TECHNICAL DOSSIER

READY-TO-USE
IDLI 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 2-7
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 10
6.1 Special regulations concerning production / product
6.2 Critical inputs
6.3 Nature of effluents and wastes, recommended disposal
7.0 Man power 11
8.0 Market for product 11
B. PROJECT AT A GLANCE 12
 TECHNICAL DOSSIER ON READY-TO-USE (RTU)
IDLI BATTER IN RETAIL PACKS

A. PROCESS TECHNOLOGY

1.0 PRODUCT: Ready to use Idli batter in retail packs

1.1 Use: The shelf stable ready to use Idli batter in retail packs is meant for
instant use by the 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.

2.0 BY PRODUCTS : Nil

1
 3.0 RAW MATERIAL

3.1 Specifications:

3.1.1 Dehulled Black gram dhal: Good grade, cleaned and de-hulled black gram
(urad) dhal.
3.1.2 Rice Semolina: Commercially available double cleaned rice grits of 1-2 to
+44 BSS size.
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:

3.1.5.1 Yeast culture:

Pure and active cells of Candida versatilis

3.1.5.2 Bacterial culture:

Pure and active cells of Pediococcus pentosaceus

3.2 Standards : Nil

4.0 PROCESS DETAILS

4.1 Process description:

4.1.1 Preparation of Idli batter (30 kg batch): The dry Idli ingredients, de-hulled
Black gram dhal and raw rice in 1:4 (3.0: 9.0 kg dry weight) ratio, respectively
are cleaned weighed separately into stainless steel (SS) [20L capacity]
containers. 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 is soaked separately for ten hours using boiled and
cooled potable water followed by washing in the same quality water. This is
then ground to a thick paste in a wet grinder using boiled cooled water. The
steamed rice semolina is washed once in boiled and cooled water and mixed
with ground Black gram dhal. Common salt is added to the batter at 0.6%
level.

2
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
2×104 cfu/kg and 2×101 cfu/kg of batter, respectively.

4.1.3 Packaging of Idli batter in retail packs: The Idli 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 ± 2ºC. To enhance
its stability beyond 5 days it is required to be transferred to a refrigerator.

3
4.2 Flow diagram for idli batter preparation

DRY IDLI INGREDIENTS

RICE GRITS DEHULLED BLACK GRAM DHAL

(3 parts) (1 part)

Clean Clean

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

Soak in potable water (10 h)

Wash in potable water ( 2 parts)

Grinding in Wet Grinder

Wash in potable water (2 parts) Mix
(1 part of potable water used)

Batter

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)

4
4.3 Material and Energy balance for idli batter preparation

a. Material Balance

Black gram dhal 3 kg

Rice grits 10 kg

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

Table salt (0.6%) 180 g

Batter weight 30 ± 2 kg

b. Energy requirement

Sl. Energy
Parameter
No. (in Watts)

1. Boiling of 50 L water (for soaking & washing) 1500

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

5
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 rice grits: Should be carried out
under hygienic conditions in the shortest time.

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

Cultures should be active and pure.

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

and during packing GMP should be followed.

6. Holding the retail packs at 30  20C.

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 100 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

6
4.7 Sensory parameters: Freshly prepared batter should have no off flavor,
white to off 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 dia.) 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 Lactobacillus broth and Agar
 Ethyl alcohol

7
5.2 Method:

5.2.1 Preparation of starter cultures:

To ferment the Idli 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 1210C (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 refrigeration 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. Like wise 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 Idli 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 20 min. The distance between the UV sources and
pouches should not be more than one foot. Now the pouches are ready to
use.

8
5.2.5 Packing the batter: Immediately after filling 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.

9
6.0 GENERAL ASPECTS

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

food item with high moisture content, Good Manufacture Practices (GMP)
should be strictly adhered to throughout the manufacture of batter.
Maintaining personnel hygiene, equipment sanitation and environment
disinfection are must. Use of 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 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.

Critical inputs-ingredients and equipment: All the equipment, raw materials,

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

Nature of effluents and wastes, recommended disposal: The main and only
effluent from this process consists of wash water of dhal, rice, grits 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
in drain.

10
7.0 Man power: Two persons per shift of 8 h are required to handle this process
with upto 50-100 kg per batch. Out of the two, one should be capable of
handling microbial cultures and doing microbiological work.

8.0 Market for product: Any retail outlet of provision 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.

11
 B. PROJECT AT A GLANCE

1. Products manufactured IDLI 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) 189
Total Project Cost 1732
5. Means of Finance
Borrowed fund 986
Equity capital 745
Debt : Equity 1.32:1
`6. Utilities
a) Electricity (kWh) 19950
b) Water requirement (kL) 30
7. Employment Potential
a) Administrative staff 3
b) Production staff 2
c) Merchandising staff 1
8. Annual sales return 2970
9. Breakeven point (% capacity utilization): 50.82
10. Simple return on investment ( % ) 39
11. Payback period : in years 2.55

12