A COMPREHENSIVE STUDY OF YIELD

IMPROVEMENT, RECIPE OPTIMIZATION, AND

OIL UPTAKE REDUCTION THROUGH
INNOVATIVE COATING AND AIR FRYING
TECHNIQUES

Internal Guide Industrial Guide Presented By

Dr. Palpandi Raja Mr. Mayank Kumar Indhuja Preethi B
Asst Professor NPD Innovation Centre 2021412032
Anna University Mother Dairy M.Tech Food technology
 OBJECTIVES
PHASE I PHASE II

Developing a recipe that can be prepared using both Extensive study of coating material to reduce oil

oil frying and air frying methodologies uptake in developed snack material

Conducting a comparative sensory and texture Evaluation of overall acceptability of low fat sample

analysis methodologies

Optimizing the recipe for to improve product quality Study of shelf life & temperature abuse through the

and reduce fat uptake supply chain

 GOALS
PHASE I PHASE II
Comparing the sensory and texture properties of Deduce the acceptability of developed low fat snack
potato- based frozen snacks prepared using oil frying compared to high fat product
and air frying methodologies, to determine any
significant differences in taste, texture & quality

Develop a potato-based snack that meets specific Achieve shelf stability of the product through
sensory and texture criteria and can be prepared using accelerated shelf life study
both oil frying and air frying methodologies

Optimize the recipe for air fried potato-based frozen Ensure quality & safety through study of temperature
snacks to reduce fat uptake, improve sensory and abuse in supply chain
texture properties
METHODOLOGY
Attribute analysis
• Dry matter
• Specific gravity
• TSS
• Reducing sugars
• Starch content

Nutritional
• Carbohydrates
• Protein
• Fat
• Dietary Fibers

Functional
• Oxidative stability (FFA, PV, p-AV)
• Denaturation

Sensory
• Appearance
• Flavor
• Texture
• Taste
 ANALYSIS OF BIOCHEMICAL &
PHYSIOCHEMICAL ATTRIBUTES
AOAC 2005 - AOAC 1990 Lane & Eynon method - AOAC 1990

Dry matter % Specific gravity Reducing TSS (°Brix)

sugars(mg/100g)
23.05
1.11 5.7
1.09 54.2
1.08 5.6
22.4 40.7
40.1 39.4
22.2
5.41
21.85 0.98 5.35

CS2 CS3 LR Frysona CS2 CS3 LR Frysona CS2 CS3 LR Frysona CS2 CS3 LR Frysona

X 100 CS – Chipsona LR- LadyRosetta

Dry matter & affects the
texture and cooking properties
of the potato. A high dry
matter content is desirable for
snack development, as it
results in a crispier and less
greasy end product
A high specific gravity is
desirable for our applications
as it results in a more uniform
and crispy end product
High levels of reducing sugars Lower TSS level is desired as
can lead to browning and off- low sweetness is preferable for
flavor in the end product, savoury snack products
especially when potatoes are
fried, so low reducing sugar is
desirable
 Physical properties Starch %
Diameter Sphericity Surface area
Dg = (LWT) 0.333

486
18.35
Ф= (Dg/ L) ×100
414

18.09

403

398
16.9
S = π Dg 2
124
115

113

113
88
86
79

76
16.12

CS2 CS3 LR Fr y so n a
CS2 CS3 LR Frysona

Sharkar M et al 2019 AOAC 2000

The diameter sphericity and surface area of potato Starch % of higher level >15% is favourable for the
plays an important role in process and yield development of frozen snacks.
parameters
 Segregation of
potatoes

Sensory score
Peeling of potatoes Appearance Crispiness
Overall acceptability

20 1 2
Steam cooking 30- 19 3
40 mins 18 4

17 5

Cool to room temp 16 6

15 7

14 8
Mash the potatoes
13 9
12 11 10

Add remaining Y
& Z components Score
Appearance

Form to desired
shape (15-20g) 9
Overall acceptability Color
9 9
Blast freezing 30-
40 mins
9 9 9

Par-frying 180- Texture Flavour

190°C

Taste
Packing & Storage
-18°C
S.N
O
Compone
nt X
Compone Compone
nt Y nt Z
Sensory
acceptability Fat %
FORMULATION OF
1 69.75 14.65 7.98 7.5 9.89 RECIPE
2 72.75 16.00 7.41 7.5 10.9
3 63.00 14.11 6.60 6 9.62
4 63.00 13.00 8.00 5 8.6 Build Information    
File Version 13.0.5.0      
5 69.75 13.06 7.23 6 9.55
Response
7 11.9 X : Primary ingredient Study Type   Subtype Randomized
6 72.38 16.00 6.60 Surface
Y : Secondary ingredient Coordinate
7 63.15 14.32 7.57 5.5 9.6 Z : Tertiary ingredient Design Type I-optimal Runs 20
Exchange
8 77.63 14.65 7.23 8 9.68 Design Model Quadratic   Blocks No Blocks
6 9.55 Build Time (ms) 114      
9 69.75 13.06 7.23
10 63.00 16.00 7.48 6.5 11.91
Response 1: Organoleptic acceptance
11 77.63 14.65 7.23 7.5 9.6
7.5 9.89 Source Sequential Lack of Fit Adjusted Predicted
12 69.75 14.65 7.98
p-value p-value R² R²
13 78.00 13.00 6.60 8 7.8
Linear < 0.0001 0.0500 0.7999 0.7042
14 63.00 16.00 6.60 6 12.4
15 67.50 15.06 7.04 6.5 11.5
2FI 0.0066 0.1967 0.9010 0.7131 Suggested
16 78.00 16.00 8.00 9.0 10.8
17 78.00 13.00 8.00 9.0 9.7 Quadratic 0.0608 0.4056 0.9365 0.7735
18 71.25 13.93 6.60 6.50 8.90
19 77.63 14.65 7.23 7.50 9.60 Cubic 0.4056 0.9436 Aliased
20 69.75 13.06 7.23 6.50 8.14
ANOVA for 2FI Model – Organoleptic acceptance
Source Sum of Squares df Mean Square F-value p-value
Model 20.93 6 3.49 29.82 < 0.0001 significant
A-X 13.12 1 13.12 112.13 < 0.0001
B-y 0.9542 1 0.9542 8.16 0.0135
C-z 1.82 1 1.82 15.55 0.0017
AB 1.20 1 1.20 10.24 0.0070
AC 0.7584 1 0.7584 6.48 0.0244
BC 0.2842 1 0.2842 2.43 0.1431
Residual 1.52 13 0.1170
Lack of Fit 1.19 8 0.1484 2.23 0.1967 not significant
Pure Error 0.3333 5 0.0667
Cor Total 22.45 19

Fit Statistics
The Model F-value of 29.82 implies the model is significant. P-values
Std. Dev. 0.3420 R² 0.9323 less than 0.0500 indicate model terms are significant
Mean 6.95 Adjusted R² 0.9010
The Lack of Fit F-value of 2.23 implies the Lack of Fit is not significant
C.V. % 4.92 Predicted R² 0.7131
relative to the pure error
Adeq 20.2092
Precision The Predicted R² of 0.7131 is in reasonable agreement with the Adjusted
R² of 0.9010; i.e. the difference is less than 0.2
The ratio of 20.209 indicates an adequate signal
Equation of the model

0.24X + 1.544Y -7.36Z +0.041XY +0.069XZ +0.213YZ +4.927

ANOVA for 2FI Model – Fat uptake
Source Sum of Squares df Mean Square F-value p-value
Model 26.07 6 4.35 16.86 < 0.0001 significant
A-X 0.5235 1 0.5235 2.03 0.1776
B-y 16.86 1 16.86 65.43 < 0.0001
C-z 0.0048 1 0.0048 0.0187 0.8932
AB 0.6076 1 0.6076 2.36 0.1486
AC 0.7570 1 0.7570 2.94 0.1103
BC 1.48 1 1.48 5.73 0.0324
Residual 3.35 13 0.2577
Lack of Fit 2.02 8 0.2526 0.9497 0.5497 not significant
Pure Error 1.33 5 0.2659
Cor Total 29.42 19

Fit Statistics
Source Sequential p- Lack of Fit p- Adjusted R² Predicted R² The Model F-value of 16.86 implies the
value value
Linear < 0.0001 0.2478 0.7220 0.6134 model is significant. P-values less than
2FI 0.0213 0.5497 0.8336 0.7664 Suggested
0.0500 indicate model terms are significant.
In this case B, BC are significant model
Quadratic 0.3217 0.5913 0.8450 0.6969
terms. Non-significant lack of fit is good
Cubic 0.5913 0.8283 Aliased

The Predicted R² of 0.7664 is in reasonable

Equation in terms of actual factors agreement with the Adjusted R² of 0.8336
-0.113x+6.475y+2.180z-0.029xy+0.069xz-0.486yz-46.18
 ORGANOLEPTIC ACCPETANCE

The 3D graph shows that the main ingredient (X) at higher range and the secondary components (Y) ingredient in
the lower level has a significant effect on the organoleptic acceptance of the sample. It also shows that there is a
better acceptance of the product upon increasing the composition of the (Z)ingredient.
 FAT UPTAKE

The 3D graph shows that for low value of Main ingredient (X) and component ingredient (Y) the fat content
value is acceptable. Between X&Z composition, there is a small interaction between the main ingredient and
binding/ crisping ingredients have an effect on the fat % of the developed product. The higher composition of the
binding agent and lower proportion of the secondary ingredient shows that the ratio has an invariable effect on the
final fat% of the product.
 OPTIMIZATION &
DESIRABILITY
The desirability values of the ramp model show the
effect of multiple responses for the optimization of the
formulation.
The desirability of 0.806 is favourable as this
combination shows the most probable proportion of
ingredient components that provides the best response
organoleptically.
There is still scope for improvement in ranges of Fat%

FUTURE STUDY
1. Extensive study of coating material to reduce oil uptake in developed snack material
2. Evaluation of overall acceptability of low fat sample
3. Study of shelf life & temperature abuse throughout the supply chain
 MUCILAGE POLYSACCHARIDE AS COATING MATERIAL
Grinding of
seed
Extraction by Box-Benken design
Mix with water
S.no Fenugreek Flaxseeds Time Yield %
(1:10)
1 5.5 5.5 165  
2 5.5 5.5 165  
3 5.5 10 30  
Extraction in
Microwave 4 10 10 165  
5 5.5 10 300  
6 10 5.5 300  
7 5.5 1 300  
Centrifugation
8 5.5 5.5 165  
9 5.5 5.5 165  
10 1 10 165  
Ethanol
precipitation 11 1 5.5 30  
(95%) 12 1 1 165  
13 1 5.5 300  
14 10 5.5 30  
Drying 60°C 15 5.5 5.5 165  
16 5.5 1 30  
17 10 1 165  

Weigh sample
on coating material
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