Ref/ File No: -----------------------

Annual Progress Report for 2020-21

1. Project title: Technological solutions for value addition of sugarcane juice through scientific
jaggery production and developing Iron fortified jaggery in kandiarea of District
Hoshiarpur”

2. PI(Names & Address): Dr. Mahesh Kumar

Professor cum Head
Department of Processing and Food Engineering
College of Agriculture Engineering & Technology
PAU, Ludhiana
3. Co-PIs (Name & Address): Dr. Gagandeep Kaur Sidhu
Principal Scientist
Department of Processing and Food Engineering
PAU, Ludhiana
Dr. Preetinder Kaur
Principal Scientist
Department of Processing and Food Engineering
PAU, Ludhiana
Dr. Kiran Bains
Professor cum Head
Department of Food and Nutrition
College of Community Science
PAU, Ludhiana
4. Date of Sanction: PSCST/336 & 29.03.2020
5. Total approved project cost & duration: Rs 40,66,880/- for two years
6. Approved objectives of the project:
i. Process optimization of jaggery manufacturing from sugarcane juice to produce chemical free
jaggery with better shelf life and stable taste.
ii. Development of Iron fortified jaggery as functional product.
iii. R&D studies to enhance the shelf life of jaggery including suitable packaging material.
iv. Setting up of demonstration units at farmers’ fields for generating local bio-resource based
enterprise and on-farm training programs pertaining to technical knowhow of jaggery making for
farmers of the region.
7. Objective-wise achievements in the project:

i. Process optimization of jaggery manufacturing from sugarcane juice to produce chemical

free jaggery with better shelf life and stable taste
 The process of manufacture of chemical free jaggery has been modified by including use of
quality assessment gadgets like refractometer, pH meter, Laser temperature gun etc. The
measurement of juice TSS (target 19% and more) and its acidity (approx 6.4) using safe
neutralizer prepared out of food grade lime stone helped to produce adulteration free quality
jaggery having better storage life.
  To improve the juice recovery, horizontal crusher having three rollers with sharp grooves
for tearing and crushing of cane instead of traditional three vertical crusher has been
incorporated. This modification has potential to increase the juice recovery by 10%.
 To check the losses of final processed product i.e. jaggery, its moisture content is of vital
importance. Freshly prepared jaggery has moisture content in the range of (13-15) %. At this
moisture content, jaggery deteriorates shortly within one and half month depending upon the
storage temperature. The current method proposed by FSSAI for assessment of moisture
content is cumbersome and time consuming. Moreover it require competent worker to carry
out this measurement. Hence a quicker method employing microwave oven has been used to
indicate the moisture content of jaggery quickly for ready reference has been formulated.
(Annexure1).

Va
cuum Oven
Weighing scale

Micro
wave Oven Final dried sample

 The storage structure (approximately 10 ton capacity) for safe storage of jaggery for a period of
six to seven months is required to be designed, constructed and tested. Similarily a quality control
laboratory to guide and act as calibration/reference unit needs to be set up at the Department of
Processing and Food Engineering, PAU, Ludhiana. The unspent funds out of NRC grant of 15
lakhs provided for the first year be revalidated for this purpose.
 The study for optimization of packaging for shelf life enhancement of jaggery is in
progress.
ii. Development of Iron fortified jaggery as functional product
 The iron salts has been standardized, for fortification of jaggery cubes. Firstly, three food grade,
cost effective and with good bioavailability iron salts namely Ferrous Fumarate, Ferrous
Ascorbate and Ferric Ammonium Citrate has been selected and amount of salts were planned
according to WHO recommendation i.e. fortification of iron not more than 50% of RDA, so all
three salts were used to standardize (Figure 1) the salt content in such amount that candies
provide 2,4,6,8, 10 & 20 mg of elemental iron (bioavailable iron) per candy (Annexure 2a). On
the basis of Sensory evaluation (Annexure 2b) of the samples the combinations which are best in
terms of overall acceptability and has been selected for bulk production. The samples with salt
Ferric Ammonium Citrate which provide 2,4 and 6 mg elemental iron (bioavailable iron) per
candy with 1.2 , 2.3 and 3.4gmper kg(Annexure 2c) has been produced. The distinct feature for
use of C6H11FeNO7 for this fortification is its solubility in water and cane juice. It has
an INS number (International Numbering System for Food Additives) and is used as
an acidity regulator in beverages. Fortified jaggery candies of weighing 5 gms has been produced
in the jaggery processing plant(Figure 2) and samples sent for evaluation of its bioavailability
analysis to NABI. The results depicted that the candy with 6mg iron per 10grams with mango
flavor is best in terms of iron bioavailability (Annexure 2d) so to evaluate impact on hemoglobin
and iron stores in people a sample of reproductive age group women (14-50 years) has been
selected for dietary supplementation. The Hb of women has been checked before
supplementation and will be checked again after 180 days of supplementation. The experiment is
still going on.

Figure 1: Standardization of Iron Salt

 Figure 2: Bulk production of Iron fortified jaggery at Jaggery Processing Unit at Khudda

iii. R&D studies to enhance the shelf life of jaggery including suitable packaging material

The prepared jaggery has been packed in different types of packaging material and stored
under ambient conditions. The Vacuum packed jaggery has shown the best results in terms of
moisture gain, color, texture and Sensory Evaluation.

iv. Setting up of demonstration units at farmers’ fields for generating local bio-resource
based enterprise and on-farm training programs pertaining to technical knowhow of
jaggery making for farmers of the region : As per this project, specifications for modern
three pan jaggery plant have been formulated after discussion with the academia and
industry. This unit has been procured from an enterprise duely certified by Indian Institute of
Sugarcane Research following tendering process. The EOI for supporting
SHG/FPO/Cooperative etc were called through advertisement in the “The Ajit’ The
Applications received were scrutinized by a committee and based on the recommendation of
the committee, a FPO namely FAPRO, at village Ghugial in District Hoshiarpur was
selected for establishing Modern Jaggery Processing Unit with following specifications:
S NO Specifications
1. Three Pan Jaggery Unit
1. Sugarcane Crusher having capacity 1ton of cane per hour
Heavy, CI. roller sugarcane crusher with planetary gear box & motor etc. Mills-C.I. Graded Rollers
– 3.
A - Roller Dia - 213mm – Length - 216 mm, A-Roller Groove- 6 mm.
B - Roller Dia - 213 mm – Length - 216 mm, B- Roller Groove - 6 mm.
C - Roller Dia - 196 mm – Length - 216 mm, C- Roller Groove - 12 mm.
Mill base fabricated from M.S. Channels.

Motors: 7.5 hp Electric Motor and electric starter panel, one time lubricants filling like Oil &
Grease

24” Juice Filter

Contact Parts: - S.S. 304, Non Contact Part :- MS Painted, Double deck machine
Mesh Size :- 1st – 80 mesh # & 2nd - 100 mesh #, With Electric motor 0.5 H.P
2. M.S. filter tank with 2” nipple; Juice collecting tank with screen Juice transferring pump:
With Piping’s
Open pan set (kadai) 1 set
 Main M.S. Open Pan Round-1 Nos., Pan Length-1525 mm., Thickness of Pan-25 mm., Pan
Deepness-80 mm., Border (Collar) Thickness-6 mm., Border (Collar) Height-220 mm., Pan
Handles Thickness 25 mm-4 Nos.
 2nd M.S. Open Pan Round-1 Nos., Pan Length-1525 mm., Thickness of Pan-20 mm., Pan
Deepness-80 mm., Border (Collar) Thickness-6 mm., Border (Collar) Height-220 mm., Pan
Handles Thickness 25 mm-4 Nos., Juice Exit Bottom Pipe-50 mm., Gate Valve (Brass) 50
mm-1 Nos.
 M.S. Gutter Pan-1 Nos., Base Thickness-12 mm, Base size-L-1524 mm x W-914 mm., Side
Plates Thickness-6 mm., Side Plates Size-L-1524 mm x H-204 mm–2 NOS, L-914 mm x H-
204 mm-2Nos., Angle Iron-35 x 5 mm., Outlet Pipe-Length-6”, Dia-50 mm (4”)., Brass Gate
Valve-50 mm.
3. Accessories: C.I. Fire Bar-1 Set, M.S. Tank for Bhindi Juice 1.5’ x 1.5’-1 Nos., M.S. Tank for
Juice Mud 1.5’ x 1.5’ with Nipple & Gate Valve-1 Nos., Scoop Small with S.S., Handle (for
juice transferring one pan to another)-2 Nos., Scoop Big with S.S., Handle (for juice transferring
one pan to another)-2 Nos., Scum Remover with S.S., Handle-2 Nos., Wooden Laddle with S.S.
Handle-1 Nos., S.S. Khurpa with S.S. Handle-2 Nos., S.S. Supdi with S.S. Handle-1 Nos., S.S.
Pawdi with S.S. Handle-1 Nos., Stainless Steel Mug Big-1 Nos., Stainless Steel Mug Small-1
Nos., S.S. Jaggery Transfer Plate-1 Nos.
4. Jaggery cooling pan: Granite Top, M.S. Structure, With Trolly & Wheels, Pan Size-60” x 36”
x 9”, Trolly Size-61” x 51” x 10.5”.
5. Jaggery mould table: Size-25” X 60”, Structure-M.S. With Granite Top, Wheels With Locking
System-4 Nos.
6. S.S. jaggery moulding frame
a. Mould Size-1” x 1” x 1”-20 Grams Each, Frame Size-23.5” x 22”,
b. Mold Size – 1” x 1” x 0.5” – 10 Grams Each, Frame Size – 23.5” x 22”
2. Jaggery sale counter, Packaging machine, Packaging films, Jaggery quality control gadgets at Site,
minor civil/electrical(location based eg chimney height in state fixed to 10 m (30ft) approx by
Punjab Pollution Control Board)
The above said units were set up under the technical guidance by PAU. The farmers have produced
about 200 quintal throughout the previous season in comparison to earlier production of only 65-70
quintal & provided the employment to 14-16 people by hiring them as workers and around 25 farmers of
the district have sold their sugarcane crop for jaggery production. The developed product received a
good market response as the marketing linkages were provided by Markfed Punjab & Punjab Agro.
They have sold their products at Rs 65-120 per kg against the last year rate of Rs 55/- per kg. Moreover,
their value added jaggery (peanut infused square shaped) has created different hype among the
consumers and they have sold around 800 kg jaggery as gift packages for various occasions like
birthday celebrations, marriages etc. For the upcoming season the orders has been already booked for
around 25 Quintal jaggery as Gift packages and the unit has the mission to achieve a total production
of 500 Quintal jaggery in the next season.

Particulars Before After

Annual Production of Jaggery(Quintal) 65-70 200

Labour Hired 3 14

No. of Farmers sold their crop 5-7 25

Cane Crushed during whole season 700 2000

(Quintal)

Selling Cost Per kg Plain Rs.55 Plain Rs.55

Masala Masala Rs. 70
Rs.70 Square Shape
Rs.120
Per season utilization of plant by 3 Farmers Around 10 Farmers
 8. Interim modification of objectives/ methodology, (if any with justification): Nil

9. Numbers of training & demonstration/ awareness programme conducted (in tabular form):

S. Purpose Organizing Place Date

No Departments
.

1 One day training (online) Directorate of Extension Pakhowal 23.11.2020

course on safe processing of Education & Department -
sugarcane juice into of Processing and Food
adulteration free jaggery. Engineering, PAU,
 Ludhiana

2 One day Training Program Punjab State Council for Village Chaharke 11.01.2021
on scientific and hygienic Science and Technology, , Distt Jalandhar
Jaggery production by using Chandigarh&Departmen
quality control equipments. t of Processing and Food
Engineering, PAU,
Ludhiana.

3 One day training program on Punjab State Council for Village Ghugial, 25.01.2021
Scientific and hygienic Science and Technology, Block Bhunga
jaggery production. Chandigarh&Departmen District
t of Processing and Food Hoshiarpur
Engineering, PAU,
Ludhiana.

4 One day training program on Department of RSS, 18.02.21

sensitization of quality Processing and Food BallowalSaunkri
control equipments for Engineering, PAU, District
making scientific and Ludhiana. Hoshiarpur
hygienically safe jaggery.

5 One day training program on Punjab State Council for KVK, Bahowal, 22.02.2021
sensitization of quality Science and Technology, Block Mahilpur
control equipments for Chandigarh&Departmen District
making scientific and t of Processing and Food Hoshiarpur
hygienically safe jaggery. Engineering, PAU,
Ludhiana.

6 One day training program on Punjab State Council for Village Khudda 10.03.2021
sensitization of quality Science and Technology, Block Dasua
control equipments for Chandigarh&Departmen
District
making scientific and t of Processing and Food
Hoshiarpur
hygienically safe jaggery Engineering, PAU,
and discussion regarding
 benefits available to jaggery Ludhiana.
processing units under
PMFME Scheme.

10. Numbers of beneficiaries trained in the project: More than 850 beneficiaries have been
trained under the project duration of 2 years under various trainings organized by PAU and
PSCST in collaboration as well as PAU solely.

11. Self-employment generated/ entrepreneurship development on the basis of technologies

demonstrated under the project:

The plant at FAPRO has been erected and made fully functional towards the end of crushing season. A
good number of interested entrepreneurs have visited this site with the intention to install similar unit.
They are successfully running the plant and has been delivered around 200 Quintal jaggery in different
variety of products such as Plain Jaggery, Shakkar, Masala Gur, Peanut Gur (Square shape) etc. Around
50 farmers and workers have got the employment either in direct and indirect form. Moreover, the
selling cost of the products have been increased from the previous years with the value addition of
jaggery (using mould, spices and nuts).
12. Name of interventions applied in the project:
i. On-site demonstration has been provided to the farmers regarding usage of Quality
control equipment (Refractometer, pH meter and temperature gun) to the farmers to
produce good quality jaggery and jaggery products.

ii. Total 10 set of including one refractometer and one pH meter has been distributed
among SC community at Village Bahowal, Block Mahilpur, District Hoshiarpur on
22.02.2021.
13. List of publications/ brochures/ pamphlet/ leaflet: A leaflet, pamphlet and a book has been
developed regarding process optimization of manufacturing safe and chemical free jaggery.
14. Technology developed/ transferred:
i. Process optimization of jaggery manufacturing from sugarcane juice to produce chemical
free jaggery with better shelf life and stable taste.
ii. First Modern Jaggery Processing Unit has been established for generating local bio-
resource based enterprise and on-farm training programs at village Ghugial in District
Hoshiarpur under a FPO namely FAPRO.
iii. Beneficiary of second plant has been selected and establishment of the same will start
soon.

15. No. of beneficiaries who adopted the technology as part of their income generating activity
(with details):

i. Sh Harinder Singh of Nakodar has set up same plant and is operating it at commercial
scale successfully.

ii. Sd Jaswinder Singh of Amritsar has set up a new Jaggery plant. He has created a web
page also and his brand is “Pure Jaggery”. He has been able to send few consignments
of jaggery to European countries like Italy & USA.
 iii. Mr Gurmukh Singh, Village Baran, Patiala has expanded his jaggery processing
activities after our training. Many of celebrities from Punjabi and Hindi Film Industry of
the country are his regular customers for jaggery. His brand name is ‘Sardar Ji Gur”.

iv. PAU has set up similar plant at its new Agro processing center at campus with the
purpose using it for commercial operations.

v. One such story of how trainings conducted by PAU are helping people to start their own
business to produce safe and quality product is of “Sahela Gur “. An UK based person
Sandeep Singh under the guidance of Dr. Mahesh Kumar has established a Brand
“Sahela Gur “ and processing sugarcane juice to produce quality jaggery.

16. Visible impact of the project/Impact assessment of technology demonstration & adoption
by beneficiaries (should be highlighted in the report as a key tangible outcome): In the year
of 2021-2022 a total of 500 farmers all around the state have been trained for safe and scientific
jaggery production. Almost 200 trainees came from Hoshiarpur district to get scientific
knowledge and information regarding tools used to check TSS,pH and temperature. Moreover,
during the year of 2020-21 more than 250 farmers were sensitized during hands on trainings and
more than 50 jaggery processing units have been covered for the same. The survey conducted
during the year 2021 has shown that the hands on trainings drastically shifted the mindset of
local producers and helped them in various aspects to process quality products. Some of the
visible impacts are as shown in the following figure:

100
90
80
70
60
50
40
30
20
10
0
ty ial an
t
ve
d ls ed
arie ter c o too ov
v a rifi pr f r
op gm cla im eo m
p
Cr gin l
lif
e ag ti
ka r ba le f Us Co
s
P ac He Sh

Before After
Figure 3: Impact of trainings conducted on campus (PAU) and on field:

The knowledge of the manufactures also improved in following terms:

1. Selection of sugarcane variety for making Jaggery
2. Selection of 3 Pan modern system
3. Natural clarificant (Sukhlai stems or roots) and no need to add preservatives or synthetic color.
4. Low density polythene (LDP) sealed packaging to improve shelf life of the product
5. Usage of moulding frame (cube shape jaggery) to add value to the product
6. Addition of dry fruits, herbs and spices to make value added product
7. Proper separate storage area to store jaggery (as recommended by PAU) to increase shelf life of
the product
8. Licensing, FSSAI and GST numbers to make consumer ensure that product has been developed
under safe and hygienic conditions.
9. Proper dedicated sales counter to keep product dust, dirt and flies free.
10. Especially local farmers/manufactures following the above mentioned points which have not
only improved their quality of product but also widen their consumer range.
17. Likelihood of product / process development with time frame:
Activity Dec Apr- July– Oct- Jan – Apr- July– Oct-
19- June Sep Dec March June Sep Dec
March 20 20 20 21 21 21 21
20
Process development &
optimization for scientific &
fortified jaggery production.

Capacity building/hands on
training programmes of
local farmers/entrepreneurs.

Development of Iron
fortified jaggery cubes

Biochemical Analysis of
iron fortified jaggery cubes

Setting up of Demonstration
Unit

Scale up and shelf life

studies

18. Cost-benefit analysis studies (increase in net revenue and production capacity after
technology transfer):
Shall be carried at newly installed plant in the next crushing season at FAPRO.

19. Approach for Cluster Development under the project:

i. Relevant literature in Punjabi Language has been prepared and distributed to majority of
jaggery processors of the state.
 ii. On farm demonstration has been conducted at farmer’s field where jaggery was
processed in front of trainees and their queries for quality production were answered.

20. Summary on the Progress (within 300 words): As per the objectives mentioned above, the
process of manufacturing chemical free jaggery has been standardized. Starting from
procurement of sugarcane to the type of cane crushers to be used for maximum recovery, use of
 organic clarificants for removing scum, utilization of Quality Control Equipment (to evaluate
the vital quality parameter like TSS, pH, temperature of boiling juice at strike point) to
manufacture superior quality product, precise structure of jaggery processing unit, practice of
wooden container or square mould, usage of special storage container for storage and drying of
jaggery to improve its shelf life and Quality testing of jaggery from affiliated laborites and the
packaging of processed jaggery. The type and dose of iron fortification has been developed and
standardized in the laboratory of the department. The different sources of iron were tried and
ultimately optimized with Ammonium Ferric citrate. The distinct feature for use of C6H11FeNO7
for this fortification is its solubility in water and cane juice. It has an INS number (International
Numbering System for Food Additives) and is used as an acidity regulator in beverages. The
formulations further sent to NABI for biochemical analysis. The cubes with 6mg iron per 10
grams has been selected for further supplementation among anemic women of age in between
14-50 years to see its impact on Hb level after 180 days of consumption period. Furthermore, the
vacuum packaging is considered as the best packaging in order to retain its color, texture,sensory
and moisture. Based on the recommendation of the committee, a FPO namely FAPRO, at village
Ghugial in District Hoshiarpur was selected for establishing Modern Jaggery Processing Unit
and the unit has successfully completed its last season with total production of 200 Quintal
jaggery and for the upcoming season they already have the advanced booking for the production
of 25 Quintal jaggery. For the second plant the beneficiary has been selected after scrutinizing
the applications by the competent authority of PAU comprising Chief Agricultural Officer of
Hoshiarpur, Deputy Director of KVK, Bahaowal, team of Scientists of Punjab State Council for
Science & Technology, Chandigarh. The order has been placed for the 3-Pan Modern Jaggery
Processing Unit from Patel Manufacturing Company, Rajkot, Gujarat after following the
tendering process as per established procedure of Punjab Agricultural University, Ludhiana. The
selected supplier is the licensee of Indian Institute of Sugarcane Research for establishment of
Modern jaggery processing plant in the country.

Date:

Place: (Signature of PI)

 Annexure-1

1. Standardization of moisture determination method by microwave drying of jaggery

samples for commercial operations: A 10 gram finely crushed sample was placed in a petri-
dish having fine sand bedding (pre-weighted). The sample was exposed to microwave heating for
a period of 2 to 4 min at power level of 900 W and frequency of 2500 hz. After drying, the petri-
dish was immediately put in desiccator for cooling so that moisture cannot be regained. After it
was cooled, the was petri-dish re-weighed to estimate the moisture content according to
following formula:
Los s∈weight ( g )
Moisture ( % )= ×100
Weight of sample ( g )

Drying time (min) Moisture content (%wb)

10 9.567±1.008
9 9.217±0.441
8 8.678±0.199
7 8.052±0.321
6 7.552±0.22
 5 7.145±0.548
4 6.246±2.185
3 4.358±0.814
2 2.959±1.363

Values as Mean±SD

(Annexure-2a)
Preliminary study: Standardization of amount of iron fortification
S. Type of Salt Amount (per Bioavailability Bioavailable
No 100 gm of iron(mg)
jaggery) (per candy
of 10 gm)
1. Ferric ammonium citrate 110 mg 18% 2
2. Ferric ammonium citrate 230 mg 18% 4
3. Ferric ammonium citrate 340 mg 18% 6
4. Ferric ammonium citrate 560 mg 18% 10
5. Ferric ammonium citrate 1120mg 18% 20
6. Ferrous fumarate 305 mg 33% 10
7. Ferrous fumarate 605 mg 33% 20
8. Ferrous ascorbate 1 tablet* - 10
9. Ferrous ascorbate 2 tablet* - 20
*1 tablet contains 10 mg bio-available iron.
 (Annexure-2b)
Sensory evaluation of fortified jaggery cubes @10 mg and 20 mg (per 10 gm) elemental iron from
three selected salt

Ferric Ammonium Citrate Ferrous Fummarate Ferrous Ascorbate

Sample 10mg 20mg 10mg 20mg 10mg 20mg

Apperance 8.12±0.26 7.44±0.18 7.66±0.46 6.91±0.23 6.45±0.10 5.54±0.18

Texture 8.39±0.17 7.42±0.09 8.21±0.31 6.85±0.30 6.72±0.13 5.48±0.20

Flavour 8.37±0.11 7.705±0.20 8.15±0.25 6.98±0.31 6.26±0.18 5.51±0.17

Taste 8.31±0.29 7.26±0.28 7.97±0.36 7.45±0.23 6.58±0.11 5.46±0.14

 O.A 8.29±0.20 7.45±0.18 7.99±0.34 7.04±0.26 6.50±0.06 5.50±0.06

Ferric Ammonium Citrate was considered as the most preferred formulations among all with average
score of overall acceptability 8 and 7 for formulations having 10 mg and 20 mg free iron, respectively.

(Annexure-2c)
Detailed study: Formulations developed for bulk production fortified with Ferric Ammonium Citrate

Values as Mean±SD
 Parameters Exp. No. 1 Exp. No. 2 Exp. No. 3

Salt Fortified Ferric ammonium citrate(FeAC) FeAC FeAC

Amount in % (per 1.2% 2.3% 3.4%
kg)
Amount in 1.2gm 2.3gm 3.4gm
grams(per kg)
Amount in grams 60gm 115gm 170gm
(per lot of 50 kg)
Flavour - - Mango
Amount of flavour - - 1ml/kg
Bioavailability 18% 18% 18%
(%)
Bioavailable iron per 2mg 4mg 6mg
10 gram
Women 7% 14% 21%
Pregnant 5% 10% 15%
Lactating 9% 18% 27%
Children
1-3 Yrs 25% 50% 75%
4-6 yrs 19% 38% 47%
7-9 yrs 13.5% 27% 40%
Girls
10-12 yrs 7.2% 14.3% 21.6%
13-15 yrs 6.7% 13.4% 20.8%
16-18 yrs 6.3% 12.5% 18.8%

(Annexure-2d)
Iron evaluation of fortified jaggery cubes
Formulations Total Iron(mg/10 gm) Bioavailability Percent Bioavailability (%)
Iron (mg/10 gm)

Formulation 1 3.78 1.927 51

Formulation 2 5.14 2.775 54

Formulation 3 9.71 5.826 60