TECHNICAL DOSSIER

READY-TO-USE
DOSA BATTER
IN RETAIL PACKS

CSIR - Central Food Technological Research Institute

MYSORE 570020
 CONTENTS

A PROCESS TECHNOLOGY
1.0 Product 1
1.1 Use
1.2 Specifications
1.3 Standards
1.4 Packaging and storage - specifications
2.0 By-products 1
3.0 Raw materials 2
3.1 Specifications
3.2 Standards
4.0 Process details 3-7
4.1 Process description
4.2 Flow diagram
4.3 Material and Energy balance
4.4 Process parameters
4.5 Critical steps
4.6 Detailed equipment specifications
4.7 Sensory parameters
5.0 Quality assurance 7-9
5.1 Laboratory facilities
5.2 Methods
6.0 General aspects 9
7.0 Man power 10
8.0 Market for product 10
B PROJECT AT A GLANCE 11
 TECHNICAL DOSSIER ON READY-TO-USE (RTU)
DOSA BATTER IN RETAIL PACKS

A. PROCESS TECHNOLOGY

1. PRODUCT: Ready to use dosa batter in retail packs

1.1 Use: The shelf stable ready to use (RTU) Dosa batter in retail packs is meant
for instant use by consumers.

1.2 Specifications:
 pH of the product : 4.0 ± 0.3
 Moisture content : 60 ± 2%
 Total acidity : 1.0 ± 0.3

1.3 Standards: Nil

1.4 Packaging & Storage specifications: Packed in plain PET/Polyethylene

transparent pouch. Can be stored at 30 ± 2ºC for 3-5 days. Transfer to
refrigerator if storage required beyond 5 days. If stored in refrigerator, the
product should be used within 10 days from the date of manufacture.

2. BY PRODUCTS : Nil

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 3. RAW MATERIAL

3.1. Specifications:

3.1.1 Dehulled Black gram dhal: Good grade cleaned dehulled black gram (urad)
dhal.

3.1.2 Rice: Raw rice of good grade cleaned.

3.1.3 Salt: Powdered common salt of commercial grade.

3.1.4 Packaging materials: Gas barrier transparent film of 12 µ polyethylene

terepthalate (PET)/ 37.5 µ low density poly ethylene (LDPE). This material is
made into 11″× 9″ pouches.

3.1.5 Microbial culture:

3.1.6.1 Yeast culture:

Pure and active cells of Candida versatilis

3.1.6.2 Bacterial culture:

Pure and active cells of Pediococcus pentoseceus

3.2 Standards : Nil

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4.0 PROCESS DETAILS

4.1 Process description:

4.1.1 Preparation of dosa batter (32 kg batch): The dry dosa ingredients,
dehulled Black gram dhal and raw rice in 1:4 (3.0: 12.0 kg dry weight) ratio
respectively are cleaned, weighed separately into stainless steel (SS) [20 L
cap.] containers. Fenugreek seed 60 g (at 2.0 g/kg of dosa batter) is weighed
and added to the black gram dhal. The containers are tightly closed with SS
lids and loaded into horizontal autoclave and steamed under free flowing
steam for 20 min. Steamed black gram dhal fenugreek seed mix and raw rice
are soaked separately for ten hours using boiled and cooled potable water
followed by washing in the same quality water. Black gram dhal and
fenugreek seed mix ground to a thick paste in a wet grinder using boiled
cooled water. The raw rice is also ground separately to a thick paste in a wet
grinder and mixed with ground Black gram dhal. Common salt is added to the
batter at 0.6% level.

4.1.2 Addition of culture: The freshly prepared starter cultures (refer section 5.0)
of Candida versatilis and Pediococcus pentosaceus are added to the batter at
2x104 cfu/Kg and 2x101 cfu/Kg of batter, respectively.

4.1.3 Packaging of dosa batter in retail packs: The dosa batter is packed as
500 g units in plain transparent PET/LDPE pouches (refer section 5.0). The
pouches are sealed at top, leaving space for accumulation of gases produced
in situ during batter fermentation, labeled and stored at 30 ± 20 C. To enhance
its stability beyond 5 days, it is required to be stored in a refrigerator for an
enhanced shelf life of upto 10 days, from the date of manufacture.

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4.2 Flow diagram for dosa batter preparation

DRY DOSA INGREDIENTS

RAW RICE (12 Kg) DEHULLED BLACK GRAM DHAL (3 Kg)

FENUGREEK SEED (60 g)

Clean Clean

Free flowing steam (20 min.) Free flowing steam (20 min.)

Soak in potable water (10 h) Soak in potable water (10 h)

Wash in potable water (twice) Wash in potable water (twice)

Grinding in Wet Grinder Mix Grinding in Wet Grinder

Add common salt (0.6%)

Inoculate with Starter cultures

(Candida versatilis 2x104 cfu/kg & Pediococcus pentosaceus 2x101 cfu/kg batter)

PET/LDPE pouches (11x9 inch size)

UV Sterilization (10 min.) Pack Batter (500 g units)

Heat Seal

In situ fermentation
(30+20C/24 hrs)

Ready for sale

Store at 30 ± 20C (4-5 days)

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4.3 Material and Energy balance for dosa batter preparation

a. Material Balance

Black gram dhal 3 kg

Raw rice 12 kg

Water (soaking, grinding, starter culture, etc.) 17 ± 2 kg

Table salt (0.6%) 180 g

Batter weight 32.18 ± 2 kg

b. Energy requirement

Sl. Energy
Parameter
No. (in Watts)

1. Boiling of 50 liters water (for soaking & 1500

washing)

2. Steaming of ingredients for 20 min. 5000

3. Grinding of black gram dhal 1500

4. Pouch making & sealing 250

5. Centrifugation of cultures 250

6. Miscellaneous 500

Total 9000

4.4 Process parameters: The following are the process parameters for batter
preparation:

 Moisture content
 pH of batter: Initial and after fermentation
 Acidity of batter: Initial and after fermentation
 Fermentation temperature

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4.5 Critical steps:

1. Boiling and cooling of potable water.

2. Steaming of raw ingredients: to reduce the initial microbial load.

3. Wet grinding of Black gram dhal and raw rice: Should be carried out
under hygienic conditions at the shortest time.

4. Preparation of starter culture and addition of culture to batter:

Cultures should be active and pure.

5. Packing of dosa batter in poly packs (pouches): while making

pouches and during packing GMP should be followed.
6. Holding the retail packs at 30+20 C.

7. Labeling the pouches with batch No, date of manufacture, date of

expiry (best before date).

8. Instruction sheet should be self-explanatory and contain appropriate

safety instructions.

4.6 Detailed Equipment Specifications:

Sl. No.
Items
No. required
1. Table top weighing m/c – 15 kg cap (with digital display) 1
2. Steaming unit 1
3. Wet grinder – 15 L cap. 1
4. Portable heat sealer – 12” sealing area, 350 w 1
5. pH meter 1
6. Incubator (Bacteriological) 1
7. B.O.D. incubator – 250 L cap. 1
8. Centrifuge – 10,000 rpm speed (Lab Model) 1
9. Portable autoclave – 15 L cap. 1
10. SS vessels with tight lids – 50 L cap 1
SS Vessels – 25 L cap 1
11. Refrigerator – 165 L cap 1
12. Vortex mixer 1
13. Water distilling unit 1
14. Table top balance with 0.01 g sensitivity and 2 kg cap 1
15. UV light 1
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4.7 Sensory parameters: Freshly prepared batter should have no off flavor, and
should be white in colour. It should not have high acidic taste. After
fermentation, yeasty flavor can be observed immediately after opening the
pouch. It may impart slightly fermented acidic taste.

5.0 Quality assurance

5.1 Laboratory facilities:

A. Glassware

Qty.
Items
(Nos.)
Petri plates (9 cm diameter) 25
Test tubes (18x150 mm) 100
Burette (10 ml cap) 1
Pipettes (10 ml cap) 4
Pipettes (1 ml cap) 3
Conical flasks – 200 ml 12
100 ml 6
Beakers – 100 ml 6
Autoclavable centrifuge cups – 100 ml 4

B. Miscellaneous items:

 Non-Absorbent cotton rolls

 Disinfectant solution
 Aluminum foil rolls
 Test tube stands
 Inoculation needles
 Latex hand gloves – 18” (full size)
 Tissue paper rolls

C. Chemicals and Media

 Sodium chloride
 Potato dextrose broth and Agar
 MRS Lactobacillces broth and Agar
 Ethyl alcohol

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5.2. Method

5.2.1 Preparation of starter cultures:

To ferment the dosa batter, starter culture inoculum is added to the batter.
Prepare 100 ml each of potato dextrose (PD) broth and deMan Rogosa
Sharpe (MRS) Lactobacillus broth by following the instructions given on the
media bottles. Autoclave (sterilize) the media at 1210 C (15 lbs) for 15 min..
The culture of Candida versatilis CFR 505 is grown for 72 h at 25-300C in PD
broth. The culture of Pediococcus pentosaceus CFR 2123 is grown for 48 h at
370C in MRS broth. The cells of both the cultures are harvested by
centrifugation at 8000 rpm for 20 min at ambient temperature. Harvested cells
are washed with sterile 0.85% saline and recentrifuged to obtain the cells,
which are then suspended separately in 10 ml of sterile saline, and stored in
refrigerater until use. The cell suspension of Candida versatilis is diluted using
sterile saline so as to get 2x104 cfu (colony forming units) per kg batter.
Likewise the Pediococcus pentosaceus cell suspension is diluted to get 2x101
cfu per kg batter.

5.2.2 pH determination of batter: Take around 50 g of dosa batter into a 100 ml

glass beaker and mix the contents thoroughly. Dip the electrode of pH meter
into the batter and press the pH button. Make a note of the pH reading
displayed on the instrument.

5.2.3 Titratable acidity: Weigh accurately 1.0 g of batter into a 100 ml conical
flask. Add 9 ml of distilled water and 2-3 drops of 1% phenolphthalein
indicator and mix thoroughly. Titrate with N/10 sodium hydroxide solution and
record the volume of sodium hydroxide required to neutralize the acid
produced during fermentation. Multiply this value with 0.9 to get the
percentage titratable acidity of the product.

5.2.4 Pouches: Procure pouches of the quality as mentioned in section 3.1.4 Store
the prepared pouches in airtight container. Just before use, keep the pouches
under UV light for 10 min. The distance between the UV sources and pouches
should not be more than one foot. Now the pouches are ready to use.

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5.2.5 Packing the batter: Immediately after filing the pouches with half kg quantity
(500 g) of batter wipe the topside of the pouch and seal the pouch at the top.
Clean the external surface of the pouches to remove adhered batter to avoid
microbial growth.

6. General aspects:

6.1 Special regulations concerning production/product: As the product is a

food item with high moisture content, Good Manufacturing Practices (GMP)
should be strictly adhered to throughout the manufacturing of batter.
Maintaining personnel hygiene, equipment sanitation and environment
disinfections are must. Using sterile hand gloves (full size), nose mask and
headgear should be made compulsory. Keep the manufacturing areas free
from flies, insects, rodents and dust, as these are the carriers of
microorganisms that can spoil the product. Cleaning and sanitizing the
equipment (especially the wet grinder and vessels) immediately after
manufacturing of each batch should be carried out.

While grinding, the wet grinder should be covered with a transparent sheet or
see through type cover, to reduce the exposure of the batter to external
environment. The manufacturing steps like washing, grinding, mixing, addition
of culture and salt, packaging should be completed in one sequence with no
time gap in between the steps, to avoid unnecessary contamination from work
environment and cross contamination from negligence on part of the
personnel. Care should be taken while handling and preparing the slant
cultures.

a. Critical inputs-ingredients and equipment: All the equipment, raw material,

starter cultures and packing material are locally available. Hence, no need of
importing.

b. Nature of effluents and wastes, recommended disposal: The main and only
effluent from this process consists of wash water of dhal, rice, fenugreek
seeds and equipment wash water, which consists mainly of proteinaceous
material. For large-scale process, sedimentation or setting tanks can be used
prior to disposal of waste water.
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7. Man power: Two persons per shift of 8 hours are required to handle this
process with up to 50-100 kg per batch. Out of two, one should be capable of
handling microbial cultures and doing microbiological work.

8. Market for product: Any retail outlet of provisions and or milk products/
supermarkets in cities. As it is a ready to use convenience food item there will
be lot of market potential for this product once it enters the market.

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 B. PROJECT AT A GLANCE
1. Products manufactured : DOSA BATTER IN RETAIL PACKS
2. Production Schedule
Days Capacity
300 90 Ton/annum
3. Expected capacity Utilization
1st Year = 60% 2nd Year = 75% 3rd Year = 90% onwards
4. Estimated Project cost
Capital Outlay Rs. in '000
1 Land 250
2 Building 500
3 Principal Plant & Equipment 288
4 Auxiliary Equipment 188
5 Other fixed asset 90
6 Preliminary/Preoperative expenses 227
7 Working Capital (Margin) 193
Total Project Cost 1736
5. Means of Finance
Borrowed fund 986
Equity capital 749
Debt : Equity 1.32:1
6. Utilities
a) Electricity (kWh) 20025
b) Water requirement (kL) 300
7. Employment Potential
a) Administrative staff 3
b) Production staff 2
c) Merchandising staff 1
8. Annual sales return 3150
9. Breakeven point (% capacity utilization): 51.34
10. Simple return on investment ( % ) 38
11. Payback period : in years 2.61

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