STUDY OF EXTENDING WINGKO SHELF LIFE BY INNOVATIONS IN PROCESSING AND PACKAGING TECHNOLOGY TO IMPROVE COMPETITIVENESS OF SMALL-MEDIUM ENTERPRISES

By: YUNITA SITI MARDHIYYAH HAFIZ FAKHRURROZY SARAH TIARA SULISTYANTI F24080015 F24080058 F24080023 2008 2008 2008

BOGOR AGRICULTURAL UNIVERSITY BOGOR 2012

AUTHORIZATION SHEET

Title

Subtheme Paper Head of Participant NIM Faculty/Major University Address Phone Email Consultant Lecture NIP Address Email Phone Core competence

: Study of Extending Wingko Shelf Life by Innovations in Processing and Packaging Technology to Improve Competitiveness of SmallMedium Enterprises : Food Processing and Engineering : Yunita Siti Mardhiyyah : F24080015 : Faculty of Agricultural Engineering and Technology / Food Science Technology : Bogor Agricultural University : Babakan Raya 4 No:115 Rt 03/07, Dramaga Bogor 16680 : 085655404982 : yunita28@gmail.com : Dr. Ir. Yadi haryadi, M.Sc. : 19490612.197603.1.003 : Lengkeng Street No. 10 Kampus IPB, Dramaga Bogor 16680 : yadi_h@hotmail.com, yadihary@gmail.com : (0251) 8621547, 081298909583 : Food Storage, Food Packaging, Post Harvest Pest Control, Food Product Development.

Bogor, January 23rd 2012 Consultant Lecture Head of participant

(Dr. Ir. Yadi haryadi, M.Sc.) NIP. 19490612.197603.1.003

(Yunita Siti Mardhiyyah) NIM. F24080015

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ABSTRACT Wingko is an Indonesian traditional snack. It was originated from Babat, East Java. Many Small-Medium Enterprises (SMEs) in Central Java and East Java produce wingko. Wingko is an intermediate moisture food that has aw value between 0,7 and 0,85 and moisture content between 20% and 50%. Unfortunately, this product only has shelf life of about 3 days. It is caused by rancidity and mold contamination. The rancidity is a result of fat oxidation by lipase enzyme and water, whereas mold contamination in wingko is triggered by the increase of aw value during storage. The sources of fat in wingko are coconut and margarine. In this project, five steps of innovations are to be introduced in the new process of wingko production. The first step is the reformulation of wingko basic ingredients (waxy rice flour, coconut, and sugar) to 2:2:1. The second step is using desiccated coconut instead of raw coconut. The third step is steaming desiccated coconut before being used in the formula. The fourth step is using plastic composite film of nylon-LLDPE as packaging material. And finally the fifth step is by introducing vacuum packaging technique with oxygen absorber. By the combination of process and packaging technique, it is expected that the shelf life of wingko will be extended up to 60 days. Hence, wider market area of wingko will be covered and the probability of product return will be reduced. Cost analysis showed that these innovations are feasible and profitable for wingko SMEs. Keywords: wingko, coconut, rancidity, shelf life, drying, steaming, vacuum packaging, oxygen absorber

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PREFACE In the name of Allah SWT, the Authors want to say thank you to God, because only God help we have finished our paper which has a title Study of Extending Wingko Shelf Life by Innovations in Processing and Packaging Technology to Improve Competitiveness of Small-Medium Enterprises on time and without matter problem. In this case the Authors would like to thank Dr. Ir. Yadi Haryadi, M.Sc. who has spent his time to guid and give advice in finishing this paper. This paper was made to join National Student Paper Competition 2012 and also the Authors want to provide a solution to Wingko Small-Medium Enterprises (SMEs). This paper describes wingko product which is a traditional food from Babat that has short shelf life. The short shelf life is caused by rancidity and mold contamination. Therefore, this paper provides a solution for extending wingko shelf life. It is truly hoped that this paper will give a worthy edition to the existing knowledge on Food Science and Technology area, help to develop Wingko SmallMedium Enterprises, and the readers will get useful informations. .

Bogor, January 2012

The Authors

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TABLE OF CONTENTS

TABLE OF CONTENTS ........................................................................................ v LIST OF TABLE .................................................................................................. vii LIST OF FIGURE ................................................................................................ viii LIST OF APPENDIX ............................................................................................ ix I. INTRODUCTION ............................................................................................... 1 A. BACKGROUND ......................................................................................... 1 B. RESEARCH QUESTIONS.......................................................................... 2 C. OBJECTIVES .............................................................................................. 2 D. BENEFITS ................................................................................................... 2 II. LITERATURE REVIEW ................................................................................... 3 A. WINGKO ..................................................................................................... 3 B. INTERMEDIATE MOISTURE FOOD (IMF) ............................................ 3 C. WATER ACTIVITY (AW)........................................................................... 4 D. COCONUT .................................................................................................. 4 1. 2. Chemical Composition ............................................................................. 4 Desiccated Coconut .................................................................................. 5

E. RANCIDITY ................................................................................................ 6 F. STEAMING AND BAKING ....................................................................... 7

G. VACUUM PACKAGING ........................................................................... 7 H. OXYGEN ABSORBER ............................................................................... 8 III. WRITING METHOD ....................................................................................... 9 A. DETERMINING IDEA ............................................................................... 9 B. TYPE AND SOURCE OF DATA ............................................................... 9 C. DATA ANALYSIS ...................................................................................... 9 D. DETERMINING CONCLUSION AND SUGGESTION ........................... 9 IV. DISCUSSION ................................................................................................. 10 A. WINGKOS INGREDIENTS AND TECHNOLOGY PROCESS............. 10 B. PROBLEM OF WINGKOS SHELF LIFE ............................................... 10 C. INNOVATION .......................................................................................... 11

1. 2. 3.

Composition of Raw Materials............................................................... 11 Processing ............................................................................................... 12 Packaging ............................................................................................... 12

D. COST ANALYSIS ..................................................................................... 13 V. CONCLUSION ................................................................................................ 15 REFERENCE ........................................................................................................ 16 APPENDIX ........................................................................................................... 20

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LIST OF TABLE Table 1. Table 2. Table 3. Table 4. Table 5. Chemical Composition of Coconut in 100 grams .......................... 5 Fatty Acid Composition of Coconut Oil ........................................ 5 Proximate Analysis of Desiccated Coconut................................... 6 Specific permeability of some types plastic .................................. 8 Comparison between cost for each wingko and shelf life of wingko in different process and packaging ................................... 14

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LIST OF FIGURE Figure 1. Figure 2. Figure 3. Wingko........................................................................................... 3 The Relationship between Water Activity and Rate of Some Reactions ....................................................................................... 4 Correlation between TBA Number and Shelf Life of Sale Pisang 13

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LIST OF APPENDIX Appendix 1. Flow Chart of Desiccated Coconut ................................................ 20 Appendix 2. Flow Chart of Wingko Processing ................................................. 21

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I. INTRODUCTION A. BACKGROUND Local food products in Indonesia develop fastly in retail market. There are three kinds of food producer i.e.: small industry, medium industry, and big industry. Small-medium industry segment is 99% of all enterprises population in Indonesia (Hida 2010). This segment industry is usually called as Small-Medium Enterprises (SMEs). BPS recorded that there was increasing of SMEs contribution for Indonesian Gross Domestic Poduct (GDP) in 2007, it was from 53,3% in 2006 up to 53,6% in 2007. The highest growth occurred in building sector at 9,3%, followed by trading, hotel and restaurant sector at 8,5%, and mining sector at 7,8%. SMEs' contribution of trading sector in GDP (14,40%) was higher than big enterprises (0,53%). If it was observed from labor absorption aspect, labor absorption value of SMEs increased from 96,13% in 2006 up to 97,3% in 2007. Top three labor absorption SMEs sectors were agriculture sector (46,40%), trading and hotel sector (25,18%), industry sector (11,35%). This BPSs data was supported by statement of Sjarifuddin Hasan (The Minister of Cooperatives and Small-medium Enterprises) that estimation number of SMEs in 2011 was 55,21 millions consist of 54,6 million micro enterprise units, 602.195 small enterprise units, and 44.280 medium enterprise units. SMEs labor absorption was 101,72 million people in 2011 or increased 3,55% from 99,401 million people in 2010 (Qory 2011). It indicates that SMEs is one of important sectors that give contribution significantly for Indonesian economy. In the other hand, development of globalization has caused market product become various and competitive, includes import products. Various import food products have been very plentiful in Indonesian market, such as Korea and Japans products. They slowly will displace Indonesian unique foods, such as traditional food. One of the Indonesian traditional foods is wingko. Many smallmedium enterprises in Central Java and East Java produce wingko. These enterprises have been alive from 1944 and still remained competitive until now although global crisis has occurred in Indonesia. Wingko can be produced everyday because raw materials can be obtained easily and not affceted by weather. Wingko also is interested by many people. So, wingko SMEs are very potential to be developed in Indonesia. Today, there are about 40 wingko SME units in Babat and Lamongan sub-district and it can absorb 350 labors directly (Anonymous 2011). Wingko SMEs is part of trading, hotel, and restaurant sector that gives significant role for Indonesian economy. However, SMEs still have many probelms such as infrastructure, transportation, distribution, quality control, standardization, economy, promotion, and marketing. According to Sparringa (2012), the main problems that faced by SMEs are misapplication of dangerous materials that added into food product, addition of food additives excessively,

chemical and microbilogical contamination. These problems must be solved together by producer, consumer, and government. In fact, wingko has shelf life problem. It has short shelf life of about 3 days. After 3 days, wingko has been not good for consumption because of rancidity and mold contamination. Wingko has high fat content about 10% originated from coconut and margarine that used in formulation. So, it is needed innovations for extending wingko shelf life. For example, renewal process and product reformulation. These technical improvement efforts are expected to improve quality of Indonesian traditional food in order to support Indonesian economy in the future. B. RESEARCH QUESTIONS The research questions of this project are: 1. What are the factors that cause wingko has short shelf life? 2. What are the innovations for extending wingko shelf life? C. OBJECTIVES The objectives of this project are: 1. To identify factors that cause wingko has a short shelf life related to ingredients and processing of wingko. 2. To find the innovations for extending wingko shelf life. 3. To improve wingko quality as efforts for developing Indonesian traditional food in face of globalization era. 4. To know wheter these suggested innovations are feasible and profitable for wingko SMEs. D. BENEFITS The benefits of this project are: 1. To provide alternative suggestion of processing wingko for SMEs. 2. To help wingko SMEs for extending shelf life product. 3. To expand the market area of wingko SMEs. 4. To enhance the competitiveness of wingko SMEs in globalalization era. 5. To give information about feasibility of applying suggested innovations to extend wingko shelf life for SMEs.

II. LITERATURE REVIEW A. WINGKO Wingko is a kind of Indonesian traditional snack from Babat. Babat is a sub district of Lamongan, East Java. Based on SNI 01-4311-1996, wingko is an intermediate moisturize food made from grated coconut, waxy rice flour, and sugar then processed by baking, added or not by legal food additives (BSN 1996). The traditional baking procedures that use firewood can give special flavor to this product. Greated coconuts also give special flavor, and savory taste (Palungkun 1992). The Figure 1 shows wingko appearance.

Figure 1. Wingko (Anonymous 2011) Wingko is usually sold in railway stations, bus stations, and cake stores. The development of wingko is related to Surabaya-Jakarta train route. The wingko producer moved from Babat to Semarang and they continued wingkos production. Finally, wingko is famous not only in Lamongan (East Java) but also in Semarang (Central Java) (Afnita 2009). There are many brands of wingko, such as Cap Kereta Api, Cap Kelapa, Cap Kapal Terbang, Cap Bus Bisnis, Cap Kapal Laut, Cap Mobil Antik, etc. B. INTERMEDIATE MOISTURE FOOD (IMF) Intermediate moisture food (IMF) is soft food, processed with one or more treatments, consumed directly, no thermal or cooling or freezing treatments, but just by combining ingredients well, adjusting pH, using food additives and controlling aw (water activity) (Hegenbart 1996). IMF has aw values between 0,7 and 0,85 and moisture content between 20% and 50%, so it is impossible for bacteria growth (Fennema 1996). Sudarsono (1981) has divided IMF products to three class based on shelf life. The first class is IMF products that have shelf life less than a week, such as tape singkong, tape uli, pindang, fish, and wingko. The second class is IMF products that have shelf life between 1 week and 4 weeks, such as peda fish and

big pindang fish. The third class is IMF products that have shelf life more than a month, such as dodol garut, soy sauce, tauco, terasi, salty egg, and manisan buah. C. WATER ACTIVITY (AW) Water is an important component in the food because of its role in chemical reactions; its effect on the appearance, texture, and flavor of food (Belitz and Grosch 1992). Moisture content in food plays an important role in lipid oxidation and non-enzymatic browning. Moreover, water activity (aw) is the main microorganism controlling factor in IMF. Every microorganism requires different amount of water and minimum aw to support its growth. In general, bacteria lives in aw value more than 0,9; mold lives in aw value between 0,6 and 0,7; and yeast lives in aw value between 0,8 and 0,9 (Fennema 1996). According to Fennnema (1996), the water activity in IMF between 0,7 and 0,85; moisture content between 20% and 50% (wet basis). The existence of low aw in IMF can effectively prevent the microorganism growth, so that food has longer shelf life. Moreover, IMF shelf life is also very dependent on the composition of food, processing, packaging, using a preservatives and microbial activity. The relationship between moisture content, rate of microbiological, chemical, enzymatic, and non-enzymatic in food can be seen in Figure 2.

Figure 2. The Relationship between Water Activity and Rate Of Some Reactions (Bell and Labuza 2000) D. COCONUT 1. Chemical Composition The chemical composition of coconut meat is determined by the age of the coconut. Table 1 shows chemical composition of coconut at different age. Fat content in old coconut meat is the second largest component after water. Fat is energy source for the growth of coconut embryos. There are 90-94% saturated fatty acids in coconut oil (Eckey 1955). According to Sonnytag

(1979), mayor components of coconut oil are lauric acid, myristic acid, and palmitic acid. Fatty acid composition of coconut oil are presented in Table 2. Table 1. Chemical Composition of Coconut in 100 grams (Departemen Kesehatan RI 1992) Composition Calorie (kal) Protein (g) Fat (g) Carbohydrate (g) Calsium (mg) Fosfor (mg) Iron (mg) Vit. A (S.I) Vit. B1 (mg) Vit. C (mg) Water (g) b.d.d (%) Young Coconut Meat 68,00 1,00 0,90 14,00 7,00 30,00 1,00 0,00 0,06 4,00 83,30 53,00 Old Coconut Meat 359,00 3,40 34,70 14,00 21,00 98,00 2,00 0,00 0,10 2,00 46,90 53,00

Table 2. Fatty Acid Composition of Coconut Oil (Ensminger et al. 1983) Components Saturated Fatty Acid 1. Caproic 2. Caprilic 3. Capric 4. Lauric 5. Myristic 6. Palmitate 7. Stearic 8. Arachidat Unsaturated Fatty Acid 1. Heksadecenoic 2. Oleic 3. Linoleic
2. Desiccated Coconut

Total (%) 7,8 7,6 45,0 18,0 9,5 5,0 8,2 -

Desiccated coconut is one of dried coconut meat product, chrushed from coconut meat and processed in hygienic condition (Grimwood 1975). Desiccated coconut is more practical and durable than fresh coconut. According to Child (1964), shelf life of desiccated coconut is strongly influenced by moisture content. Flavor changes of desiccated coconut is caused by hydrolysis that converts oil into free fatty acids and glycerol, which are mostly volatile short chain fatty acid. Hydrolysis occurs because of the

active lipase enzyme in fatty materials with high moisture content. Based on these observations, moisture content must be controlled for saving desiccated coconut in long time. Desiccated coconut has high fat content, approximately between 68% and 72% (Rhee and Lusas 1979). The proximate analysis of desiccated coconut can be seen in Table 3. Table 3. Proximate Analysis of Desiccated Coconut (Supiadi 1993) Components Moisture content Fat content Carbohydrate content Protein content Crude fiber content Ash content Free fatty acid content Total (% wb) (%db) 2,34 67,13 68,74 16,91 17,32 8,09 8,28 3,55 3,64 1,68 1,72 0,29 0,30

E. RANCIDITY Fat has function as texturizer, flavor, and heat conductor in food. In the other hand, high fat content in food also causes problems. Hydrolytic and oxidative damage of fat will destruct fat structure so that fat loses its function. Byproduct of fat destruction is short chain free fatty acids. They usually give off flavor and those are indicator of rancidity. Hydrolytic and oxidative damage can be accelerated by lipase enzyme and lipoxygenase enzyme. These enzymes are naturally in food or produced by mold. Hydrolytic damage is happened when fat reacts with water in food matrix and produces glycerol and fatty acid (Charley 1982). Fat oxidation can occur enzymatically or non-enzymatically. Enzymatic oxidation is happened as result of unsaturated fat oxidation by oxygen or free radical that catalyzed by lipoxigenase enzyme and produces peroxide compound. Peroxide compound is unstable and it will break down into short chain carbon compounds such as fatty acid, aldehide, and ketone. These compounds have responsibility in off flavor rancidity development (Charley 1982). Non-enzymatic oxidation is happened because of auto-oxidation (free radical) or photo-oxidation. Free radical mechanism is based on the kind of fat molecules that interact with oxygen. In the other hand photo-oxidation is happened when photosynthesis molecules (riboflavin or metal ionic) absorb light. The oxygen as the photosynthesis product will react with fatty acid and produce hidyroperoxide (Champagne 1994).

F. STEAMING AND BAKING Steaming is thermal process that often applied by using a lot of water, but the water doesnt contact directly with product. Food material is put in covered pan and boiled. Steaming is wet heating that can kill microorganisms by denaturing protein (microorganism enzymes) (Fardiaz 1992). According to Fennema (1996), steaming can inactivate lipase enzyme. Lipase is enzyme that can hydrolyze fat into fatty acid and glycerol. Lipase enzyme is a protein that formed from three structures i.e.: primary, secondary, and tertiary structure. Denaturation of protein will destruct secondary and tertiary structure. The denaturation is irreversible, so enzyme that has been denaturated can not work as its function (Ophart 2003). Other thermal process is baking. In common term, baking is dry heating of food material that can be applied for changing sensory characteristic so the product can be more accepted by consumer. Baking also causes food material more durable because the process can inactivate microorganisms and enzymes, and also decrease aw. While baking, there are heat and mass transfer simultaneously. Heat transfer occurs from heat source to food material through heat medium (hot surface or hot air). Mass transfer that occurs is water movement from food material to air in vapour form. Baking can be applied directly or indirectly. In direct baking, heat source heats food material directly through no media. In indirect baking, heat source heats air or heater plate, then it heats food material. Baking operation can be applied in batch, semi-continuous, and continuous process (Fellows 2000). G. VACUUM PACKAGING Packaging is a protecting method for food material or product that has not been processed yet or has been processed, so it is still in good condition and protected until consumer. The purposes of food packaging are for protecting food product while transportation and storage, preventing injury and unwanted changes (Jenie et al. 1993). One of method packagings that usually used is vacuum packaging. Vacuum packaging is hermetic packaging system that the pressure in package is decreased until less than 1 atm through excreting air from the package. This treatment can extend product shelf life. Main purpose of vacuum system is for removal of some oxygen which can cause oxidation of food product (Winarno 1993). Other purpose is to inhibite microorganisms growth. According to Petersen et al. (1999), low oxygen level in package causes inhibiting of microorganisms growth, such as Pseudomonas, Moraxella, Acinobacter, Flavobacterium, and Cytophaga. Availability of oxygen can affect microorganisms growth. Vacuum packaging technique is applied by packaging the product into package which followed by air removal and sealing uses vacuum packaging machine (Jay 1996). Packaging material which is often used for food product is

plastic. Physical characteristics of plastics which are used as package can be seen on Table 4. Table 4. Specific permeability of some types plastic (Buckle et al. 1988) Permeability (cm3/cm2/mm/det/cmHg) x 1010 N2 O2 (at 300C) CO2 H2O (at 250C, RH 90%) 19 55 352 800 2,7 10,6 35 130 2,9 11,0 88 12000 0,1 0,38 1,6 7000 23,0 92 680 0,4 1,2 10 1560 0,05 0,22 1,53 1300 0,0094 0,053 0,29 14 0,08 0,3 1,7 240 84 2,8 0,5 265 7,8 2000 68 100000 130000 75000

Type of plastic LDPE HDPE Polystyrene Polyamide (nylon 6) Polypropylene Polyninyl chloride (rigid) Polyester (mylar) Polyvinylidene chloride Rubber hydrochloride (pliofilm NO) Polyvinyl acetate Ethyl cellulose Cellulose acetate

H. OXYGEN ABSORBER According to Nakamura and Hoshino (1983), oxygen absorber is a material that can absorb oxygen chemically so oxygen level decreases. Oxygen absorber material should have some characteristics, such as not dangerous, able to absorb oxygen fastly, raw material can be found easily, and cheap. Oxygen absorber and modified atmosphere packaging (MAP) have same advantage. It is ability to reduce oxygen to very low levels. Oxygen absorber material actively reduce oxygen level in head-space of package until 0,01% so that can prevent oxidation, colour change, microorganisms growth, and also extend shelf life of the product (Butler 2001). The form of oxygen absorber can be in powdered iron that 1 gram can react with 300 mililiters of oxygen. Disadvantage of using this iron is product can not through metal detector in packaging line. This problem can be solved by using absorber in the form of ascorbic acid or enzyme. Material of oxygen absorber such as ascorbic acid, sulfite, or powdered iron is put into the polymer with sustainable permeability for water and oxygen, such as polyvinyl chloride (PVC).

III. WRITING METHOD A. DETERMINING IDEA For determining a good idea, the Authors found information about something that required by SMEs today. So, the result of this idea is not just on the project, but also can be applied in real world. Finally the Authors determine the idea to study about extending wingko shelf life by innovation of processing and packaging technology. B. TYPE AND SOURCE OF DATA The type of data that used in this project are primary and secondary data. The primary data is obtained from direct observation to wingko product. Moreover, the secondary data is obtained from literature in library and internet. C. DATA ANALYSIS Data analysis is done by descriptive approach. Observation to wingko product conclude that the important thing is about short shelf life. For solving this problem, the Authors find information in library as well as in internet about wingko research. After colecting the information, then authors syntesis solutions based on it. Sharing with lecture also helped to get the solution. D. DETERMINING CONCLUSION AND SUGGESTION Finishing step of this project is determining conclusion from discussion so that it will determine suggestions for wingko SMEs.

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IV. DISCUSSION A. WINGKOS INGREDIENTS AND TECHNOLOGY PROCESS Wingko is traditional food made from waxy rice flour, grated coconut, sugar, egg, water, salt and margarine. Each ingredient has its own function in wingko formulation. Composition of ingredient obviously alters the characteristic, sensory and nutrition of the product. Waxy rice starch in the flour has function as filler and mass body of wingko. The starch will gelatinize when wingkos dough is being baked and form the body. Grated coconut as fat source will give flavor and savory taste to wingko (Palungkun 1992). Sugar gives sweet taste and brown colour as the result of caramelization and Mailard reaction when wingko is being baked. According to Whistler and Daniel (1985), in high temperature sugar will melt and form caramel that has brown color. In other way, the brown color is formed when water evaporates, and sugar reacts with amino acid to form melanoidin. This is called Maillard reaction. Egg has funtion as emulsifier and also has responsibility in Mailard reaction (Ekawatiningsih et al. 2008). Water is solvent of other ingredients. In addition, margarine has function as lubricant so wingko will not sticky to the baked pan. Wingko processing is simple. There are 2 main steps, they are mixing and baking. Mixing of ingredients should be done step by step to get homogenous phase. Baking will make waxy rice starch gelatinizes. If baking is continued, water will evaporate and make the water content of product reduce (Suprapto 2006). Baking will also form curst in wingkoss surface. The curst can be barrier to protect wingko from contamination. There are two kinds of baking that usually applied by wingko SMEs. They are individual baking using small mould and using big pan. In big pan baking, after wingko was cooked then wingko is sliced become smaller pieces. According to Pratiwi et al. (2005), when wingko dough is being baked using small mould causes the movement of evaporated water occur in all surface product so that the moisture content is lower than big pan baked wingko. Small mould baking also reduces microorganism contamination and fat reduction. B. PROBLEM OF WINGKOS SHELF LIFE Wingko is an IMF product because it has moisture content between 20% and 50% and has aw value between 0,7 and 0,85. According to Fennema (1996), food with that specific characteristics should be durable food. However, when wingko compared with other IMF products, wingko has short life of about 3 days. This is due to wingko has fairly high fat content about 10% originated from coconut and margarine in formulation. So that product can be rancid easily. Charley (1982) said that high fat content in food could be the source of hydrolytic and oxidative damage. Hydrolytic damage will cause fat hydrolysis into glycerol and free fatty acids. This free fatty acids, especially unsaturated fatty acids are

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oxidized easily which produce shorter chain fatty acid such as aldehyde and ketone so cause rancidity. According to Palungkun (1992), raw material from half old coconut (9-10 months) has fairly high nutrient content. So, after it was peeled and grated, coconut quickly get chemically, enzymatically, or microbiological damage. Other thing that becomes critical factor related to wingko shelf life is mold contamination. This is caused wingko has aw value between 0,7 and 0,85 that is the optimum aw for mold growth as seen in Figure 2. Suhajati (1995) said that common type of mold identified in the IMF products are Aspergillus and Penicillium. The existence of mold growth can also accelerate rancidity when the mold produces lipase enzyme. Packaging of wingko product that just wrapped by non-stick paper without sealing can increase the probability of product contamination and entry of oxygen from the environment. The problem of short shelf life results limited market area of wingko SMEs. This problem can be an inhibitor for SMEs to produce wingko in larger scale and distribute it to wider area. This causes wingko products are usually found only in the around of the producers (Central Java and East Java). C. INNOVATION 1. Composition of Raw Materials In order to produce optimal product, the selection of raw materials and the proper formulation is very important. For getting longer shelf life it is sugggested to use desiccated coconut. The complete process of desiccated coconut can be seen in Appendix 1. For getting good desiccated coconut (no clumping), it is sugggested to use coconut that have age about 11 months-12 months due to galactomanan and phospholipida content in the age of the levels is fairly low (1%-2%) (Barlina 1999). Galactomanan and high moisture content in the coconut meat form viscous solutions and gel, so causes the grains of desiccated coconut can clump. In addition, phospholipida or phosphatides containing fatty acid esters, phosphoric acid and other compounds that contain nitrogen and will be decomposed into ketone coumponds (Kirchenbauer 1960). Coconuts are processed into desiccated coconut in order to reduce the initial contamination, to denaturate protein, to inactivate lipase enzyme, and to reduce moisture content. This is caused by drying that make water discharges from food matrix using heat energy, so it can decrease moisture content. Drying can preserve food because of some water in food is removed. So, spoilage microorganism can not grow in such limited water condition (low aw). And also enzymes that stimulate chemical reactions in food can not be active without water (Singh and Heldman 2001). Based on research conducted by Suprapto (2006), wingko that use desiccated coconut has shelf life of about 9 days. However, the desiccated

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coconut was soaked for 12 hours so that could increase the risk of contamination. Therefore, the Authors suggest steaming for desiccated coconut before being used in the formula. In order to replace soaking and reduce recontamination. Then suggested the reformulation of wingko basic ingredients (waxy rice flour, coconut, and sugar) to 2:2:1. This new formulas is determined based on observation. If in the formulation coconut was used excessively, wingko will be too soft and rancid easily. Moreover, if sugar was used excessively, wingko will be burnt fast. Then if waxy rice flour was used excessively, wingko will be too solid. Hence, the new formula is selected. 2. Processing Suggested wingko processing steps are applying of drying and steaming. Drying is used to get desiccated coconut. Then, steaming is used to pre-treatment desiccated coconut. This process occurs in approximately 15 minutes to give mass for desiccated coconut so that gives juiciness and to inactivate lipase enzyme that still alive in the desiccated coconut. Inhibiting of lipase enzyme by steaming has been evidenced by research that done by Yuniarrahmani (2001) in gran. The research showed that TBA (thiobarbituric acid) number in steamed gran decreases after steaming. Then, research that done by Adinugraha (2009) showed that treatment of steaming for Jatropha seeds within 45 and 60 minutes causes heat energy transfer, so most of the lipase in Jatropha seeds contact with heat and will be denaturated. Then suggested baking step is using of banana leaves as base of pan. The purpose is for reducing fat content in wingko. It is because of using of margarine as spreader for pan can increase fat content in wingko. Moreover, using of banana leaves can also decrease of production cost because banana leaves can be found easily everywhere. Banana leaves can also give unique aroma in final product. The complete process of making wingko can be seen in Appendix 2. 3. Packaging Suggested packaging technology is using nylon-LLDPE plactics that combined with using oxygen absorber. Composite plastic is a kind of plastics consists of many types of plastic. The purpose of using composite plastic is to get optimal function. Nylons are thermoplast polyamide plastics. In general, nylons are clear, thermoformable, strong, and tough over a broad range of temperatures. Nylons show excellent chemical resistance and are good barriers to gas, oil, and aromas (Hernandez 2004). According to Buckle et al (1988), water permeability of nylons is high enough; it is 7,0x1010cm3/cm3/mm/sec/cmHg at temperature 250C with RH 90% (Table 4). Compared to other plastics, nylon has weakness as water barier.

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Linear low-density polyethylene (LLDPE) is characterized by narrow molecular weight distributions, a linear structure with very short branches, and low density values (0.916 to 0.940 g/cm3). Due to its molecular linearity, LLDPE is more crystalline and therefore stiffer than LDPE. LLDPE has better tensile strength, puncture resistance, tear properties, and elongation than LDPE. Because of its greater crystallinity, LLDPE is more hazy and glossy than LDPE (Hernandez 2004). For most applications, nylons are combined with other materials, such as LLDPE, LDPE, ionomer, and EVA, to add moisture barrier and heat sealability. Multilayer films containing a nylon layer are used principally in vacuum-packing bacon, cheese, bologna, hot dogs, and other processed meats (Hernandez 2004). Nylon-LLDPE composite plastic has both nylon and LLDPE characteristic. It will be good barrier for air (oxygen) and also water, which can prevent rancidity and get longer wingko shelf life. Siswantos research (1998) showed that sale pisang (fatty food) storage uses PP plastic and oxygent absorber could give 8 week shel life time, longer than using double PP plastic or single PP plastic. TBA number as oxidation parameter of sale pisang could be decreased as figured in Figure 3. Result of Siswantos research is supported by Indras research (1991) that wingko storage uses oxygen absorber has shelf life about of 60 days, whereas the original one only has shelf life about of 2 days.

Figure 3. Correlation between TBA Number and Shelf Life of Sale Pisang

D. COST ANALYSIS
Basic ingredients cost to make wingko is about 16000 IDR, and it will produce about 75 pieces of wingko in round form with diameter about 3 centimeters and width about 1 centimeter. So, each wingko has basic ingredients cost is about 210 IDR. This wingko is packaged in box contain 20 pieces. Wingko with standar process has processing cost is about 70 IDR/wingko. Drying and steaming make the processing cost become 160 IDR/wingko. For packaging, wingko with standar packaging uses PE plastics has packaging cost

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about 100 IDR for a pack (20 pieces of wingko). When using vacum packaging with oxygen absorber, the packaging cost incerases up to 2100 IDR for a pack. Table 5. Comparison between Cost for Each Wingko and Shelf Life of Wingko in Different Process and Packaging Basic ingedients cost (IDR) 210 210 Processing cost (IDR) 70 160 Packaging cost (IDR) 5 5 Basic Production cost (IDR) 285 375 Shelf life estimation 3 days 9 days

Treatments Standard Drying and steaming Drying, steaming, vacum packaging, and oxygen absorber applying

210

160

250

620

60 days

Table 5 shows that wingko SMEs can improve the adding value of wingko by extending wingko shelf life in feasible cost. For standard wingko, basic production cost (BPC) is about 285 IDR, for changed process wingko is about 375 IDR dan for changed process and packaging wingko is about 620 IDR. If wingkos price by standard treatment was between 700 IDR and 1000 IDR, the combination of reformulation and new treatments will increase the price up to 1200 IDR until 1500 IDR. Increasing of cost and price of wingko is proportional with extending of product shelf life. Initial shelf life of wingko is just about 3 days and by this innovation it becomes about 60 days (20 times longer). By extending of shelf life, wider market area of wingko will be covered and the probability of product return will be reduced.

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V. CONCLUSION Wingko is an Indonesian traditional food that has short shelf life of about 3 days. It is caused by rancidity and mold contamination. There are five steps of innovations are to be introduced in the new process of wingko production. The first step is the reformulation of wingko basic ingredients (waxy rice flour, coconut, and sugar) to 2:2:1. The second step is using desiccated coconut instead of raw coconut. The third step is steaming desiccated coconut before being used in the formula. The fourth step is using plastic composite film of nylon/LLDPE as packaging material. And finally the fifth step is by introducing vacuum packaging technique with oxygent absorber. By the combination of process and packaging technique, it is expected that the shelf life of wingko will be extended up to 2 months. Hence, wider market area of wingko will be covered and the probability of product return will be reduced. After cost analysis was done, the basic production cost comparison between standard wingko and innovated wingko (new formulation,processing, and packaging) is 285 IDR and 620 IDR. The price comparison between standard wingko and innovated wingko is 700 IDR-1000 IDR and 1200 IDR-1500 IDR. So, cost analysis showed that these innovations are feasible and profitable for wingko SMEs.

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APPENDIX Appendix 1. Flow Chart of Desiccated Coconut Mature Coconut (11-12 months) Sorted Good coconut meat Testa peeled Washed Coconut meat free testa Sliced into a small piece Grated Dried in oven (T = 1000C ; t = 1,5 Hours

Desiccated coconut

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Appendix 2. Flow Chart of Wingko Processing Waxy rice flour, salt, sugar

Mixed

Desiccated coconut

Mixed

Egg, water

Mixed

Dough Formed Putted on the tray Baked in oven (T=1800C ; t= 30 minutes) Wingko