .......................... 221

Chemical composition ......... 221

Method of manufacture ofkalakand ....................... 221

Chapter 22

Khoa-based Sweet -Gulab Jamun ... 223-224

Introduction .......................... 223

Composition of gulabjamun ............................ 223


Chapter 23

Milk-based Sweet -Burfi ................. 225-227

Introduction .......................... 225

Composition of burfi ............ 225

Method of preparation ofburfi ............................... 225

Microbiologicalstandards ...................... 227

Chapter 24

Chhana-based Sweet -Rasogolla ......... 228-230

Introduction .......................... 228

Composition ofrasogolla ....................... 228

Method of rasogolla

preparation .................... 228

Microbiological standards .... 230

Chapter 25

Preparation ofKulfi .................. 231-232

Introduction .......................... 231

Materials required ................ 231

Procedure ............................ 232

Chapter 26

Yoghurt ................... 233-238

Definition .............................. 233

History .................................. 233

Types of yoghurt .................. 233

Method of manufacture........ 235

Traditional method ofyoghurt making ............. 236

Industrial method ofyoghurt making ............. 236

Therapeutic value ofyoghurt .......................... 236

Examination of yoghurt ........ 237

Defects of yoghurt ............... 237

Chapter 27

Production ofSandesh ........... 239-247

Introduction .......................... 239

Traditional method ofsandesh preparation ..... 240

Production of sandesh. ........ 241

Mechanisation of sandeshpreparation .................... 241

Optimisation of processingparameters formechanisedproduction ..................... 243

Vented extruder for thecontinuous cookingof chhana sugarmixture .......................... 244

Testing of ventedextruder ......................... 245

Evaluation of sandesh ......... 247

Chapter 28

Manufacture ofShrikhand byUltrafiltrationProcess ............ 248-256

Introduction .......................... 248

Materials and methods ........ 249

Ultrafiltration (UF) unit ......... 249

Basket centrifuge ................. 249

Shrikhand making ................ 250

Sensory evaluation .............. 250

results and discussion ........ 251

Chapter 29

Preparation ofTraditionalSweets.............. 257-259

Karah (halwa) ...................... 257

Instant mix for halwa ........... 257

Shelf stable halwa ............... 258

Choorma/panjiri .................... 259

Pinnis ................................... 259

x xiTechnology of Sweets, Namkeen and Snacks Food with Formulae Contents-cum-Index

Chapter 30

Gulab Jamun/Rasogullas ....... 260-262

Gulab jamun/rasogullas ....... 260

Chaamp, kaleji, keema ........ 260

Rice products ....................... 261

Marunda ............................... 261

Phirni .................................... 261

Kheer ................................... 261

Gur wale chawal .................. 261

Bhelpuri ................................ 261

Chirva ................................... 261

Mrumura/kheel ..................... 261

Pulav .................................... 262

Khichri .................................. 262

Phulwarian ........................... 262

Chapter 31

Winter Products ..... 263-265

Marunda ............................... 263

Gacchak ............................... 263

Reorian ................................ 263

Summer drinks..................... 264

Sattu (bary water) ................ 264

Ganne ka ras (cane juice) ... 264

Kanki .................................... 264

Chapter 32

Some SelectedRecipes ofTraditionalFoods ............... 266-278

Mathi .................................... 266

Ingredients ........................... 266

Method ................................. 266

Matri ..................................... 266

Ingredients ........................... 266

Method ................................. 267

Sevian .................................. 267

Ingredients ........................... 267

Method ................................. 267

Suji halwa ............................ 267

Ingredients ........................... 267

Method ................................. 267

Pinnis ................................... 268

Ingredients ........................... 268

Method ................................. 268

Mall pura .............................. 268

Ingredient ............................. 268

Method ................................. 268

Gulab jamun ........................ 269

Ingredients ........................... 269

Method ................................. 269

Poories ................................. 269

Ingredients ........................... 269

Method ................................. 269

Jalebi .................................... 270

Ingredients ........................... 270

Method ................................. 270

Samosa ................................ 270

Ingredients ........................... 270

Method ................................. 271

Dalia (broken wheatporridge) ....................... 271

Ingredients ........................... 271

Method ................................. 271

Phulvarian ............................ 271

Ingredients ........................... 271

Method ................................. 271

Rice khichri .......................... 272

Ingredients ........................... 272

Method ................................. 272

Sweet rice ............................ 272

Ingredients ........................... 272

Method ................................. 272

Sugarcane juice kheer ......... 273

Ingredients ........................... 273

Method ................................. 273

Phirni .................................... 273

Ingredients ........................... 273

Method ................................. 273

Puffed rice laddoo................ 273

Ingredients ........................... 273

Marunda ............................... 274

Ingredients ........................... 274

Method ................................. 274

Black gram (urad) papads ... 274

Ingredients ........................... 274

Method ................................. 274

Vadian .................................. 275

Ingredients ........................... 275

Method ................................. 275

Besan poora ........................ 275

Ingredients ........................... 275

Method ................................. 275

Besan laddoos ..................... 276

Ingredients ........................... 276

Method ................................. 276

Pakoras ................................ 276

Ingredients ........................... 276

Method ................................. 276

Bhuga ................................... 277

Ingredients ........................... 277

Method ................................. 277

Sesame gachak ................... 277

Ingredients ........................... 277

Method ................................. 277

Chikki ................................... 278

Ingredients ........................... 278

Method ................................. 278

Gulgulas ............................... 278

Ingredients ........................... 278

Method ................................. 278

Chapter 33

Dessert Powders &Puddings.......... 279-284

Gelatin dessert powders ...... 279

Gelatin dessert powder ....... 280

Flavours for gelatindesserts ........................ 280

Strawberry ............................ 280

Cherry .................................. 280

Pineapple ............................. 280

Lemon .................................. 281

Orange ................................. 281

Lime ..................................... 281

Pudding powders ................. 281

Chocolate flavour:formula no. 1 ................ 281

Vanillin flavour ...................... 282

Formula no. 1 ...................... 282

Formula no. 2 ...................... 282

Formula no. 3 ...................... 282

Cocoanut flavour pudding ... 282

Maple-flavor powderedpudding ......................... 282

Custard pudding .................. 283

Custard cream (frenchstyle) ............................. 283

Custard filling for pies .......... 283

xii xiiiTechnology of Sweets, Namkeen and Snacks Food with Formulae Contents-cum-Index

Custard pie—rich and non-watering ........................ 284

Dry vanilla creampowders ........................ 284

Chapter 34

Extruded Snacks .... 285-316

Terminology .......................... 286

Extrusion process ................ 288

Preconditioningconfiguration ................. 288

Extruder configuration.......... 289

Die configuration .................. 293

Expanded snacks ................ 293

Fried collettes ...................... 294


Process description ............. 295

Formulation .......................... 296

Baked collettes or shapes ... 296



Formulations ........................ 298

Third generation snacks ...... 302

Quality controlconsiderations .............. 302



Formulations ........................ 306

Pre-cooked masa

snacks .................................. 307



pre-cooked masa snacks .... 308

Coextruded snacks .............. 309



Die design ............................ 310

Flatbread and crackersnacks ........................... 311



Formulation .......................... 313

Further possibilities .............. 314

High moisture doughsnacks ........................... 314



Formulation .......................... 315

Concluding comments ......... 316

Chapter 35

Potato-based TexturedSnacks ............. 317-336

Raw materials ...................... 318

Potato granules .................... 320

Potato flakes ........................ 321

Potato starch ........................ 323

Potato flour .......................... 323

Methods of manufacture ...... 324

Forming and frying of wet dough .................... 324

High shear dry extrusion ..... 328

Low shear pelletextrusion ....................... 329

Potato chip manufacture ..... 334

Similar products using abasis other thanpotatoes ........................ 335

Flaked cereals ..................... 335

Puffed cereals ...................... 335

Chapter 36

Snacks and NamkeenRecipes ............ 337-349

Aloo bhujia ........................... 337

Ingredients ........................... 337

Method ................................. 337

Other recipe ......................... 338

Ingredients ........................... 338

Preparation .......................... 338

Masala khakra:a tastyIndian snack ................. 339

Ingrediants for masalakhakra ........................... 339

Directions to make masalakhakra: .......................... 339

Khakra gujarathi dish........... 340

Ingredients required forthis gujarathi dish: ........ 340

Method to make khakra –gujarathi dish ................ 340

Recipe of ganthia ................ 341

Ganthia (chickpea snack) .... 341

Ingredients ........................... 341

Method ................................. 341

Ingredients ........................... 341

Method ................................. 342

Dhokla .................................. 342

Ingredients ........................... 342

Preparation .......................... 343

Condiments .......................... 343

Dhokla recipe fromGujarat .......................... 344

Ingredients (serves 4): ......... 344

Seasoning ............................ 345

Method ................................. 345

Sandwich dhokla.................. 346

Ingredients ........................... 346

For yellow dhokla ................. 346

For white dhoklas ................ 346

For green chutney ............... 346

Method ................................. 346

Bhel puri ............................... 347

Ingredients ........................... 347

Ingredients for tamarindchutney ......................... 348

Ingredients for mintchutney ......................... 348

Method ................................. 348

Method for bhel puri ............ 348

Bhel puri recipe ................... 349

Bhel puri recipe ................... 349

Ingredients ........................... 349

Method ................................. 349

Chapter 37

Snack FoodPreservation &Packaging ........ 350-365

Conventional snacks ........... 351

Packaging materials formaintaining productintegrity ......................... 351

Factors responsible forloss of quality in snackfoods ............................. 352

Barrier properties ofplastic films ................... 354

Metallized films .................... 359

Cosmetic improvements ...... 359

Cost savings ........................ 360

Bags ..................................... 360

Machinery ............................ 361

Form-fill-seal (ffs)machines ...................... 361

xiv xvTechnology of Sweets, Namkeen and Snacks Food with Formulae Contents-cum-Index

Bagging and cartoningmachinery ..................... 362

Computer application insnacks ........................... 363

Chapter 38

Details of Plant,Machinery andEquipments forSnacks Food .... 366-382

Comminution and particlesize control ................... 367

Comminution of low-moisture snack-foods or snack foodingredients .................... 368

Impact milling or hammermilling ............................ 370

Comminution to producesuspensions andemulsions...................... 370

Lamination ........................... 371

Sizing and shaping .............. 372

Coating ................................. 373

Enrobing ............................... 374

Liquid spray coating ............ 374

Dusting ................................. 374

Immersion ............................ 375

Panning ................................ 375

Decorating of snacks ........... 375

Dewatering and removalof liquid fat .................... 376

Heat transfer ........................ 376

Mechanical andengineering facts oforganoleptic qualitycontrol of snacks .......... 377

Ambience ............................. 377

Mechanical and weightand/or volume controlof snack ........................ 378

Moisture control ................... 379

Hygiene control .................... 380

Composition control ............. 381

Contaminant and foreignbody control .................. 381

Specific gravity ..................... 382

Magnels ............................... 382

X-ray examination ................ 382

Chapter 39

Namkeen andSweets.............. 383-398

Manufacturing processof namkeen ................... 384

Dalmoth ................................ 384

Chanachur ........................... 385

Bhujia ................................... 385

Dal moth .............................. 386

Chanachur ........................... 386

Bhujia ................................... 386

Flavour and essences ......... 387

Lemon flavour essence ....... 387

Orange flavour oil ................ 387

Universal flavouressence ........................ 387

Wheat flour grades .............. 387

Straight flour ......................... 387

Patent flour .......................... 387

Cut straight flour .................. 388

Clear flour ............................ 388

Plant economics .................. 388

Land and building ................ 388

Plant and machinery ............ 388

Fixed capital ......................... 388

Raw materials ...................... 389

Total working capital/month . 389

Total capital investment ....... 389

Turn over/annum.................. 389

Preparations of sweets ........ 390

Moong dal ladoos ................ 390

Process ................................ 390

Besan ladoos ....................... 390

Process ................................ 390

Mysore pak .......................... 391

Process ................................ 391

Moong dal halwa ................. 391

Process ................................ 391

Rash bara (badar dippedin jaggery syrup) ........... 392

Process ................................ 392

Boondi ladoo ........................ 392

Process ................................ 392

Manufacture of petha........... 392

Sone papadi ......................... 393

Process of manufacturing .... 393

Raw material ........................ 394


Formulation II for 1 kgElaichi Laddu ................ 395

Formulation - III for 1 kgCashewnut Laddu ......... 395

Formulation IV -PistachioLaddu ............................ 395

Formulation - V (BaisinLaddu 1 kg) .................. 395

Formulation - VI ................... 396

Plant economics .................. 397



Fixed capital ......................... 397

Raw materials ...................... 398

Total working capital/month ............................ 398


Turn over/annum.................. 398

Chapter 40

Processed Productsfrom Potato ...... 399-407

Classification of processedproducts ........................ 400

Fried products ...................... 401

Potato chips ......................... 401

French fries .......................... 401

Dehydrated products ........... 401

Dehydrated potato chips,dices and waris ............. 402

Potato flakes and granules .. 402

Potato starch ........................ 403

Potato flour .......................... 404

Potato custard powder ......... 405

Soup or gravy thickener ...... 405

Potato biscuits ..................... 406

Canned potatoes ................. 407

Chapter 41

Pappad and BariyanPlant ................. 408-413

Manufacturing processof bariyan ...................... 409

Packaging of pappad ........... 410

Automatic pappad plantand machinery .............. 410

Plant economics .................. 412


xvi xviiTechnology of Sweets, Namkeen and Snacks Food with Formulae Contents-cum-Index


Fixed capital ......................... 412

Raw materials .................... 41x2



Turn over/annum.................. 413

Chapter 42

Potato Chips/Waffers ............. 414-420

Process of manufacture ...... 416

Details of machinery ............ 417

Operation ............................. 417

Potao wafer mchine ............. 417

Plant economics .................. 419



Fixed capital ......................... 419

Raw materials ...................... 419



Turn over/annum.................. 420

Chapter 43

Potato Chips(AutomaticPlant) withImportedMachinery ........ 421-430

Packaging requirementsfor fried potatochips ............................. 421

Physico-chemicalchanges duringstorage .......................... 422

Transparent and opaquepackage ........................ 422

Packaging materials ............ 423

Packaging and storagestudies .......................... 424


Sorting, cleaning andwashing ......................... 425

Slicing and washing ............. 425

Drying of slices .................... 425

Treating with chemicals ....... 426

Chip frying ............................ 426

Batch frying method ............ 426

Method of batchprocessing .................... 426

Packaging ............................ 426

Working of importedcontinuous potatoproducing unit ............... 427

Imported plant andmachinery ..................... 428

Description machineries ...... 428

Optional equipmentavailable ........................ 429

Processing section .............. 429

Investment ........................... 430

Potato chips(imported plant) ............ 430

Chapter 44

Rice Puff ................. 431-434

Raw materials ...................... 431


Puffed rice ............................ 431

General considerations ........ 431

Details of process ................ 432

Oven puffed process ........... 432

Plant economics .................. 433



Fixed capital ......................... 433

Raw materials ...................... 433



Turn over/annum.................. 434

Chapter 45

Rice Flakes, Cornflakes andWheat flakes(integratedunit) .................. 435-444

Raw materials ...................... 435

Corn ..................................... 435

Nutritive value ...................... 435

Composition of grains .......... 436


Manufacturing process of wheatflakes ............................ 440

Plant economics .................. 442



Fixed capital ......................... 443

Raw materials ...................... 443



Turn over/annum.................. 444

Chapter 46

Snack Food ............ 445-451


Humidification ...................... 445

Puffing .................................. 446

Cutting .................................. 446

Roasting ............................... 446

Seasoning (by rotaryseasoning machine) ..... 446

Finishing and drying ............ 447

Packaging ............................ 447

Protein snack ....................... 447

Process ................................ 447

Protein crackers ................... 448

Process ................................ 448

Process details .................... 448

Details of snacks food plant 449

Plant economics .................. 450


Fixed capital ......................... 450



Turn over/annum.................. 451

Chapter 47

Packaging ofSnack Foods .... 452-460

Íntroduction .......................... 452

The product group ............... 452

Packaging materialsfor snack foods ............. 454

Packaging system ............... 459

Gas flushing ......................... 460

Compensated vacuum......... 460

technology of sweets (mithai) namkeen and snacks food with formulae

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