Process optimization and product stabilization of peanuts

(Arachis hypogaea L.), chickpea (Cicer arietinum L.) by modified

atmospheric packaging using nitrogen (E941)

Full Semester Project- (17FSP2999)

Submitted by

TAMIL SELVAN A (URK17FP094)

In partial fulfillment for the award of the degree

Of

BACHELOR OF TECHNOLOGY

In

FOOD PROCESSING AND ENGINEERING

Under the supervision of

Dr T.V. RANGANATHAN

DEPARTMENT OF FOOD PROCESSING TECHNOLOGY

KARUNYA INSTITUTE OF TECHNOLOGY AND SCIENCES

(Deemed-to-be - University)
Karunya Nagar, Coimbatore – 641 114. INDIA

APRIL 2021
i
 BONAFIDE CERTIFICATE

This is to certify that the project report entitled “Process optimization and

product stabilization of peanuts (Arachis hypogaea), chickpea (Cicer arietinum

L.) by modified atmospheric packaging using nitrogen (E941)” is the bonafide

work of “TAMIL SELVAN A(URK17FP094)” who carried out the project work

under my supervision.

SIGNATURE SIGNATURE
DR. T.V. RANGANATHAN DR. K. THANGAVEL
Professor Head of the Department
Department of Food Processing Department of Food Processing
and Engineering and Engineering

Submitted for the full semester Viva Voce held on …………………..

Internal Examiner External Examiner

ii
iii
 ABSTRACT

Modified atmospheric packaging can increase the shelf life of the product. In MAP,

different gases are used for packaging. Nitrogen (E941) gas was widely used in MAP to

replace the oxygen inside the package. Nitrogen (E941) was inert, odorless, colorless, and

does not react with food products packed. The raw materials were soaked for 4 hours and

blanched with 1% salt for 15 minutes. Peanuts (Arachis hypogaea L.) and chickpea (Cicer

arietinum L.) packed with a different vacuum – nitrogen concentration 100 - 200, 100 -

300, 150 – 350, 150 – 450, 100 - 400, 200 - 500, 300 - 500, and 350 -450. The packed

products were kept for storage for one month. Quality parameters like physiological loss

in weight, pH analysis, and microbial analysis were made for packed products. Sensory

analysis is made to determine the organoleptic characters of the product. The optimized

concentration for peanut is 100 – 300. For Kabuli chickpea and desi chickpea, 100 – 200

and 150 – 350 were identified. At this concentration, products were stabilized and had

good sensory attributes.

Keywords: Nitrogen (E941), optimization, organoleptic, concentration.

iv
 DECLARATION

I, Mr TAMIL SELVAN A hereby declare that the thesis entitled “Process optimization
and product stabilization of peanuts (Arachis hypogaea L.), chickpea (Cicer
arietinum L.) by modified atmospheric packaging using nitrogen (E941)” submitted
to Karunya Institute of Technology and Sciences, Coimbatore for the award degree in
B. Tech Food Processing and Engineering is an authentic record of work carried out by
me under the supervision and guidance of Dr T.V. Ranganathan, Department of Food
Processing and Engineering from December to April 2021.

I further declare that the result of this work has not been previously submitted in any
manner.

DATE:

PLACE: COIMBATORE

TAMIL SELVAN A
URK17FP094

v
 ACKNOWLEDGEMENT

First and foremost, I praise and thank ALMIGHTY GOD for being with me throughout
the project.

I am grateful to our beloved founders Late Dr D.G.S. Dhinakaran, C.A.I.I.B., PhD and
Dr Paul Dhinakaran, M.B.A, PhD, for their constant prayers and blessings.

I extend my thanks to Vice-Chancellor Dr P. Mannar Jawahar and Registrar Dr R.

Elijah Blessing for giving me this opportunity to do this project.

I express my sincere thanks to our respected head of the department, Dr K. Thangavel,

to motivate us to carry out the project successfully.

I express my gratitude to my internal guide. Dr T.V. Ranganathan, Professor,

Department of Food Processing and Engineering, for permitting me on this project and
his advice, words of encouragement, and guiding me throughout the project with patience
and understanding.

I express my gratitude to my external guide, Mr M. Kathiravan, Factory Manager,

Ycook India Private Limited, for his advice and for guiding me throughout the whole
project with patience and understanding.

Furthermore, I would like to thank all the other department staff members for their
patience and openness.

Finally, I thank my parents and all my friends who helped me complete my project.

TAMIL SELVAN A
URK17FP094

vi
 TABLE OF CONTENT

S.NO TITLE PAGE NO

I BONAFIDE CERTIFICATE ⅱ
II ABSTRACT ⅳ
III ACKOWLEDGEMENT ⅵ
IV TABLE OF CONTENT ⅶ-ⅸ
V LIST OF TABLES ⅹ
VI LIST OF FIGURES ⅺ
VII LIST OF ABBREVIATIONS ⅻ
1 INTRODUCTION 1-8
1.1 Modified Atmospheric Packaging 1
1.2 Gases used in MAP 1
1.2.1 Oxygen 2
1.2.2 Carbon dioxide 2
1.2.3 Nitrogen 2
1.2.4 Argon 3
1.2.5 Carbon monoxide 3
1.3 Packaging films used in MAP 4
1.3.1 Polyolefin 4
1.3.2 Vinyl polymers 5
1.3.3 Styrene polymers 6
1.3.4 Polyamide 6
1.4 Nitrogen (E941) 7
1.5 Market Overview 7
2 LITERATURE SURVEY 9 - 25
2.1 Nitrogen MAP 9
2.1.1 Advantage of Nitrogen MAP 9
2.1.2 Disadvantage of Nitrogen MAP 9

vii
 2.1.3 Food application Nitrogen MAP is used 10
2.2 Peanuts (Arachis hypogaea L.) 12
2.2.1 Factors affecting the shelf life of peanuts 13
2.2.2 Nitrogen MAP of peanuts 13
2.3 Chickpeas (Cicer arietinum L.) 13
2.3.1 Nitrogen MAP of chickpea 14
2.4 Machinery used of Nitrogen MAP 15
2.4.1 Chamber machines 16
2.4.2 Snorkel machines 16
2.4.3 Form-fill-seal machine 17
2.5 Sterilization 18
2.5.1 Methods of sterilization 18
2.5.2 Thermal death Time (TDT) 19
2.5.3 D – Value 19
2.5.4 Z – Value 19
2.5.5 F – Value 20
2.5.6 12 – Concept 20
2.6 Retorting Processing 21
2.7 Sensory Analysis 23
2.8 Aim and objective of work 25
2.9 Importance of work 25
3 MATERIALS AND METHODS 26-35
3.1 Materials 26
3.1.1 Peanut (Arachis hypogaea L.) 26
3.1.2 Chickpea (Cicer arietinum L.) 26
3.1.3 Sampling of raw materials 27
3.1.4 Nitrogen (E941) 27
3.1.5 Top and Bottom film 28
3.1.5.1 Specification of to film 28

viii
 3.1.5.2 Specification of bottom film 28
3.1.6 Thermoforming packaging machine 29
3.1.7 Retort processing machine 29
3.2 Methodology 30
3.2.1 Procedure for raw material processing 30
3.2.2 Procedure to Nitrogen MAP 31
3.2.3 Vacuum – nitrogen gas concentration 32
3.2.4 Analysis of the sample 33
3.2.4.1 Physiological loss in weight (PLW) 33
3.2.4.2 pH Analysis 33
3.2.5 Microbial test 34
3.2.5.1 Determination of Total Plate Count 34
3.2.5.2 Determination of coliform test 34
3.2.6 Sensory Analysis 35
4 RESULT AND DISCUSSION 37 - 44
4.1 Physiological loss in weight (PWL) of final product 37
4.2 pH analysis of the final product 38
4.3 Determination of Total plate count and coliform 39
4.4 Study of different concentration of nitrogen (E941) 40
4.4.1 Peanuts (Arachis hypogaea L.) 40
4.4.2 Kabuli chickpea (Cicer arietinum L.) 41
4.4.3 Desi chickpea (Cicer arietinum L.) 42
4.5 Sensory Analysis 43
5 SUMMARY AND CONCLUSION 45
6 REFERENCE 46 - 49

ix
 LIST OF TABLES

S.NO TITLE PAGE NO

Table: 1 Chemical and Physical Properties of gases used for MAP 3
Table: 2 Thermodynamic properties of gases used for MAP 4
Table: 3 Gas Composition for food products 11
Table: 4 Nutritional value of peanuts per 100g 13
Table: 5 Nutritional value of chickpea per 100g 14
Table: 6 D – Value for different microorganisms 19
Table: 7 Methods of sensory analysis 24
Table: 8 Nutritional values of boiled peanuts per 100g 25
Table: 9 Nutritional values of boiled chickpea per 100g 25
Table: 10 Specification of nitrogen gas 26
Table: 11 Different concentration of nitrogen gas 30
Table: 12 Product packed at the different gas concentration 31
Table: 13 PLW of peanuts, Kabuli chickpea and desi chickpea 36
Table: 14 pH of peanuts, Kabuli chickpea and desi chickpea 38

x
 LIST OF FIGURES

S.NO TITLE PAGE NO

Figure: 1 Molecular Structure of Polyethylene Terephthalate 6
Figure: 2 Nitrogen (E941) 12
Figure: 3 Nitrogen generator 12
Figure: 4 Peanuts (Arachis hypogaea L.) 15
Figure: 5 Kabuli Chickpea (Cicer arietinum L.) 15
Figure: 6 Desi Chickpea (Cicer arietinum L.) 15
Figure: 7 Chamber machine 16
Figure: 8 Vertical form-fill-seal machine 17
Figure: 9 Horizontal form-fill-seal machine 17
Figure: 10 Z – value 21
Figure: 11 D – value 21
Figure: 12 Retort processing Machine 23
Figure: 13 Total Plate Count 34
Figure: 14 Coliform bacteria 34

xi
 LIST OF ABBREVIATIONS

PET – POLYETHYLENE TEREPHTHALATE

ALOx – ALUMINIUM OXIDE

BON – BI–AXIALLY ORIENTED NYLON

RCPP – RETROTABLE CAST POLYPROPYLENE

CPP – CAST POLYPROPYLENE

PP – POLYPROPYLENE

T – TIE LAYER

PA – POLYAMIDE

OTR – OXYGEN TRANSMISSION RATE

WVTR – WATER VAPOUR TRANSMISSION RATE

xii
1 INTRODUCTION

1.1 Modified Atmospheric Packaging (MAP):

Modified Atmospheric Packaging (MAP) can be defined as alternating the gaseous

composition within the packaging material to increase the shelf life of the product. MAP
could create an optimum condition that could increase the shelf life of the product and
inhibits oxidation. Modified atmospheric packaging could be made in two different
methods: Active MAP and Passive MAP. Active modified atmospheric packaging is
defined as the displacement of gases in the package with desired gas composition. In
contrast, passive modified atmospheric packaging is made by generating within the
package naturally by respiration of the produce and film permeability results in diffusion
of gases to achieve the required gas composition over time. The atmosphere within the
packaged material changes continuously during the storage period due to respiration by
the product and the permeation of the gases through the films. Modifications of
atmospheric air composition (78% nitrogen, 21% oxygen, and 0.1% carbon dioxide) in
the packaging material significantly increase the shelf life of the perishable foods and
reduce the growth of microorganisms. Oxygen is primarily responsible for oxidation and
causing rancidity to the food products. Aerobic microorganisms will grow in the food
product when products are exposed to the oxygen environment. This could reduce the
shelf life of the food product. In MAP, using inert gases like nitrogen, carbon dioxide,
carbon monoxide, and argon, changing the gas composition can increase the shelf life of
the product. (Edward et al, 2017)

1.2 Gases used in MAP:

The basic concept of modified atmospheric packaging is to change the air

composition of the food within the packaged material to desired gaseous composition in
different proposition to air [nitrogen (N2) 78.03%, oxygen (O2) 20.99%, argon (Ar)
0.94%, carbon dioxide (CO2) 0.03%, hydrogen (H2) 0.01%]. (Meredith et al, 2014)

1
1.2.1 Oxygen (O2):

Oxygen is responsible for the growth of aerobic microorganisms, and it causes

oxidative deterioration in foods. Oxygen must be excluded in the modified atmospheric
packaging. But they can be added in controlled quantities to maintain the freshness of the
food and its natural Colour and maintain the respiration in some fresh fruits and
vegetables packed by MAP. (Meredith et al, 2014)

1.2.2 Carbon dioxide (CO2):

Carbon dioxide has an inhibiting effect on the growth of aerobic microorganisms

and molds. CO2 is colorless, odorless and tasteless. CO2 is used to increase the shelf life
of the product. Higher the CO2, the shelf life of the product will be high. If CO2 dosage is
high, the product becomes sour. The package may get collapse as the gas may diffuse, or
it may absorb by the product. Many foods absorb CO2 because fats and water in the food
absorb CO2. It can cause flavor tainting, drip loss, pack collapse when excess CO2 is
packed in the package. Minimum 20% CO2 is required to control bacterial and mold
growth. CO2 is effective against gram-negative and aerobic spoilage bacteria which can
cause off-colour, flavor in meat, poultry, and fish products. It could permeate the
packaging thirty times faster than other gases that are used for packaging.

1.2.3 Nitrogen (N2):

Nitrogen is an inert gas. It is colourless, odourless and tasteless. It has low

solubility in both water and fat. It is primarily used in modified atmospheric packaging to
displace oxygen. By doing so, it delays oxidation and rancidity in fat-rich products. It
retards the growth of aerobic spoilage microorganisms in perishable foods. It is used as
the balance gas so that it could prevent pack collapse. Nitrogen is relatively in high purity
owing to its production process. It slowly displaces through the packaging films so that it
could remain longer in the packaging. 100% nitrogen can be used for dried products to
prevent oxidative rancidity. The use of nitrogen in food packaging is an effective way of
slowing food deterioration and improving longevity. (H Meredith et al, 2014)
2
1.2.4 Argon (Ar):

Argon has the same properties as nitrogen. Argon is chemically inert. It is

colourless, odourless, and tasteless. Argon is heavier than nitrogen, and its solubility is
twice that of nitrogen. To a greater degree, it does not affect any microorganism. It also
inhibits microbial growth, enzymatic activity, and specific chemical reactions. In a
controlled atmosphere, it is used as a replacement for nitrogen for many applications. The
molecular characteristic of argon gave special properties, as it can be used for vegetable
packaging. It also reduces respiration and slows down metabolic reactions.

1.2.5 Carbon Monoxide (CO):

Carbon monoxide is a highly toxic gas. CO is colourless, odourless, and

flammable. Carbon monoxide is used with a high amount of CO2 in MAP to increase the
shelf life of the meat product and retain their bright red Colour due to carboxy myoglobin
formation. Carbon monoxide is stable up to 400°C. It is not commercially used for MAP
packaging as it is highly toxic and not approved as it may cause a health hazard. It has an
inhibitory effect on different spoilage and pathogenic microorganism.

Table: 1 Chemical and Physical Properties of gases used for MAP:

Properties at 1 atm and 10°C

Molecular Molar Diffusion
Gas
formula mass(g/mol) Density(Kg/m3) coefficient Solubility in
in water(mmol/kg)
are(m2/s)
Oxygen O2 32 1.38 1.80 × 10−5 1.7
Carbon
CO2 44.01 1.9 1.43 × 10−5 53.7
dioxide
Argon Ar 39.95 1.72 1.73 × 10−5 1.9
Oxygen O2 32 1.38 1.80 × 10−5 1.7
Air 28.98 1.25 9.62 × 10−6 –

3
Table: 2 Thermodynamic properties of gases used for MAP: (Ruppin et al, 2020)

Triple point Triple point

Boiling point at 1 ΔvapH at
Gas temperature pressure
atm (Tb, °C) Tb(kJ/kg)
(°C) (atm)

Oxygen –183.0 213 –218.8 0

Carbon
–78.5 571.3 –56.6 5.11
dioxide

Argon –185.9 162.3 –189.3 0.68

Oxygen –183.0 213 –218.8 0

Air –194.3 205 – –

1.3 Packaging films used in MAP:

1.3.1 Polyolefin:

Low-density polyethylene (LDPE): It is highly versatile and inert chemically. It is a

homopolymer and constituted by ethylene monomers. LDPE accounts for the most
significant proportion of packaging plastics. Water vapor permeability is moderately low,
but for gas, permeability is high with a poor odour barrier. Ethylene and vinyl acetate
produces copolymer ethylene vinyl acetate and is related to LDPE. The copolymer has a
lower heat threshold as it has superior sealing quality. Linear low-density polyethylene
has good performance comparing low-density polyethylene. (W Zhang et al, 2014)

Linear low-density polyethylene (LLDPE): It is a linear polymer and made by

ethylene copolymerization. It is produced at low temperatures. Due to the absence of
long-chain branching, linear low-density polyethylene is structurally different from
LDPE. Compared to LDPE it has high tensile strength, high impact, and puncture
resistance. It is chemical resistant, flexible, and expands under stress.

4
High-density polyethylene (HDPE): Thermoplastic polymer which provides superior
barrier properties. It produces from ethylene monomer. It is a harder film and has a
higher softening point compared to LDPE. For the sealing layer, it is not suitable. Gas
barrier properties are better compared to low-density polyethylene, but its clarity is poor.

Polypropylene (PP) and Oriented Polypropylene (OPP): Polypropylene is chemically

similar to polyethylene. It has good heat-sealable characteristics. Oriented polypropylene
has a higher moisture vapor barrier. It has a higher gas barrier, almost seven to ten times
compared to polyethylene. It has good grease resistance. (Benjakul et al, 2010)

1.3.2 Vinyl polymers:

Ethylene-vinyl acetate copolymer (EVA): It is a polymer with high flexibility in sheet

form. It has high water vapor and gas permeability compared to low-density
polyethylene.(Mangaraj et al, 2009)

Polyvinyl chloride (PVC): In modified atmospheric packaging (MAP), it is widely used

as a bottom web in un-plasticized form. PVC is suitable for both technical and
commercial forms compared to polyesters and polystyrenes. It is a moderate barrier to
water vapor but an excellent gas barrier. In its un-plasticized form, it has excellent oil and
grease resistance. (Goswami et al, 2009)

Polyvinylidene Chloride (PVdC) copolymer: It is a copolymer of vinylidene chloride

and vinyl chloride. It is used in MAP as a gas barrier coating for lidding films. It has
good barrier properties and low permeability to water vapor and gases.

Ethylene-vinyl alcohol (EVOH): It is moisture sensitive and has high gas barrier
properties for gases like oxygen, nitrogen, and carbon dioxide in the form of film. It is an
expensive, flexible thermoplastic copolymer with excellent crack resistance. It loses its
gas barrier properties when exposed to moisture. It is used as packaging materials for
foods, drugs, and perishable products to extend shelf life. (Goswami et al, 2009)

5
1.3.3 Styrene polymers:

Polystyrene (PS): It is one of the most widely used plastics and is a synthetic aromatic
hydrocarbon polymer. It is made from a monomer called styrene and is a thermoplastic
polymer. It has high tensile strength, and it is a poor barrier to moisture vapor and gases.
It has a low melting point and naturally transparent. (Goswami et al, 2009)

High-impact polystyrene (HIPS): It is a moderately low gas barrier film. It is opaque

and thermo-formable. It is an amorphous thermoplastic material used in low heat
applications. It offers high impact strength and stiffness.

1.3.4 Polyamides:

Nylon refers to a group of plastic known as polyamides. It has high tensile

strength and good abrasion resistance. Mechanical properties get altered during water
absorption, and they can be retained by drying. It absorbs moisture from the
surroundings. It provides good resistance to chemicals. It can be used in an environment
with high temperatures. (Goswami et al, 2009)

1.3.5 Polyesters: polyethylene terephthalate (PET):

It is a thermoplastic polymer that belongs to the polyester family. Polyester resins

are well known for their resistance to mechanical, thermal, and chemical properties. It has
higher strength and stiffness. It has good gas and moisture barrier properties. It has good
electrical insulating properties, and with carbon dioxide, it has low gas permeability.

6
 Figure: 1 Molecular Structure of Polyethylene Terephthalate

1.4 Nitrogen (E941):

Nitrogen (E941) (N2) is a colourless, odourless, tasteless, non-toxic and

chemically inert gas. In the food industry, liquid nitrogen (E941) is widely used as a
freezing agent due to its low temperature. Nitrogen (E941) is used to extend the shelf life
of the product and to retain the nutritional properties of the food products. In other
industry nitrogen (E941) is used to suppress the combustion process and avoid oxidation
by creating a protective environment. (Erdogan et al, 2019)

Nitrogen (E941) is employed for cooling, temperature reduction and used for
storing food products. Food products get frozen quickly due to their very low
temperature, and it prevents the formation of ice crystals and moisture accumulation. By
so food products are good in organoleptic characteristic.

Nitrogen (E941) is suitable for preventing oxidation of food products and retards
the growth of microorganism and increase the shelf life of the product in modified
atmospheric packaging (MAP). It could prevent the package from collapse.

Nitrogen (E941) is an inert gas. It can replace the oxygen in the packaging
material by pushing out the oxygen, eliminating the oxygen contact to the food product.
Repeatedly injecting the nitrogen gas can diffuse oxygen out of packaging material.

Pure nitrogen is labelled with E number E941 by European Union. It is used in

MAP to produce an unreactive atmosphere. In MAP, it is mixed with carbon dioxide to
prevent the freshness of the product.

1.5 Market Overview:

The Modified Atmosphere Packaging Market was valued at USD 12.97

billion in 2020, and it is expected to reach USD 18.28 billion by 2026, at a CAGR

7
of 5% over the forecast period (2021 - 2026). In COVID-19, the demand for
packaged foods increases during the lockdown, and so the need for a modified
atmospheric packaging market increased.

The primary purpose of packaging is to protect the food products , and 30%
of foods produced in the world were wasted in the supply chain. An enhanced
packaging solution is required to reduce the wastage of produced product s.

According to Food and Agriculture Organization, nearly 1.3 billion metric

tons of food produced for humans is wasted due to no prolonged shelf life. This
highlights that better packaging is required for food material to increase shelf life.

In the MAP process, the product is packaged in a gas composition dissimilar

to the air. By decreasing the oxygen content, helps in the delay of product
degradation and increases the shelf life. Shelf life plays an important role which
drives the profitability of retailers and distributors.

The longer shelf life of the product gives retailers to trade the product on a
larger scale. Therefore, the wastage of products decreases, and profit increases.
MAP product has a longer shelf life to be transported to different locations with
any preservatives and chemicals.

In the retail sector, MAP significantly increases the product quality and
reduces the wastage of the product. MAP applications are used for packing snacks,
coffee and processed meat. It is used in packing convenience foods that meet
consumer requirements like quality, aroma, taste and health.

8
2. LITERATURE SURVEY

2.1 Nitrogen (N 2 ) MAP:

Nitrogen MAP is used in industry to increase the shelf life of the fat -rich
product. Nitrogen, due to its inertness and dryness, is used as protective gas.
Oxygen in the package is replaced by nitrogen by repeated flushing. Nitrogen is
colorless, odorless, and tasteless, and is unreactive. Nitrogen MAP prevents the
growth of aerobic microorganisms and inhibits oxidation in foods. It retains
nutritional value in the food products.(Edward et al, 2017)

2.1.1 Advantages of Nitrogen MAP:

Longer Shelf Life: Nitrogen MAP could extend the product's freshness and shelf
life under a protective environment. Nitrogen gas composition could be varied for each
product. (Meredith et al 2017)

Economic Loss: Food products get spoiled due to less shelf life, and wastage
occurs. This can be reduced by modified atmospheric packaging.

Production efficiency: Perishable foods can be packed using nitrogen MAP. This
results in shipping products to different geographical locations and long-distance.

Organoleptic characteristic: Nitrogen MAP could retain the product aroma,

taste, flavour, and texture of the packed products.

2.1.2 Disadvantages of Nitrogen MAP:

High complexity: Each product requires different nitrogen gas composition.

Excess nitrogen gas within the package can alter the properties of the product.

High cost: Nitrogen MAP requires a nitrogen cylinder to supply gas. High-quality
films are needed for packaging the products. (Norman et al, 2007)

9
2.1.3 Food application Nitrogen MAP is used:

To maintain the moisture content of the food during transportation and movement
of the package, high barrier property films are used for packing foods with hermetic
closure. Nitrogen as an additive will retain the properties of the food and increase the
shelf life of the product. Nitrogen will not diffuse through the film, and the product could
store for a more extended period. (Thippeswamy et al, 2011)

Rancidity can be reduced in food products by creating anoxic conditions. An

anoxic condition can be made by supplying the nitrogen continuously to the package.
Oxygen present inside the package could be replaced by nitrogen. Residual oxygen
concentration present inside the package will be reduced. Rancidity occurs when oxygen
gets mixed with a fat-rich product. By doing this, a fat-rich product like peanuts (Arachis
hypogaea L.) can be packed. (Porlich et al, 2006)

In ready-to-eat foods like chips and dried nuts, 100% nitrogen is used to maintain
its crispiness, texture, aroma, and flavor. This could prevent the product from rancid and
increase the shelf life.

Peanuts (Arachis hypogaea L.) are sensitive to rancidity due to the oxidation of fats
and oils, limiting the product lifetime. Nitrogen MAP could prevent the product from
oxidation. Oxidation occurs when oxygen gets in contact with the reactive chemicals in
the product. Flavor, color, and aroma get degrade due to chemical oxidation.
Lipoxygenase and oxidase catalyze the enzymatic oxidation in foods, and product quality
gets rapid degradation. To reduce the oxygen concentration in contact with foods, the
oxygen gas must be replaced by an inert gas like nitrogen. (Lelijveld et al, 2009)

Aflatoxin can be produced by aspergillus flavus when peanuts (Arachis hypogaea

L.) are packed in higher concentration of carbondioxide with an oxygen environment in
modified atmospheric packaging. Nitrogen MAP will reduce the growth of aspergillus
flavus, and the production of aflatoxin can be reduced.

10
Table: 3 Gas Composition for food products: (Muhlisin et al 2014)

Product N2 % CO2% O2%

Coffee 100 0 0

Wine, red 100 0 0

Wine, white / Rose 80 20 0

Snacks/Crisps/Peanuts 100 0 0

Sandwiches 70 30 0

Pasta/Pizza 40-70 30-60 0

Ready-made meals 40-70 30-60 0

Vegetables, cooked 70 30 0

Fruit / Vegetables, fresh 80-90 3-10 3-10

Cakes, biscuits 50 50 0

Crispy breads 0-50 50-100 0

Milk powder 80-100 0-20 0

Yoghurt 70-100 0-30 0

Raw low-fat fish 20-40 40-60 20-30

Raw high-fat fish 60 40 0

Cooked / smoked fish 40-70 30-60 0

Shellfish and crustaceans 30 40 30

11
 Figure: 2 Nitrogen(E941) Figure: 3 Nitrogen generator

2.2 Peanuts (Arachis hypogaea L.):

Peanuts, also known as groundnut (Arachis hypogaea L.), are widely grown in
tropical and sub-tropical regions worldwide. It is a legume crop and comes from the
family Fabaceae. It is taxonomically classified as Arachis hypogaea. Each elongated pod
is around 3 to 7 cm long and contains between one to four seeds. Peanuts contain high
protein and fats and are rich in essential nutrients. Peanuts are an excellent source of
vitamin E, B vitamins, and several minerals. (Maqsood et al 2010)

Peanuts are classified into four categories: Spanish group, runner group, Virginia
group, valencia group. Spanish group peanuts contain higher oil content and are used for
oil extraction. Runner group peanuts are rich in flavor, roasting character, and higher
yield comparing to the Spanish group. These peanuts are used to make peanut butter.
Virginia group peanuts are larger compared to all other groups and are the most
marketable peanuts. (Ashorn et al, 2003)

Peanuts, also called groundnuts they grew underground. Peanut plants are entirely
removed from the soil to harvest it, and they are left on the surface of the ground for dry.
Peanuts are available in raw and roasted form. By-products of peanuts include peanut oil,
peanut butter, and peanut flour. (Curtis et al, 2016)

12
Table: 4 Nutritional value of peanuts per 100g

Compositional Trait (%)

Protein 25.8
Fat 49.2
Ash 2.3
Carbohydrate 16.1
Total dietary fiber 8.5
Total sugar 4.7

2.2.1 Factors affecting the shelf life of peanuts:

The shelf life of peanuts depends on many different factors. In MAP, the shelf life
majorly depends on gas composition, the film used for packaging, and the properties of
packaging film. Extremely low oxygen must be filled in the package that will slow down
the oxidation process of fats and retains the taste, flavour, and aroma.

2.2.2 Nitrogen MAP of peanuts

Peanuts are rich in fat, and it contains 46-56% oil. Peanuts are sensitive to
rancidity due to the oxidation of fats and oils, limiting the product lifetime. Nitrogen
MAP could prevent the product from oxidation. Oxidation occurs when oxygen gets in
contact with the reactive chemicals in the product. Flavor, color, and aroma get degrade
due to chemical oxidation. Lipoxygenase and oxidase catalyze the enzymatic oxidation in
foods, and product quality gets rapid degradation. To reduce the oxygen concentration in
contact with foods, the oxygen gas must be replaced by an inert gas like nitrogen.

2.3 Chickpeas (Cicer arietinum L.)

Chickpea (Cicer arietinum L.), commonly known as Bengal gram, channa is the
third most important pulse crop in the world. It is an annual legume and comes under the
family Fabaceae. Chickpea is cultivated in a subtropical and semi-arid area in the warm
13
season. Chickpea contains high protein and is used in animal feeds. India accounts for
more significant global production (66%) of chickpea. They are used for nutritional
consumption. It is consumed in the form of whole grain, dhal and used to prepare
different snacks. (Salim et al, 2007)
Chickpea is one seedpod containing one-two to three peas. Chickpea is classified
on their shape, Colour and size. Globally two main types of chickpeas are produced
'Kabuli and Desi'. Kabuli chickpea is white seeded and is majorly grown in the northern
part. Desi chickpea is brown seeded and is grown in the southern part of India. Based on
seed size, Kabuli chickpea is classified into three types: large-seeded, medium seeded,
small-seeded. (Galam et al, 2004)
Table: 5 Nutritional value of chickpea per 100g

Compositional Trait (%)

Protein 20.47

Fat 6.04

Ash 3.1

Carbohydrate 62.95

Total dietary fiber 12.2

Total sugar 10.7

2.3.1 Nitrogen MAP of chickpea:

Nitrogen MAP of chickpea will maintain the physio-textural properties and

microbiological quality. The post-harvest life of chickpea is good in MAP packaging.
MAP of chickpea maintains the seed viability. Chickpea sprouts are packed in a different
gas combination of nitrogen, carbon dioxide and oxygen. Chickpea sprouts have an
excellent organoleptic character. By packing chickpea in modified atmospheric
packaging, adding preservatives can be avoided and longer shelf life. (Curtis et al, 2016)

14
 Figure: 4 Peanuts Figure: 5 Kabuli Chickpea

Figure: 6 Desi Chickpea

2.4 Machinery used for Nitrogen MAP

Modifying the atmosphere is the primary function of the MAP machine and retains
the product on thermoformed or pre-formed trays. MAP machine seals the pack, trim and
cut the waste film and produce the pack. There are different types of MAP machine
available for packaging products. (Pramod et al, 2014)

15
2.4.1 Chamber machines

Chamber machines are sufficient for low production. Pre-formed pouches are used
in chamber machine. The product is filled in the pouches and loaded into the machine,
and the chamber closes, vacuum is pulled out of the pack, and modified atmospheric gas
is flush into the pouches. The packet is sealed using heated seal bars, the chamber gets
open, and the pack is removed. The cycle continues. Chamber machines are cheap but
labour intensive. It is a relatively slow process and simple operation.

Figure: 7 Chamber machine

2.4.2 Snorkel machines

Pouches and pre-formed bags are used for packaging in a snorkel machine.
Chambers are not used here. Bags are packed with products and kept in the position.
Snorkel is introduced into the bags. It sucks the gas inside the bag and creates a vacuum.
Desired gas composition is filled inside the pouches and sealed by heated bars.

16
2.4.3 Form-fill-seal machine

The form-fill-seal machine is classified as a vertical from-fill-seal machine(VFFS)

and horizontal form-fill-seal machine(HFFS). This machine from, fill, and seal the
package. In MAP, the form-fill-seal machine controls the atmosphere within the package
and extends the shelf life of the perishable foods. This machine forms pouches from the
continuous film by pre-formed trays or thermoformed trays. Horizontal FFS is used in
many food industries.

Thermoformed form-fill-seal machine uses different webs for base web and
lidding material. The base film passes through the machine attached to the end of the
machine and passes through forming, filling section, gas modification, sealing, cutting,
and discharge section. Waste films are cut and disposed off.

Applying heat to the base roll, the base tray is produced. Heat applied will soften
the base roll, and desired shape and size is made. Compressed air blew and made film
soften against the heating plate. Product is filled, and desired gas composition is filled,
and pouches are heat-sealed and discharged.

Figure: 8 Vertical form-fill-seal machine Figure: 9 Horizontal form-fill-seal machine

17
2.5 Sterilization

Sterilization is the process of destroying or eliminating all forms of

microorganisms (fungi, bacteria, spores) by physical or chemical methods. Heat,
chemicals, and irradiation can achieve it. Sterilization is different from sanitation and
pasteurization. Sterilization is usually made above 100°C, where every bacteria and other
organism were destroyed. (Lerouge et al, 2012)

2.5.1 Methods of Sterilization

Methods of sterilization

Physical Chemical Physio-chemical

Liquid

Sunlight Heat Vibration Radiation Filtration Alcohols

Non-ionizing Aldehyde

Dry heat Moist heat Ionizinng Phenolics

Read heat Below 100°C Electromagnetic Halogens

Flaming At 100°C Particulate Dyes

Incineration Above 100°C Gaseous

Hot air oven Eathernware Formaldehyde

Infrared Asbestos Ethylene oxide

Sintered glass Plasma

Membrane

18
2.5.3 Thermal death time (TDT)

Thermal death time (TDT) is defined as the time in minutes required to kill
microorganisms at a specific temperature. The time needed to destroy all cells are
determined by keeping the temperature constant. The temperature necessary to eliminate
all the microorganisms at a fixed time is called thermal death time. After incubation, the
inability of an organism to form colonies is called death. Thermal death time is plotted
against log scale and corresponding temperature. (Rutala et al, 2013)

2.5.2 D – value (Decimal reduction time)

D-value is equal to the time in minutes required to reduce the microorganism

count by 1 log unit at a specified temperature. D-value determines the death rate of
microorganisms. At a specific temperature, microorganisms are resistant to it. In acidic
foods, D-value is low and high in high protein foods.(Mazzola et al, 2004)

Table: 6 D – Value for different microganisms:

Organism D value min @ 121.1˚C

Bacillus Stearothermophilus 4-5
C. thermosaccharolyticum 3-4
Desulfotomaculum nigrificancs 2-3
Clostridium botulinum 0.1-0.25
C. sporogenes 0.1-1.5
B. coagulans 0.01 - 0.07

2.5.4 Z - value

Z – value is the temperature in degrees necessary to achieve a tenfold reduction in

D – value. It gives information on different destruction temperatures for which
microorganisms are resistant. (Chubb et al, 2012)
19
For example:

Z – value of clostridium botulinum is 10°C. For every 10°C change, there is a

change in ten-fold change in death rate.

2.5.5 F – value

F – value is the time in minutes required to all organisms at 121.1°C. When the Z
value of the process is 10˚C, F is denoted as Fo. The unit of sterilization is Fo. Fo can be
defined as the integrated heating effect received by all points inside the can. Fo value of 1
is equivalent to holding the product at 121.1˚C for one minute. (Eleni et al 2010)

Fo = D (log a-log b)
D = Decimal reduction time (D value)
a = initial cell numbers
b = final cell numbers

2.5.6 12 – Concept

12 – Concept is used in low acid and medium acid foods (pH > 4.6). Bacteria
commonly found in foods are C.botulinum and are toxin. 12D concept refers to thermal
processing requirements to reduce the survival of the most heat resistant C.
botulinum spores to 10-12. This helps determine the time required at the temperature of
121oC to reduce spores of C. botulinum to 1 spore in only 1 of 1 billion containers.
(Neelima et al 2019)

If one spore of C.botulinum present in the container

m = log N0 / Nt = log 1 – log 1012 = 12

F0 = mD0 = 12 x 0.21= 2.52 minutes

C. botulinum
F = 2.52 min
121.1℃

20
 D value of C. botulinum = 0.21

Factor of 1012 = 12 x 0.21 = 2.52 min

D = t / (loga – logb)

t= time of heating

a= initial number of spores

b=number of survivors

Figure: 10 Z – value Figure: 11 D – value

2.6 Retort Processing

Retort processing is a thermal-based process. Retort processing is a commercial

sterilization technique that is used in the food manufacturing industry. In retort
processing, foods are kept inside the hermetically sealed Pressure vessels. It is mainly
applicable in high heat food products. High temperature is used in retort to destroy all the
pathogenic organisms both inside and outside of the container of the food product. It is
the reason that the retort is designed as the pressure vessel. (J Panin et al, 2018)

21
 Retort designed with a "pressure vessel." Thermal sterilization of shelf-stable, low
acidic foods [defined as products with a finished equilibrium < 4.6 and a water activity <
0.85] is usually performed at or above 121°C+-5°C. Temperature and time are inversely
proportional. If the temperature is high, then the time will be less. If the temperature is
low, then the time will be more. (Bindu et al, 2012)

There are many types of retorts: full water immersion, Water sprayer, and Forced
Steamer (with fan). Here we are using water-spraying retort. It is a high-pressured style
retort. In the water-spraying retort, food products are arranged in the perforated tray and
kept inside the retort. Initially, at the bottom of the retort, 500 to 600 litre of water is
filled. After closing the retort, water starts to circulate with the help of a motor, and it
passed through a plate heat exchanger and is sprayed inside the pressure vessel to
maintain a set temperature. (Sagar et al 2009) The whole process is divided into three
phases first is the heating phase, second is the holding phase ad last is the cooling phase.
The cooling phase is made suddenly to stop its cooking process. Water spraying retort is
effective than water immersion retort because it uses less quantity of water. Pressure
should be maintained properly because if we didn't hold, the pressure packages might
damage due to lack of counter pressure. (Sahoo et al, 2019)

Retort time and temperature for each food product may vary due to its physical
and chemical properties. The time and temperature of the food product undergoing the
retort process are determined by f0 value. (Smita et al, 2009)

F0= ∆t × 10 (T - 121/Z)
Where as,
∆t = 60 sec = 1 minute
T = Temperature for serilization
Z = 10°C

22
 Figure: 12 Retort processing Machine

2.7 Sensory Analysis:

Sensory changes are a result of intentional or unintentional interactions of food

products with packaging material. This results in the failure of material form protecting
product quality. Quality is the ultimate criterion for food products to consumer
desirability. Sensory is an essential parameter for both producers and consumers. Sensory
play a crucial role in consumer for buying and consuming the product. (Sidel et al, 1981)

The first important attribute for selecting a food product is appearance. Colour,
size, shape, and uniformity comes under an impression. Product without defect is also
essential. Texture and consistency is the second important attribute. Flavor defines taste,
feeling, and smell. Sweet, sour, salty, and bitter are a sense of taste humans limited.
Flavor attributes are measured subjectively. (Chambers et al, 2017)

Sensory analysis is a scientific aspect that applies principles of statistical analysis

and experimental design to the use of human senses like touch, sight, taste, and small to
examine the quality of the food product. Sensory properties are a significant factor in
evaluating the quality of food products. This type of analysis is made with a trained
panellist. They are trained specially for sensory analysis. In some cases, untrained
23
ordinary people can also be used, but the panelist will be more mare than trained
panellists. Nowadays, big MNC has a separate department for sensory evaluation. The
results found from sensory analysis provide more information on specific production
parameters and processes on perceptible sensorial properties. Ingredients and factors
significantly control consumer acceptance. Sensory analysis is an essential analyzing
method because it provides information about the ingredients and characteristics of the
food product. And it helps to improve the quality of food. (Kemp et al, 2008)

Table: 7 Methods of sensory analysis: (Rangana et al 2014)

SI.
Type Method No of sample
No

Paired comparison 2

Difference - 3 (2 identical and 1

1 Duo trio
qualitative different)
3 (2 identical and 1
Triangle (triad)
different)

Ranking 2-7

Single sample (monadic) 1

4 pair of an unknown ad
Two sample difference
Rating - control sample
2
quantitative
Multiple samples and
5 – 6 it includes
quality difference
Hedonic 5 - 10
Numerical scoring 5 - 10
Composite 1-4
Threshold 5 - 10
3 Sensitivity
Dilution 5 - 10
Descriptive flavor
4 Common and Agreed scale 1-5
profile

24
2.8 AIM AND OBJECTIVE:

 The present research is focused on optimizing the process of nitrogen-modified

atmospheric packaging.
 To determine the nitrogen concentration at which peanuts and chickpeas get
standardize.
 At different vacuum – nitrogen concentration, peanuts, and chickpea is packed
 Selection of best vacuum – nitrogen concentration.
 Physiological loss in weight, pH analysis, and microbial analysis of the packed
product.
 Sensory analysis of the product.

2.9 IMPORTANCE OF WORK:

 Stabilization of the product will increase the organoleptic characters of the

product.
 Increase in the shelf life of the product.
 Optimizing the current packaging process leads to different packaging of new
products.
 Standardize the vacuum – nitrogen concentration for different raw materials for
packaging.

25
3 MATERIALS AND METHOD:

3.1 MATERIALS

3.1.1 Peanut:
Peanuts (Arachis hypogaea L.) are harvested on the local farm and are transported
to the company by truck. These peanuts are graded through size, shape, and defects.
Fresh peanuts are soaked for 4 hours, are blanched for 20 minutes. 2% salt is added to the
blancher. After that, they are packed through modified atmospheric packaging.
Table: 8 Nutritional values of boiled peanuts per 100g

Compositional Trait (g)

Protein 13.5
Fat 22.01
Carbohydrate 21.26
Total dietary fibre 8.8
Total sugar 2.47

3.1.2 Chickpea:

Kabuli chickpea and desi chickpea (Cicer arietinum L.) are obtained from the
local market and are transported to the company by truck. These chickpeas are graded
through size, shape, and defects. Fresh chickpeas are soaked for 4 hours are blanched for
20 minutes. 2% salt is added to the blancher. After that, they are packed through modified
atmospheric packaging.
Table: 9 Nutritional values of boiled chickpea per 100g
Compositional Trait (g)
Protein 8.86
Fat 2.59
Carbohydrate 27.42
Total dietary fiber 7.6
Total sugar 4.8

26
3.1.3 Sampling of raw materials:

Peanuts, Kabuli chickpea, and desi chickpea are weighted through a laboratory
level weighing scale (Model CX 504, N-TECH electronics, India), having the least count
of 0.001g and a maximum of 10kg. The plate is placed on the weighing scale, and tare is
pressed to obtain zero in the scale. The weight of raw materials used in nitrogen modified
atmospheric packaging is

S. No Raw material weight(g)

1 Peanuts 180

2 Kabuli chickpea 180

3 Desi chickpea 225

3.1.4 Nitrogen (E941):

Nitrogen 5N food grade is obtained from SLN enterprises with tolerance ± 1% and
accuracy ± 3%. Nitrogen has the following specification:

Table: 10 Specification of nitrogen gas:

Nitrogen 99.999%

Oxygen <2 PPMV

Moisture < 2 PPMV

THC < 1 PPMV

CO < 0.5 PPMV

CO2 < 1 PPMV

Dew Point -78°C

Pressure 145 Kg/cm2

27
3.1.5 Top and Bottom film:

Top and bottom web is manufactured by food grade approved polymers and meets
the requirements for safe use in contact with foodstuffs and Multivac Laraon India Pvt.
Ltd supplies it.

3.1.5.1 Specification of Top film:

Film Type 12 PET-AlOx / 15 BON / 70 RCPP

Roll Width 420 mm
Dimensional Tolerance ± 2 mm
Thickness 105 μ (± 2%)
GSM 108 (± 2%)
Interlayer Bond Strength PET-AlOx/ BON: > 4 N/15mm, BON/CPP: >7 N/15mm
WVTR <0.5 gms/m2/24 hours @38° Celsius at 90%R/H
OTR <0.5 cm3 /m2/24 hours @ 23° Celsius at 0%R/H
Odor Test (Organoleptic) Pass
Migration Negative for Foods, Additives, Flavor, Odor
Sealing Temperature 170-190°C

3.1.5.2 Specification of Bottom film:

Film type PP/T/PA/T/PP/T/PA

Micron 200µ
Coil width 423mm
OTR 12.5 gms/m2/24 hours
WVTR 2.15gms/m2/24 hours
GSM 198.00-200.10
Seal strength 8.90 - 9.13 Kg/25mm
Tensile strength MD - 421 - TD - 419 Kg/cm2
Elongation MD - 427 - TD - 420 %
Dart impact strength 850 grams at 152 cm
Surface defect no defect like dust / foreign particles

28
3.1.6 Thermoforming packaging machine:

In industry, the Multivac R126 machine is used for packing raw materials. It is a
compact machine for standard packs. A Rectangular, square pack can be made. Flexible
and rigid films can be used for packing. Die needs to change manually. It is controlled
manually.
Forming station: The base web is made in the forming station by the effect of
heat. It is then thermoformed utilizing compressed air and vacuum. If required, this
process can be aided by the use of forming plugs.
Loading area: The thermoformed pack cavities can be filled manually or
automatically in the loading area.
Sealing station: The upper web is applied to the filled pack cavities in the sealing
die. The upper and lower webs are sealed hermetically to each other through a seal seam.
Cross-cutting and longitudinal cutting units: The cross-cutting and longitudinal
cutting units sever the individual packs from the strip of packs in the web.

3.1.7 Retort processing machine:

Static Steriflow water cascading machine was used for retorting the finished
product. The Steriflow Static has a powerful pump for shorter and more homogeneous
cycles. All the products inside the autoclave get equal thermal treatment, regardless of
their position. The cycle time is reduced and also ensures the best results. Large pouches,
plastic trays, small pouches, plastic or glass containers, and canned products can be
retorted in this autoclave and adapted for all packaging material. It can load with a
capacity of around 2 to 7 baskets. This machine can operate both manual and automatic.
It contains fewer mechanical parts. Therefore breakdown is more occasional.
Maintenance cost is lower compare to all other retorts. A stackable basket with stainless
trays is used for stacking the packaged product so that distortion can be avoided. At the
cooling phase, all products are cooled using sterilized water.

29
3.2 Methodology:

3.2.1 Procedure for raw material processing:

Raw material
(Peanuts, Kabuli chickpea, Desi chickpea)

Grading

Soaking for 4hrs

(Room temperature)

Blanching for 20min @ 80°C

(2% salt solution)

Draining hot water

Filling raw materials

Modified atmospheric packaging

(Different vacuum switch and nitrogen switch point)

Pouch integrity check

Retort processing for 20mins

(Holding at 121°C)

Curing and inspection

Batch printing

Dispatch

30
3.2.2 Procedure to Nitrogen MAP:
Multivac machine was set to modified atmospheric packaging. The cylinder
containing nitrogen (N2) gas was checked for pressure. The cylinder valve was open, and
pressure was set above 5 bar. The nitrogen gas was passed through the tube to the buffer
tank. The gas was supplied through the tube to the MAP machine for food product
packaging.
The packaging material was kept in the packaging unit. The vacuum was created
by evacuating air present in the packaging material, and then the set value of nitrogen
concentration was filled in the packaging material.
In MAP machine, for effective packaging bottom ventilation delay 0.200s, top
ventilation delay 0.200s, die closing 1.492s, vacuum 0, security time 2.5s was kept. For
effective sealing, the sealing time was increased to 2.5s to 4s. Gas switch point and
vacuum switch point values are changed for different nitrogen concentration packaging.
Atmospheric air has 913 mbar pressure, and change in vacuum switch point and
nitrogen gas switch point alters the atmospheric gas concentration. In the packaging
material and value set for the gas switch point, the nitrogen gas concentration will be
filled in the packaging material.
Table: 11 Different concentration of nitrogen gas:

S.No Vacuum switch point (mbar) Gas switch point (mbar)

1 100 200
2 100 300
3 100 400
4 150 350
5 150 450
6 200 500
7 300 500
8 350 450

31
3.2.3 Vacuum – nitrogen gas concentration:
Table: 12 Product packed at the different gas concentration

Vacuum switch point Gas switch point

S.no Raw Materials weight(g)
(mbar) (mbar)

1 100 200
2 100 300
3 100 400
4 150 350
Peanut 180
5 150 450
6 200 500
7 300 500
8 350 450
9 100 200
10 100 300
11 100 400
12 150 350
Kabuli chickpea 180
13 150 450
14 200 500
15 300 500
16 350 450
17 100 200
18 100 300
19 100 400
20 150 350
Desi chickpea 225
21 150 450
22 200 500
23 300 500
24 350 450

32
3.2.4 Analysis of the sample:

3.2.4.1 Physiological Loss in Weight (PLW)

Weight loss of peanuts, Kabuli chickpea, and desi chickpea can be determined by
physiological loss in weight. Raw materials are packed in different nitrogen gas
concentrations. Its initial weight is measured using a laboratory level weighing scale with
a least count of 0.001g and a maximum count of 10kg. The plate is placed on the
weighing scale, and tare pressed to get zero, and the initial weight of the product is
measured during the time of packaging. After months, the product's final weight is
calculated using the same weighing scale, and the loss percentage is calculated. At
different nitrogen gas concentrations, loss in weight can be calculated. (Greenway et at,
2015)

Initial weight – Final weight

PLW (%) = X 100
Initial weight

Where PLW (%) - Physiological Loss in Weight

3.2.4.2 pH Analysis:

pH analysis of the samples is observed using a portable pH meter (H160G portable

pH meter). To analysis pH, a sample mixture needs to be prepared. The sample mixture is
ready in a 1:1 ratio. 10g of sample is taken and crushed using pistol and mortal, and 10ml
of distilled water is mixed, and pH is observed. The pH meter is calibrated using a buffer
solution of pH 4 and 7, and errors can be corrected. This pH buffer solution is made by
mixing pH buffer power with 100ml distilled water and is mixed well. pH is then
observed for the desired buffer solution, and an error is made. The initial pH of the
sample is measured after retorting is made. The final pH is measured by leaving the
sampling for desired storage time, and pH is measured. By this test, if a change in pH of
samples at different nitrogen concentrations can be observed. (Alosa et al, 2014)

33
3.2.5 Microbial test

3.2.5.1 Determination of Total plate count – Pour plate count method. (Arifan et al,
2019)

Aim: To find the microbial colony count in the given sample.

Equipment: Petri plate, conical flask, autoclave, laminar flow

Media: Plate count agar

Procedure:

 You should autoclave all the equipment required with media (121℃ for 15min),
 Sanitize the sample from outside,
 Sanitize the laminar airflow and switch on UV light for 10min
 Then take out the plates and bottles,
 After taking out the plates and bottles from the autoclave label it
 Light the lamp and sanitize the pestle and mortar,
 Take 10g of sample and smash it and mix that with 90 ml saline water,
 Mix it properly and from that take 1ml and put into plates,
 Then start putting media to that, but media should not be poured when it will be
too hot.
 Then keep it incubator to observe the results.

3.2.5.2 Determination of coliform test (Gurber et al, 2014)

Aim: To find the coliform count in the given sample.

Equipment: Petri plate, conical flask, autoclave, laminar flow

Media: Violet red bile agar

Procedure:
 Heat till media get dissolved.
 Sanitize the sample from outside.

34
  Sanitize the laminar airflow and switch on UV light for 10min.
 Then take out the plates and bottles.
 After taking out the plates from the autoclave, label them.
 Light the lamp and sanitize the pestle and mortar.
 Take 10g of sample and smash it and mix that with 90 ml saline water
 Mix it properly, and from that, take 1ml and put it into plates.
 Then start putting media to that, but media should not be poured when it will be
too hot.
 Then keep it incubator to observe the results.

Figure: 13 Total Plate Count Figure: 14 Coliform bacteria

3.2.6 Sensory Analysis:

Hedonic Rating-test

This type of sensory analysis is made to measure the consumer acceptability of the
improved product. One to four samples can do at a time. The panelist is asked to rate the
acceptability of the product, usually on a scale of 0 to 9. 0 will denote “dislike
extremely,” and 9 will indicate “like extremely.” The obtained data from the panelist is
processed to get the result. (Rangana et al 2014)

35
 SENSORY EVALUATION

Name of Panellist :
Age :
Experiment No :
Product :

PROCEDURE ATTRIBUTES Score

Pre-consumption attributes Aroma
Taste
Shell
Chewiness
The mouthfeel of Millets
Sweetness
Flavour
Overall likability
Final Ranking [1/2/3]
Reason for Preference

Comments

Note: Rating Scale as follows Score/ Standard Hedonic Scale

Instructions:
1. Test one sample at a time
for all attributes in 1st
column before moving to
next
2. Taste the sample only after
the Pre-tasting attributes
rating
3. Eat puffed rice and water
before each sample
4. Rate the sample from 1 to 9
for each attribute as
mentioned in the below
standard hedonic scale.
Rating
9 I like extremely
8 I like very much
7 I like moderately
6 I like slightly
5 I neither like nor dislike
4 I dislike slightly
3 I dislike moderately
2 I dislike very much
1 I dislike extremely

36
4. RESULTS AND DISCUSSION:

4.1 Physiological Loss in Weight (PLW) of final product:

Table: 13 PLW of peanuts, Kabuli chickpea, and desi chickpea

Raw Vacuum switch Gas switch point Initial Final

PLW(%)
Materials point (mbar) (mbar) weight(g) weight(g)
100 200 178 1.11
100 300 175 2.77
100 400 178 1.11
150 350 166 7.77
Peanut 180
150 450 165 8.33
200 500 175 2.77
300 500 170 5.55
350 450 178 1.11
100 200 165 8.33
100 300 167 7.22
100 400 166 7.77
Kabuli 150 350 172 4.44
180
chickpea 150 450 172 4.44
200 500 165 8.33
300 500 167 7.22
350 450 167 7.22
100 200 218 3.11
100 300 214 4.88
100 400 218 3.11
Desi 150 350 210 6.66
225
chickpea 150 450 210 6.66
200 500 217 3.55
300 500 216 4
350 450 218 3.11

37
 The physiological loss in weight (PLW) of the resorted by bounding atmospheric
storage temperature, relative humidity, and suitable designed package. It is evident that,
at the end of one month of storage time, at different nitrogen concentrations, there is a
change in the product's weight. Maximum weight loss is 8.33%, and minimum weight
loss is regarded as 1.11% in peanuts. The maximum weight loss observed in Kabuli
chickpea is 8.33%, and the minimum weight is 4.44%. The maximum weight loss
observed in desi chickpea is 6.66%, and the minimum weight loss observed is 3.11%.
The weight loss observed in raw materials is different, and it depends on the properties of
the raw materials. Weight loss is different for peanuts, Kabuli chickpea, and desi
chickpea at different concentrations. For peanuts, the initial weight is 180g, and the least
and maximum weight loss is 178g and 165g. For Kabuli chickpea, the initial weight is
180g, the least and maximum weight loss is 172g and 165g. The initial weight of desi
chickpea is 225g, and the least and maximum weight loss is 218g and 210g.

4.2 pH analysis of the final product:

The pH value of the peanuts, Kabuli chickpea, and desi chickpea initially packed
is acidic, having a pH value of more than 6.0. It is observed that the pH value of the
peanuts initially packed is 6.2. After one month of storage, pH was 6.9 and 6.8 at
different nitrogen concentrations. The pH of the peanuts in different nitrogen
concentrations is acidic throughout the storage time. The pH value of the initially packed
Kabuli chickpea is 6.4. After one month of storage, the pH observed was 6.3, 6.4, 6.6,
and 6.7 at different nitrogen concentrations. The pH of Kabuli chickpea was acidic during
the entire storage time at different nitrogen concentrations. In the case of desi chickpea,
the initially packed product pH is 6.3. pH was observed to be 6.3, 6.4, and 6.6 at the end
of one-month storage. The pH of the desi chickpea is acidic throughout the storage time
at different nitrogen concentrations. The pH of the product at different nitrogen
concentrations is not much declined. Lowering pH and increasing pH in products is due
to different gaseous compositions developed inside the package.

38
Table: 14 pH of peanuts, Kabuli chickpea, and desi chickpea:

Vacuum
Raw Gas switch point
switch point Initial pH Final pH
Materials (mbar)
(mbar)
100 200 6.9
100 300 6.9
100 400 6.8
150 350 6.9
Peanut 6.2
150 450 6.8
200 500 6.9
300 500 6.8
350 450 6.8
100 200 6.4
100 300 6.3
100 400 6.3

Kabuli 150 350 6.3

6.4
chickpea 150 450 6.4
200 500 6.4
300 500 6.7
350 450 6.6
100 200 6.3
100 300 6.3
100 400 6.4
150 350 6.3
Desi chickpea 6.3
150 450 6.4
200 500 6.4
300 500 6.4
350 450 6.6

39
4.4 Study of different concentration of nitrogen (E941)

4.4.1 Peanut (Arachis hypogaea L.):

Vacuum - nitrogen
concentration Study Observed
(mbar)

Appearance is good, with little change in the taste of the product. The
smell is not good, heavy odor and least slimy. The product is in dry
100 - 200
condition, and the color is good. At this concentration product
package is negligible.

Appearance is good, and the taste is good as the initial day of

packaging. The smell is good and least slimy. The product is in dry
100 - 300
condition, and the color is good. At this concentration product
package is negligible.

The Colour is good, change in odor. Slightly vary in taste—medium

100 - 400
slimy. The product is in wet condition, and the package is good.

Little change in odor, good in taste, and Colour is good. The package
150 - 350 is also good and not bulkier. The product is the least slimy and
development in minor dry condition.

Slimier, odor not pleasing, Colour is good. The package is ok and not
150 - 450
bulkier. The taste is a little bitter.
The taste is awful and a little bitter. Slimier and product are in wet
200 - 500 condition while opening. Odour is awful, and the Colour is good. The
package is bulkier.

Original taste does not retain in this concentration. It smells awful and
300 - 500 while eating, bitter taste. The Colour is good, and the product is
slimier. The product is in wet condition while opening the package.

Medium slimy, and product is in semi-dry condition while opening.

350 - 450
Foul odor in the development and taste also not good.

40
4.4.2 Kabuli chickpea (Cicer arietinum L.):

Vacuum - nitrogen
Study Observed
concentration (mbar)

Least slimy and good to eat. The product is in dry condition

100 - 200 while opening. The smell is good, and the packet did not get
bulkier after retorting. Dull in Colour.

Least slimy and good to eat. Odor change in the product. The
100 - 300 packet did not get bulkier after retorting. The Colour and
appearance are good.

Little change in taste of the product. Change in odor and packet

100 - 400 is little bulk. The product is less slimy and in semi-dry condition
and smells a little wrong.

Little change in odor, good in taste, and Colour is good. The

150 - 350 package is also good and not bulkier. The product is the least
slimy and product in minor dry condition.

Heavy in smell, little bit bitter taste. The package is good.

150 - 450 Medium slimy, so that product is in semi-dry condition while
opening the package.
The taste is awful and a little bitter. Slimier and product are in
200 - 500 wet condition while opening. Odour is awful, and the Colour is
good.

Original taste does not retain in this concentration. It smells

awful, and while eating, the Colour is good, and the product is
300 - 500
slimier. The product is in wet condition while opening the
package.

Medium slimy, and product is in semi-dry condition while

350 - 450 opening. Slight foul odor in the product and the taste also not
good.

41
4.4.3 Desi chickpea (Cicer arietinum L.):

Vacuum - nitrogen
Study Observed
concentration (mbar)

The smell and taste of the product are good. Packaging and
100 - 200 appearance are better. No slimy, and the product is in dry
condition while opening.

Slight hardness while chewing the product. Good taste and

100 - 300 appearance are good. Little change in the odor of the product. No
slimy and good to eat in dry condition.

The taste of the product is good. Change in odor and packet is

100 - 400 little bulk. The product is less slimy and in semi-dry condition
and smells a little bad.
Odour is good. The taste and Colour are good. The package is
also good and not bulkier. The product is in dry condition. No
150 - 350
slimy, and the product is dry after packaging in this
concentration.
Heavy in smell, little bit change in taste. The package is good.
150 - 450 Medium slimy, so that product is in semi-dry condition while
opening the package.
The taste is awful and a little bitter. Slimier and product are in
200 - 500 wet condition while opening. Odour is awful, and the Colour is
good.

Original taste does not retain in this concentration. It smells

awful, and while eating, the Colour is good, and the product is
300 - 500
slimier. The product is in wet condition while opening the
package.

The product is in semi-dry condition while opening. Slight foul

350 - 450
odor in the product and the taste also not good.

42
4.5 Sensory Evaluation:

Sensory evaluation is based on a hedonic rating test. Finally, the result is drawn as
the graph for sensory attributes vs standard hedonic scale.

Note: Rating Scale as follows Score/ Standard Hedonic Scale

Instructions:
1. Test one sample at a time for all
attributes in 1st column before
moving to next
2. Taste the sample only after the
Pre-tasting attributes rating
3. Eat puffed rice and water before
each sample
4. Rate the sample from 1 to 9 for
each attribute as mentioned in
the below standard hedonic
scale.
Rating
9 I like extremely
8 I like very much
7 I like moderately
6 I like slightly
5 I neither like nor dislike
4 I dislike slightly
3 I dislike moderately
2 I dislike very much
1 I dislike extremely

Peanuts: For peanuts (Arachis hypogaea L.), sensory evaluation is made for the following
vacuum - nitrogen concentration: 100 – 300 and 150 – 350.

Appearance
9
8
7
6
Overall 5 Aroma
acceptability 4
3
2
1 100 - 300
0
150 - 350

Taste Colour

Flavour

43
Kabuli chickpea: For Kabuli chickpea (Cicer arietinum L.), sensory evaluation is made
for the following vacuum – nitrogen concentration: 100 – 200 and 150 – 350.

Appearance
9
8
7
6
Overall 5 Aroma
acceptability 4
3
2
1 100 - 200
0
150 - 350

Taste Colour

Flavour

Desi chickpea: For desi chickpea (Cicer arietinum L.), sensory evaluation is made for the
following vacuum – nitrogen concentration: 100 – 200, 100 – 300, and 150 – 350.

Appearance
9
8
7
6
Overall 5 Aroma
acceptability 4
3
2 100 - 200
1
0 100 - 300
150 - 350

Taste Colour

Flavour

44
5. SUMMARY AND CONCLUSION:

In the current study, nitrogen concentration for packing peanuts (Arachis hypogaea
L.), Kabuli chickpea (Cicer arietinum L.), and desi chickpea were determined by
physiological loss in weight, ph analysis, and sensory evaluation. Raw materials were
soaked for 4 hours and blanched for 15 minutes with 1% salt. Products were packed in a
different vacuum – nitrogen concentration, and they are kept for storage. After one
month, their initial and final weight was checked. Change in pH was also determined. As
the product was retorted after their packaging, the total plate count and coliform were less
than ten. At 100–300 and 150–350, peanuts were good as the initial day of packaging. At
100-200 and 150-350, Kabuli chickpea (Cicer arietinum L.) was better to eat. At 100-200,
100-300, and 150-350, desi chickpea (Cicer arietinum L.), was better. At this
concentration, products were stabilized and had good sensory attributes.

45
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