PROJECT WORK

ON
PRODUCTION, ANALYSIS & QUALITY
CONTROL OF EXTRUDED TASTY
SNACKS

SUBMITTED BY
SABORNI ACHARYA
ROLL NUMBER: 10088621014
REGISTRATION NO: 211001888610014

UNDER THE GUIDANCE OF

DR. ANJU PAUL

SUBMITTED FOR THE PARTIAL FULFILMENT FOR THE DEGREE

OF MASTER OF SCIENCE IN FOOD SCIENCE & NUTRITION

MAULANA ABUL KALAM AZAD UNIVERSITY OF TECHNOLOGY, WB

NH-12 (OLD NH-34) SIMHAT
HARINGHATA, NADIA 741249, WEST BENGAL
 PROJECT WORK
ON
PRODUCTION, ANALYSIS & QUALITY
CONTROL OF EXTRUDED TASTY
SNACKS

SUBMITTED BY
SABORNI ACHARYA
ROLL NUMBER: 10088621014
REGISTRATION NO: 211001888610014

UNDER THE GUIDANCE OF

DR. ANJU PAUL

SUBMITTED FOR THE PARTIAL FULFILMENT FOR THE DEGREE

OF MASTER OF SCIENCE IN FOOD SCIENCE & NUTRITION

MAULANA ABUL KALAM AZAD UNIVERSITY OF TECHNOLOGY, WB

NH-12 (OLD NH-34) SIMHAT
HARINGHATA, NADIA 741249, WEST BENGAL
 TO WHOM IT MAY CONCERN

This is to certify that SABORNI ACHARYA of Semester IV, year of examination 2023
Registration No 211001888610014 Year 2021-2023 and University Roll No. 10088621014 has
successfully completed and submitted her M.Sc project thesis entitled “PRODUCTION,
ANALYSIS & QUALITY CONTROL OF EXTRUDED TASTY SNACKS” under the
Supervision of Dr. ANJU PAUL,faculty of Food Science, Department of Food Science,
under the School of Food, Pharmaceutical and Medical Science & Technology for the
partial fulfilment of her M.Sc degree to be awarded by Maulana Abul Kalam Azad University
of Technology, WB.

Supervisor Name: Head of the Department:

Designation: Name:

Place: Place:

Date: Date:
Acknowledgement

It gives me great pleasure to express my thanks & heartfelt gratitude to Dr. Sonia Kundu
Maity mam, HOD (Department of Food Science), for giving me the opportunity and Dr.
Anju Paul mam who provided me guidance in my each and every step & without whose
guidance, support, this training would not have been possible.

I am thankful to Ravi Kumar (Factory Manager), Shubham Kumar Srivastava (Quality In

charge) who gave me an golden opportunity to gain knowledge and experience in their
industry.

I am very thankful to,Ankul Tiwari (Sr. Quality Executive), Soumita Ghosh (Quality
Executive), Dhiraj Kumar (Quality Executive), Saurabh Mishra (Packing Quality
Executive) for their kind and friendly support in the lab. I couldn’t forget books and internet
which provided me with substantive matter.

Secondly, I would also like to thank my parents and friends who have boosted me morally with
their continuous support to finalize this project within the limited time frame.

Lastly but not least, I like to thank all my supporters who have motivated me to fulfill this
project before the timeline.

REGARDS
SABORNI ACHARYA
ABOUT GEOFAST
‘Geofast’ means ‘Geographically Fast’ which reflects our zeal and passion to reach our
customers fast, keeping in view of the pace of our clients’ growing needs. Geofast’s food
manufacturing units are ISO 22000:2018 certified, which is the highest standard of quality
systems in the industry. It is established on 3rd Nov in 2019 in Bihar. The company strategy is
to offer low-cost solutions to the clients & customers to any corner of the world through
specialized and trained professional teams to create superlative value for our customers.
Geofast has planned an aggressive expansion and diversification strategy by investing in state-
of-the-art manufacturing facilities, warehouses, technology / digital platforms.

Geofast Food Factory Plot No. 2069, SinghriyawanGavaspur Village Dhaniyawan,

Patna Dist, Bihar 801304

▪ Bingo TEDHE MEDHE is product which is manufactured in this industry. It is an

innovative Ready to Eat snacks. Extrusion technology is extensively used to produce
TEDHE MEDHE Masala Tadka. It is a delicious crunchy snack. It has characteristic
appearance, finger like shape, flavour and texture. High temperature and pressure play
an important role to form a finger like structure.

▪ Vision
To manufacture every product used by a consumer.

▪ Mission
Our mission is to grow profitably by delivering the top-quality products using cutting
edge technology at low cost.
Contents
Market Potential: - ............................................................................................................................... 1
Marketing Strategy – ........................................................................................................................... 1
Extrusion Cooking:- ............................................................................................................................ 2
Principle:- ........................................................................................................................................... 2
Popularity of extruded snacks food among consumer is due to – .................................................... 3
Classification :- ................................................................................................................................... 3
Characteristics of Extruded Product :- ............................................................................................... 3
Figure1 :- Different characteristics of product ........................................................................................... 3
Extruded food products :- .................................................................................................................. 4
Figure 2 :- Different types of extruded product ......................................................................................... 4
About TEDHE MEDHE :- ...................................................................................................................... 5
Figure 3:-TedheMedhe Masala Tadka ....................................................................................................... 6
BACKGROUND STUDY ........................................................................................................................ 7
Figure 4 : Global Extruded Snack Market ................................................................................................... 8
Figure 5:- Extruded Snack Market Growth & Size in India ...................................................................... 8
Materials Required for Extruded Products ........................................................................................... 9
RM (RAW MATERIALS) :- ............................................................................................................... 9
Equipment’s Required ........................................................................................................................... 12
Method: Process Line Flow Chart of Extruded Snacks ..................................................................... 15
Process Line Description ....................................................................................................................... 17
Blending Process: - ............................................................................................................................. 17
Extrusion Process – American single screw Random Extruder 850F ........................................... 18
Different parts &Recommended life span of extruder: - ............................................. 18
Effect of extrusion process parameters on quality characteristics of developed products :- ...... 19
Bulk Density (BD).............................................................................................................................. 19
Texture ............................................................................................................................................. 19
Moisture Content ............................................................................................................................. 19
Frying Process .................................................................................................................................. 20
Objectives......................................................................................................................................... 20
Control Factors of Fryer ................................................................................................................... 20
Frying Oil Quality Test ...................................................................................................................... 20
Seasoning Application ...................................................................................................................... 21
Slurry Preparation ............................................................................................................................ 21
Packaging ................................................................................................................................................ 22
Packing quality check– ...................................................................................................................... 22
 LeakageTest...................................................................................................................................... 22
Air fill test ......................................................................................................................................... 22
Bursting Strength ............................................................................................................................. 23
Perforation Testing........................................................................................................................... 23
QUALITY PARAMETERS OF FG : - ................................................................................................ 24
Online testing :- .................................................................................................................................. 25
Sample preparation for moisture & salt content – .......................................................................... 25
Moisture Content – .......................................................................................................................... 25
Salt Content - ...................................................................................................................................... 26
Procedure: ........................................................................................................................................ 27
Calculation:....................................................................................................................................... 27
Bulk density – ................................................................................................................................... 27
Bits & Pieces – ........................................................................................................................................ 29
Skinny –................................................................................................................................................... 29
Procedure to check Bits & Pieces and Skinny : ............................................................................... 29
Calculation:......................................................................................................................................... 30
Seasoning Coverage – ........................................................................................................................ 30
FG Analysis :- ..................................................................................................................................... 31
FFA (Free Fatty Acid) – .................................................................................................................... 31
Peroxide Value – .............................................................................................................................. 31
Result : .................................................................................................................................................... 33
Conclusion............................................................................................................................................... 35
Reference: ............................................................................................................................................... 36
LIST OF FIGURES
Figure 1 Different Characteristics of Product.............................................................................................................. 3
Figure 2 Different types of Extruded product ............................................................................................ 4
Figure 3 Tedhe Medhe Masala Tadka ........................................................................................................ 6
Figure 4 Global extruded snack market ..................................................................................................... 8
Figure 5 Extruded snack market growth & size in India............................................................................. 8
Figure 6 Halogen Moisture meter ............................................................................................................ 26
Figure 7 Auto titrator ............................................................................................................................... 27
Figure 8 Bulk density checking ................................................................................................................. 28
Figure 9 Bits & Pieces ............................................................................................................................... 29
Figure 10 Skinny ....................................................................................................................................... 29
Figure 11 Seasoning Coverage ................................................................................................................. 30
Figure 12 Free Fatty Acid testing ............................................................................................................. 31
Figure 13 Fat % testing ............................................................................................................................. 33

LIST OF TABLES
Table 1 Raw materials of product ............................................................................................................ 11
Table 2 Equipment’s for extruded snacks ................................................................................................ 14
Table 3 Different parts & recommended life span of extruder ............................................................... 18
Table 4 Quality parameters of Final product ........................................................................................... 24
Table 5 Result analysis ............................................................................................................................. 34
INTRODUCTION
The project assignment has been focused on Production, Analysis and Quality control of
Extruded tasty snacks.

The Indian food industry is poised for huge growth, increasing its contribution to the world
food trade every year. In India, the food sector has emerged as a high – growth and high –
profit sector due to its immense potential for value addition, particularly within the food
processing industry. The Indian Food & Grocery market is the world’s 6th largest, with retail
contributing 70% of the sales. As the foods category is growing in India, several food
companies are capturing the salty snacks market. Around 1000 snack items are sold in India
spanning various tastes, forms, textures, aromas, bases, sizes, shapes and fillings. The snack
market in India is rising multiple times annually, and the snack sector is rapidly expanding.
Namkeen is very popular fast-food item used in day-to-day life in almost all houses in the
country and also in abroad.

Market Potential: -
Demand & Supply – Namkeen manufacturing is primarily confined to the unorganized
sector. There are some national brands like Bingo, Haldiram, Lays, Kurkure, Balaji etc. but
their products are affordable andthus have limited market share. Bulk of the market is
controlled by the local brands. Market of these products is growing steadily and there are not
much seasonal fluctuations.

Marketing Strategy –Pricing is a critical aspect to complete with established

brands and the product has to be pushed through with the help of retailers. A small delivery van
is necessary. Requisite changes in the ingredients have tobe made in line with regional likings.
This is a standard practice in this industry as retailers from nearby centers prefer to bye them in
bulk for selling in local market.

1
 Extrusion Cooking:-
Extrusion cooking is a modern high – temperature short time (HTST) process
(thermo – mechanical process) which reduces microbial contamination and inactivates
enzymes.

• Extrusion technology is gaining increasing popularity in the global agro – food

processing.
• Extrusion cooking technologies are used for cereal and protein processing in food.
• The main method of preservation of both hot and cold extruded foods is by the low
water activity of the product (0.1-0.4), and for semi-moist products in particular, by the
packaging materials that are used.
• The extrusion process is remarkably adaptable in being able to accommodate the
demand by consumers for new product.
• Extruders operate at relatively low moisture while cooking food products, so less re –
drying is required.
• Extrusion has lower processing costs than other cooking and forming processes.
• Extrusion processing needs less space per unit of operation than other cooking system.

Principle:-
▪ The raw materials are allowed into the extruder barrel and the screw then convey the
food along it.
▪ Further down the barrel, smaller flights restrict the volume & increase the resistance to
movement of the food.
▪ As a result, it fills the barrel and the spaces between the screw flights & becomes
compressed.
▪ As it moves further along the barrel, the screw kneads the material into a semi-solid,
plasticized mass.
▪ If the food is heated above 100°C the process is known as extrusion cooking or hot
extrusion.
▪ Here, frictional heat and any additional heating that is used cause the temperature to rise
rapidly.
▪ High temperature of operation in presence of water promotes gelatinization of starch
components and stretching of expandable components.
▪ The food is then passed to the section of the barrel having thesmallest flights, where
pressure and shearing is further increased.

2
 ▪ Finally, it is forced through one or more restricted openings at the discharge end of the
barrel as the food emerges under pressure from the die, it expands to the final shape and
cools rapidly as moisture is flashed off as steam.

Popularity of extruded snacks food among consumer is due to –

▪ Versatility
▪ Cost
▪ Productivity
▪ Product quality
▪ Environmentally friendly

Classification :-
✓ Single screw extruder
✓ Twin screw extruder

Characteristics of Extruded Product :-

A variety of shapes, texture, colour and appearances can be produced which is not easily
formed using other production methods. The functional properties of extruded foods plays
an important role for their acceptability which include water absorption, water solubility, oil
absorption indexes, expansion index, bulk density and viscosity of the dough.

Figure1 :- Different characteristics of product

Figure 1

✓ Bulk density – The density of the final product depends upon the nature of the
solid material as well as the amount of the airspace within the product.
✓ Mechanical properties – Physical and rheological properties determine the
characteristics of the extruded products. These may be characterized by hardness
or crispiness or may be expressed as the fundamental parameters as elastic
modulus.
3
 ✓ Internal moisture – The arrangement of the components of the extruded products
leads to the physical properties described above. The state of starch, whether
partially or completely gelatinized in the final product strongly influences the
physical characteristics.
✓ Protein Quality – Nature of extruded proteins depends on the extruder operating
conditions such as temperature profile. High heat treatment causes denaturation of
many proteins, that influence physical characteristics such ad viscosity.
✓ Starch Characteristics – Properties of starch in an extruded product that influence
the quality characteristics such as water solubility index, water absorption index
and enzyme susceptibility. All these depend upon the operating parameter of the
extruder as well as the quality of the materials used.

Extruded food products :-

• Breakfast cereals including direct expanded cereals, filled cereals and flakes.
• Savoury snacks including direct expanded cereals, cereal chips, croutons, and
crackers.
• Crispy flat breads both filled and unfilled.
• Pre-cooked flours and cereal based baby food.
• Porous powders

Figure 2 :- Different types of extruded product

Figure 2

4
 About TEDHE MEDHE :-

TEDHE MEDHE is an innovative extruded snacks food format delivering multi

sensorial experience in a convenient random stick shape and having crunchy texture. Extensive
trials were conducted to finalize the process parameters for getting the desirable product.
Multiple consumer researchers were carried out to develop the consumer liked product texture
& flavors. In order to validate the final product design, extended long hours trials were carried
out with approved raw materials & set process parameters to get consistent texture/color and
product formation.

TEDHE MEDHE is made of ingredients like Rice meal coarse, Corn meal coarse
and Gram meal coarse. All these ingredients are blended together and moist with desired
quantity of water and then fed to the random extruder where it is extruded at high temperature
& pressure and form a finger like shape which is then partially dried before frying in a
continuous fryer. The fried product is then cooled to the recommended temperature before
feeding into a seasoning application system.

The specific seasoning is mixed with RBD Palmolein oil in a slurry kettle and
sprayed on the product at desired temperature & application rate to get the desired taste profile
and mouthfeel. The seasoned product is then taken onto a retention conveyor and transferred to
the packaging section on conveyors.

The packaging is done in flexible laminate pouches using VFFS machines and
nitrogen flushed to maintain oxygen content as per specifications. The finished product quality
checks are done as per the various quality norms as per finished product specifications and only
approved product is released for dispatch to market.

Namkeen is a broad term for salty snacks traditionally consumed in South

Asian cultures. Demand for Namkeen outside of traditional markets like India and South Africa
has grown significantly. Namkeen is a Hindi which means any small meal or amount of food
that tastes of salt.

Snack foods are typically designed to be quick, potable and filling. Processed
snacks are a form of convenience food that is designed to be more durable, transportable and
less perishable than homemade snacks.

5
➢ A typical process for BINGO! TEDHE MEDHE production will be as follows :-

1. Meal blend preparation

2. Extrusion
3. Fines removal
4. Frying
5. Seasoning application
6. Maturation on retention conveyor
7. Packaging

Figure 3:-Tedhe Medhe Masala Tadka

Figure 3

6
BACKGROUND STUDY
The snack food processes, which use extrusion cooking, include the
production of direct expanded extrudate and extruded pellets or half products of the
third-generation snacks. The extruded half products require a secondary puffing step.
Prior to consumption, the third-generation snacks are puffed in a fryer, or expanded in
hot air or a microwave oven.
Snack food technology of direct expanded and shaped snacks is similar to
RTE cereals processes, but normally performed at lower moistures, so that a higher
energy input from mechanical sources occurs.Direct expanded snacks are typically
puffy, crispy or crunchy cereal or starch ‘finger foods’ that come in a variety of shapes
and sizes and which are textured andoften coated to make them convenient, tasty & fun.
The demand of extruded snack foods is increasing day-by-day as they are
low in calories, healthy, tasty, easily affordable, and quick to made. The market is
currently being driven by increasing urbanization rates, rising disposable incomes,
changing lifestyles and food habits, especially the younger generation.
Historical market trends for the extruded snack food industry have been
provided 2008-2015 and forecasts have been presented till 2021. The global extruded
snack food market attained a value of USD 88.31 billion by 2022. The market is further
expected to witness a CAGR of 2.3% in the forecast period of 2023-2028 to attain USD
101.22 billion by 2028.
On a basis of material, the industry is divided into potato, corn, rice,
tapioca and mixed grains, among others.On the basis of types, the industry is
categorized into:
• Simply Extruded
• Expanded
• Co-Extruded

Based on extrusion method, the industry is bifurcated into Single screw processing and twin-
screw processing. The regional markets for the product include North America, Europe, the
Asia Pacific, Latin America and the Middle East and Africa.

7
 Figure 4 : Global Extruded Snack Market
Figure 4

Figure 5:- Extruded Snack Market Growth & Size in India

Figure 5

8
Materials Required for Extruded Products

RM (RAW MATERIALS) :-
Extrusion technology, have led to more diverse and complex formulations for snack
foods. To produce delicious, tasty, crunchy snack foods, the manufacturer must require
different types of raw materials. The most commonly used ingredients are –
1. Rice :- It is one of the largest crops grown in the world. Most of the snacks are made
with rice or rice flour. One major reason is the cost of rice as compared to that of other
snack food ingredients. Broken rice can be used as ingredient in expanded or puffed
snack products, since rice has good expansion qualities.Rice flour could be used for
texture improvement in multigrain snack foods.
2. Wheat :- In general, wheat can be classified into two types: hard and soft. Hard wheat
is higher in protein, produces stronger flour, and is better for bread making. On the
other hand, soft wheat is lower in protein and yields weaker flour, which is better for
cake making. In the snack food industry, wheat flour is used in formulation for making
baked and fried snacks, flavoured crackers, snack cakes, pretzels, bread, and the like.
Semolina (coarse particle), usually produced from hard wheat milling, is also used in
snack food formulation. The semolina product has an expansion ratio and bulk density
about the same as cornmeal. All semolina snack foods will produce a very crispy
texture. Snack products made with wheat usually have mild flavour and white to off-
white colour. It needs medium to low cooking temperature during extrusion cooking.
Milling by products (bran) can be used with soy protein and some other ingredients to
produce expanded snack foods of high nutritional and fibre value. The use of wheat in
snack food formulation is limited because of cost.
3. Corn :- Extruded snacks are a growing segment of the corn-based market. Corn (also
called maize) is a primary ingredient for corn collets and many pellet products. For
most corn-based extruded snacks, dry-milled cornmeal is used. Large quantities of
cornmeal are used in puffed extruded snack production and some are used in corn
chips. Cornmeal, corn grits, corn flour, and corn cones are all a different form of dry-
milled dent corn and in general vary only in particle size distribution. Selection of the
granulation depends upon the type of snack and type of extruder. For example, for fine
texture and cell structure, or softer bite, a fine granulation of cornmeal should be used,
whereas for crunchy texture with a slightly larger cell-structured snack, a more coarse

9
 granulation of corn meal is desired. Mostly, degermed corn is used in extruded snacks
because it expands better than whole corn. Yellow and white corns are most commonly
used in snack foods.
4. Gram :- it is not a major ingredient in the snack food formulation. Small amount of
gram is used for better taste.
5. Potato :- Different forms of potatoes (granules, flakes, flours, and starches) are used in
snack food formulations. Potato starch is often used in snacks to provide extra
expansion. Potato starch has a wide range of sizes with some granules (60–100 mm)
larger than the other cereals. This starch contains 20–25% amylose and has very low oil
contents. Potato starch develops high viscosity during extrusion cooking. It has an
excellent swelling and binding power. In snack food, it has a definite flavour and it
gives gold to light brown colour to the product. It requires low cooking temperature
since its granules break down easily. Potato flour is the major ingredient for two
common snack products, that is, direct expanded snack (product looks like French
fries) and fabricated chips.
6. Tapioca :-Tapioca (cassava) is a basic source of low calories or a supplement to cereal.
In general, tapioca starch is used in third generation snack food formulation. Tapioca
starch develops a very high viscosity and it is an excellent binder. It has a bland flavour
and requires moderate cooking temperature during extrusion cooking.
7. Sorghum :- The grains are edible and nutritious. It is a popular ingredient used in snack
food industry. In some places, Sorghum flour is used in combination with wheat flour
to make noodles & breads.
8. Oats :- In general, oats are marketed as rolled oats or as an ingredient for breakfast
cereal. Oats have not been used in grain-based snacks as wheat and corn. Recent
discoveries that oat bran can reduce serum cholesterol level in humans have boosted
the market for oats in the snack food industry. The major problem with oats is the high
oil content (7–9%) and lipase enzyme. Before using oats in the snack food formulation,
it is desirable to inactivate the lipase. Otherwise, lipase will catalyse the hydrolysis of
oil, which would lead to the reduction of bitter tasting free fatty acid. Oat starch has a
very strong flavour& it gives a light brown colour to the product. Oats contain high
levels of fibre. Snacks extruded with oat starch expand poorly. For this reason, it has
only found its way into products at low levels. By using longer barrel extruders with
preconditioner, a higher level of oats can be used in snack foods. Among the snacks
that have traditionally included oats in their formulation are cookies and granola. With

10
 new technologies and more interest in oats due to health claims, oat-based snack
products may be popular in the future.
9. Barley :- Barley is used in small quantities in some snack food formulations. It has a
mild flavour, and nutritionally, it is almost the same as wheat, except it contains
considerably more fibre. Barley starch granules are medium to large in size as
compared to other cereals. A reasonable amount of expansion can be obtained during
extrusion of snack foods using barley starch. It gives a light brown to gold colour to the
product. Snack food formulation containing barley starch needs a low cooking
temperature during extrusion. Barley fibre can be used in healthy snack foods as a fibre
supplement. Sometimes, manufacturers use barley in multigrain snack foods in order to
add one extra cereal on the label.
10. Rye
11. RBD Palmolein oil
12. Red chilliPowder
13. Salt
14. Seasonings

❖ For TMMT (Tedhe Medhe Masala Tadka) some specific raw

materials are used. These are –

Raw Materials
Rice Meal Coarse
Corn Meal Coarse
Gram Meal Coarse
RBD Palmolein Oil
Seasonings
Water
Table 1

Table : 1

11
Equipment’s Required

Machine Description Image

Ribbon Blender Used for blending solid
materials. It is the key
method for transforming
raw materials into
delectable & consumable
food. The consistency of
an industrial blender can
create the perfect texture
& appearance that a food
product requires.

Extruder It is a short bioreactor that

enables continuous
transformation of raw
ingredients into a wide
range of final products.
Extruders operate in a
similar manner, providing
transport, compression,
mixing, cooking, shearing,
heating, cooling &
shaping of raw material
final products.

12
Fryer The design of the fryers
are such that the minimum
amount of oil is utilized to
cook the products. This
allows fresh oil to be
continuously added to the
system giving a fresh taste
& long shelf life to
products.Continuous
industrial fryer has oil
filtration system & also
has pumping system for
transferring of oil from the
lower tank to the upper
tank.
Seasoning tumbler It is a tumbling device that
applies seasoning evenly
to a variety of products. It
is especially useful for
snack food manufacturers,
as it eliminates product
breakage & maximizes
flavor coverage.
Horizontal motion
conveying & applicator
evenly distributes
seasoning without
separation and minimizes
seasoning ingredient
usage.

13
Packing Machine Used to package products
or components. This
product area includes
equipment that forms,
fills, seals, wraps, clean &
packages at different
levels of automation.

Table 2

Table : 2

14
Method: Process Line Flow Chart of Extruded
Snacks
Blender

Meal transfer conveyor

Meal Sifter

Magnet

Cable conveyor

Extruder

Product conveyor

‘Z’ conveyor

Chaff tumbler

Vibratory conveyor

Fryer

De-oiling conveyor

Vibratory conveyor

Load shell (Weighing)

15
Load shell (Vibratory)

Seasoning tumbler

Retention conveyor

Vibratory feeder

Gooseneck conveyor

Bucket conveyor Cross feeder

Product infeed

Inlet chute

Dispersion feeder

Radial feeder

Pull hopper

Weigh hopper

Boost hopper

Timing hopper

Bag marker

Pouch
16
Process Line Description
Blending Process: -
The process of combining two or more ingredients together so that they lose their individual
characteristics and become smooth & uniform.
If a recipe is not blended or mixed properly ;taste, texture, colour and appearance of the final
product can all be affected.
Sequence of addition is very important to get uniform & homogenous mix, Rice meals added
first followed by corn meal then gram meal.

Flow chart for Meal Blending

Weigh the ingredients and fed the same into the Blender

Mix blending for 3mins (Shaft movement in forward for 90 sec and reverse direction for 90
sec)and take sample for dry meal moisture.

Basis of dry meal moisture, calculate water needs to be added.(Water addition in forward
direction only)

WetBlendingfor4-5mins

Check moisture % of wet blending, Target moisture and transfer the meal to the meal sifter

𝑇𝑀%−𝐷𝑀%

Water Addition– X(batch size)

100−𝑇𝑀%

17
Extrusion Process – American single screw Random
Extruder 850F
Food extrusion is a form of extrusion used in food processing in which a set of mixed raw
ingredients are forced through an opening or die with a design specific to the food, and is then
cut to a specified size by blades. The machine which forces the mix through the die is an
extruder, and the mix is known as the extrudate.

The process of combining two or more ingredients together so that they lose their individual
characteristics and become smooth and uniform.

The resulting expansion creates random shaped product which is cut and called collet.

Bulk Density of the Ex-extruder product is maintained to get desired texture & crunch into the
product.

Different parts &Recommended life span of

extruder: -
Extruder Part Maximum Life(hours)
Impeller 150
Cutter 150
Rotor Plate 450
Stator plate 450
Screw 875
Screw Nose Insert 3200
Rotor Nose Insert 3200
Rotor base 3200
Stator Base 3200
Cutter Ring 3200

Table 3

Table : 3

18
Effect of extrusion process parameters on quality
characteristics of developed products :-

Bulk Density (BD)

Bulk density and expansion ratio are dependent physical attributes. The increase
in bulk density corresponds to decrease in expansion ratio and vice-versa. Extrudate
expansion has been reported to be the most dependent on material moisture content and
extrusion temperature.
BD= M/V
If, M= mass
V= volume of container

Texture
In extruded foods, texture is of major importance, with crispness being often a
desirable attribute. Among other tests, the texture analysis of expanded snacks has been
performed through compression, penetration, acoustic procedures and texture profile
analysis. The main component which determines the texture of extruded product is flour
composition.

Moisture Content
One of the standard reference methods for moisture determination is the oven drying
method. Target moisture of extruder product is 8-10%. The samples placed for the moisture
analysis in the Halogen moisture analyser. Normally moisture analyser wills take 12-13 min for
results.

19
 Frying Process

Frying is a very complex process including simultaneous heat, mass and momentum transfers
accompanied by a series of physical and chemical reactions.

During the frying process, heat is transferred from oil to fried foods leading to mass transfer
(e.g., water evaporation and oil uptake).

Refined Bleached Deodorized Palmolein oil is used for frying.

Temp. of fryer should be maintained from190 –193°C.

Fryer submerging time should be maintained between 30-34sec.

After frying collets are removed from fryer by the takeout conveyer (53-55 sec).

Collet temp. at de-oiling conveyer should be less than 75º -80ºC.

Objectives
▪ Remove excess moisture from collets.
▪ Development of flavour in collets by addition of cooking oil.
▪ Make the collets light, crunchy & crispy texture.
▪

Control Factors of Fryer

▪ Fryer oil quality
▪ Fryer oil level & temp.

Frying Oil Quality Test

i. Check fryer oil temp.
ii. FFA, PV, & p-AV checking of oil at an interval of 4hrs.
iii. Checked fat content of Ex–Fryer.

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 Seasoning Application
➢ In this process something used to add taste or flavour to food, such as salt, spices & other
condiments.
➢ Seasonings are usually added near the end of the cooking process.
➢ Before seasoning tumbler there is a weight conveyor where collets will weight & accordingly
seasoning will get dispensed on the product (8%oftotalweight).
➢ There are nozzles in seasoning tumbler by which slurry are appropriately covering the collets.

Slurry Preparation
▪ Slurry is prepared in a stainless-steel kettle tank, with an agitator inside it operated using a
motor, by this motor seasoning & oil are mixed accurately.

Slurry= Seasonings + oil

➢ Seasoning kettle temp – 40ºC-45ºC

➢ Seasoning spray pressure – 6 bar

❖ After completion of seasoning application products are retained on the retention conveyor for
5 mins minimum.

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 Packaging

❖ Packaging is the science, art and technology of enclosing or protecting products for
distribution, storage, sale, and use.
❖ A satisfactory package for fried snack foods would need to provide a good barrier to oxygen,
light and moisture.
❖ Laminate is used for primary packaging.
❖ The temp.& humidity of packaging room should maintain <25°C & 50% respectively

Packing quality check–

Leakage Test

I. Microleakage–Minor leakage at horizontal seal.

II. Jaw Cut–Leakage at horizontal seal/cut at corner of the pouch due to wrong jaw
alignment.
III. Product/Chip in Seal/ Flavor in seal–Leakage due to collets entrapment in horizontal
seal area.
IV. Horizontal Seal Wrinkle-Wrinkle at horizontal seal area.
V. Seam Seal Wrinkle–Leakage at vertical seal area.
VI. Body Cut–Small pin hole on pack body other than seal area.

Air fill test

▪ The filling of the air in the pouches increases the size of pouches to a significant level.
▪ The air fill in the pouches provides a cushioning effect to the pouches so that the product is not
crushed during the transportation.
▪ 5 sample are required for the test.

Air fill in cm=Height in cm/Number of pouch.

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 Bursting Strength

▪ Vacuum Desiccator with Pump is used to measure the pouch bursting strength and micro leak
determination.
▪ If there is a leak, pouches will not show any deviation under vacuum and all the air will leak
out.

▪ In case of leak/burst follow the hold rejection protocol.

Perforation Testing

▪ Perforation test is used to quantify the perforation strength or tensile ability of perforated
materials like pouches.
▪ For determine the perforation value 2packs of a ladi is require to determine good perforation.
▪ The perforation value help us to determine the quality of ladi in market.

1 ladi = 12 pouches

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QUALITY PARAMETERS OF FG : -

PARAMETERS

Seasoning coverage(%)
Bits & Pieces(%)
Skinny(%)
Collet diameter(cm/20Nos)
Bulk density(g/lit)
Moisture content(%)
Total salt(%)
Seasoning application (%)
Fat on dry basis
FFA (%)
Acid value
Peroxide value(meq/kg)
Table 4

Table : 4

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Online testing :-
A common set of scientific techniques used to analyze, assess and record the
safety and viability of a product in terms of chemical composition while production
going on that needs to comply with the standards provided by the organization.
There are so many test included in online testing.

Sample preparation for moisture & salt content –

Grind the Final products in a mixer – grinder. All the ground particles should be of
approximately of the same size.

Moisture Content –
Moisture content is one of the most measured properties of food materials. It is important to
food scientists for several different reasons:

Legal and Labelling Requirements-

There are legal limits to the maximum or minimum amount of water that must be present in
certain types of food.

Economic-The cost of many foods depends on the amount of water they contain - water is
an inexpensive ingredient, and manufacturers often try to incorporate as much as possible in a
food, without exceeding some maximum legal requirement.

Microbial Stability-The propensity of microorganisms to grow in foods depends on

their water content. For this reason many foods are dried below some critical moisture content.

Food Quality-The texture, taste, appearance and stability of foods depends on the amount of
water they contain.

Food Processing Operations -A knowledge of the moisture content is often necessary to

predict the behavior of foods during processing, e.g. mixing, drying, flow through a pipe or
packaging.

Procedure–
i. Set the oven at 105 ± 2°C and it stabilize for about 30 min. Dry the moisture dish with
lid in the moisture oven for 30 minutes, followed by cooling in a desiccator and note
down the empty dish weight with the lid.

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 ii. Weigh 5 – 10 g of the sample into the previously dried and weighed moisture dish,
cover the dish transfer into oven.
iii. Place the dish & lid (uncovered) in the air-oven for 4.0 hours at 105 ± 1°C.
iv. Remove the dish and lid from the oven, cool in the desiccator while cooling make sure
dish should be covered.
v. Repeat the process of heating, cooling & weighing at half an hour interval until the
difference between two readings in less then 1 mg. Record the lowest mass.
vi. For Regular check in plant the drying time in oven should be 6.0 hours at 105 ± 1°C.
remove the dish from oven, cover with lid and cool in desiccator & measure the loss of
weight.
vii. For calibration of halogen moisture balance follow the constant weight after drying at
4.0 hours in oven at 105°C.

Calculation-
Moisture % = (M1 – M2) / (M1 – M) x 100

Where,

M = Weight of empty dish and lid

M1 = Weight of empty dish & lid + sample, before drying

M2 = Weight of empty dish & lid + sample, after drying

Figure 6: Halogen Moisture Meter

Figure 6

26
Salt Content -
Sodium is an essential ingredient in processed foods, but too much can be detrimental to health.
Accurate and efficient sodium determination is therefore necessary during food production and
quality control processes. It has to be reliable, accurate, precise, straightforward, and fast.

Procedure:
i. Weigh accurately 2.5 g of finely crushed sample into a titration beaker.
ii. Add 40 – 50 ml of 0.1 N sulphuric acid to make all chlorides available in the solution,
fix beaker into the titration stand.
iii. Go to method ID & select method ID number and then press Run button.
iv. Enter the sample weight & again press the Run button
v. When titration is completed, results are displayed on the titrator and print as each
sample is completed.

Calculation:
Salt content = Titer volume * Normality of AgNO3 * 58.45 * 100 / weight of sample x 100

Figure7:-Auto titrator for Salt content testing

Figure 7

Bulk density –
Bulk density is the mass of bulk solid that occupies a unit volume of a bed, including the
volume of all interparticle voids. Considering that a powder is really a particle gas mixture with
both interparticle spaces and intraparticle voids.

Procedure:
i. Place the empty beaker on the balance pan and record the weight.
ii. Fill the beaker with product to the brim. Level of the product using the template.
iii. Place the filled beaker on the balance & record the product weight in grams.

27
 iv. If it is not level, use fingers to the rearrange the top surface of the product until it is
level.
v. Note the volume to which the product is filled.

Calculation:
Bulk Density g/L = weight of sample/Volume of beaker

Figure8 :- Bulk Density checking

Figure 8

28
Bits & Pieces –
The phrase bits and pieces refer to small fragments of something or a miscellaneous assortment
of things. In bingo tedhe medhe, bits & pieces refers to small or broken collets which are less
than 30mm in size.

Figure9 :- Bits & Pieces

Figure 9

Skinny –
Skinny collets are those which lacks usual or desirable bulk, quantity, qualities, or significance.
Collets whose diameter is less than 8.5mm is a skinny collet.

Figure10 :- Skinny

Figure 10

Procedure to check Bits & Pieces and Skinny :

i. Take about 200gm of the product.
ii. Lay out collet on product inspection area.

29
 iii. Evaluate each collet & sort by defect type and priority. Each collet should be scored
only once, regardless of the number of defects.
iv. Weigh each category of defects to the nearest 0.1gm & record the weight.
v. Record the following information in the appropriate data sheet.

Calculation:
Bits & pieces % by Mass = 100 x weight of the product/Total weight

Skinny collet, % by Mass = 100 x weight of the skinny defect / Total weight

Seasoning Coverage –
It is the proper and uniform application of seasoning on the surface of collets. Brand
consistency is a key to long-term success, so variability of seasoning coverage can be a
problem in snack food manufacturing.

Figure11 :- Seasoning Coverage

Figure 11

30
FG Analysis :-
FG analysis means final goods analysis.

FFA (Free Fatty Acid) –

Free fatty acids (FFA) are produced by the hydrolysis of oils and fats. The level of FFA
depends on time, temperature and moisture content because the oils and fats are exposed to
various environments such as storage, processing, heating or frying.

Procedure:
i. Weigh about 5-10 g of extracted oil into dried 250ml conical flask.
ii. In a second conical flask take 95% ethyl alcohol & heat it to above 70°C and at this
temperature neutralize with NaOH using phenolphthalein as indicator.
iii. Add 50 ml of freshly prepared hot neutralized ethanol to the sample and boil the
mixture for about 5 min & titrate while as hot as possible with standard NaOH.
iv. End point is colorless to faint pink colour when phenolphthalein indicator is used.

Figure 12:- Free Fatty Acid testing

Figure 12

31
 Peroxide Value –

The PV is still the most common chemical method of measuring oxidative deterioration of oils.
Although hydroperoxides decompose to a mixture of volatile andnon-volatile products and they
also react further to endoperoxides and other products, the PV measurement is a useful method
of monitoring oxidative deterioration of oils, although it should normally be combined with a
method of monitoring secondary oxidation products to provide a fuller picture of the progress
of oxidation. A high PV value may reflect either increased formation of hydroperoxides or
reduced decomposition. Consequently, antioxidants may improve the flavour stability of an oil
without it being evident from PV measurements.

Procedure:

i. Weigh 5 gm of extracted fat in a 250ml glass stoppered Iodine flask & add 30ml of the
acetic acid-chloroform solution. Swirl the flask until the sample is dissolved.
ii. Add 0.5 ml of saturated potassium iodide solution. Allow the solution to stand exactly 1
min in dark and then add 50ml of distilled water.
iii. Titrate with 0.01 N sodium thiosulphate solution with constant & vigorous shaking
using 0.5 ml starch as indicator.
iv. Continue titration till the blue colour just disappears.
v. Conduct a blank determination of the reagents in the same way without sample
vi. End point is just disappearance of blue colour.

Fat% –

Fats are used in food industry for many purposes, mainly for cooking. Fats are important part of
many foods like 1. dairy products (butter, cheese), 2. Confectionery (toffees – vegetable fats are
added in sugar to make them chewer), 3. Meat (for marbling of meat products).

These fats acts as binding agents, flavoring agents, heating medium, textural & coloring agent
& also as main source of energy.

32
Procedure:

i. Weigh accurately 10 g sample into a cellulose extraction thimble.

ii. Place the thimble in the Soxhlet extractor
iii. Weigh the pre dried 250 ml flat bottom flask & set up the Soxhlet apparatus on the
water bath.
iv. Pour in about 150 ml of petroleum ether into the extractor.
v. Switch on the water bath and let allow the extraction to continue for 4 hours.
vi. After 4 hours evaporate the ether present in the flat bottom flask & dry the flask in oven
for 1 hour.
vii. Repeat the heating, cooling and weighing till constant weight is achieved.

Figure13 :- Fat % testing

Figure 13

33
Result :

TMMT (Tedhe Medhe Masala Tadka) Result Analysis Report

No. of Moistu Salt BD B&P Skinny FFA PV Fat% Seasoning

sample re (%) (%) g/L (%) (%) (%) (meq coverage
/kg) (%)
1 1.19 2.07 156 18.16 7.8 0.471 2.15 25.39 92.79
2 1.12 2.083 157 19.09 8.30 31.01 93.69
3 1.19 2.067 155 17.55 7.92 27.54 92.74
4 1.10 2.081 154 18.20 7.10 0.475 2.087 26.38 92.90
5 1.19 2.090 156 19.03 8.23 26.41 92.60
6 1.25 2.115 157 19.98 8.05 27.12 93.96
7 1.18 2.022 159 18.64 7.14 0.473 0.09 27.54 92.85
8 1.23 2.069 157 18.22 8.30 25.91 93.88
9 1.20 2.103 158 19.39 7.99 28.23 94.17
10 1.19 2.07 156 18.16 7.80 0.469 2.13 27.65 92.87
11 1.22 2.09 157 17.40 8.11 27.49 92.61
12 1.20 2.075 157 18.12 8.16 29.27 93.15
13 1.26 2.025 158 18.56 8.94 0.472 2.08 28.59 92.80
14 1.20 2.118 157 17.80 7.86 26.86 92.18
15 1.26 2.054 156 17.86 7.90 27.24 92.80
16 1.28 2.065 156 18.12 8.10 0.471 2.11 26.39 95.45
17 1.21 2.074 158 17.59 7.97 29.13 93.68
18 1.18 2.04 157 16.52 6.81 29.22 91.93
19 1.22 2.117 159 16.27 7.22 28.61 94.24
20 1.25 2.17 158 17.31 6.68 27.94 95.13

Table 5

Table : 5

34
Conclusion
Extrusion-technology is gaining increasing popularity in the global agro-food
processing industry, particularly in the food and feed sectors. In our study, starches and
protein of different nature are co-extruded and the product parameters influenced by
synergetic effects. Such inexpensive, high energy value products may be valuable in
feeding the hungry across the world as well as in promoting the health benefits of
extruded foods. This study focuses to develop the process for production of nutritionally
balanced formulated and functional snack foods which are successful in the market and
meet the intended nutritional requirements and are also accessible to the vulnerable
groups of the society at minimum possible cost. There was non-significant increase in
moisture content and hardness of products during three month of storage. It was aimed
to achieve this objective through use of abundantly available raw food ingredients
having high nutrition such cereals, as soybean, dairy products and horticultural produce
to minimize the cost and maximize nutrition.
Based on the project and analysis done throughout the period, the company
is expected to:
1. Have an ideal environment in quality lab as the project describes the significance of
the tests performed there.
2. Have lower number of market complaints compared to previous Year.
3. Better product quality.
4. Customer satisfaction.

This project helped me in gaining knowledge about-

1. The ground reality of the manufacturing units and culture followed there.
2. Enhanced my analytical skills, professional skills, leadership skills by working there
in every department possible.

35
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