c

 

The annual rice production of rice in Sri Lanka is about 2,645,385 metric tons in Maha
2009/2010 season. Sri Lanka is in very near state to achieve self sufficiency of rice. Further
annual cow milk production of Sri Lanka as at 2009 isV184,064,880 liters. The Annual cinnamon
production in Sri Lanka as at 2009 15,983 Kgs. The annual vanilla production in Sri Lanka is
about 8000 Kilograms.
All above ingredients are imported to Sri Lanka in low or high amounts. Development of this
novel food product will help to enhance economy by value addition for above raw materials.
And further this will give us a way to export our products to other rather than exporting them as
raw material it self.

0 
0
is whole and broken kernels obtained from the monocot plant species u
L. As
a cereal grain, it is the most important staple food for a large part of the world's human
population, especially n East, South, Southeast Asia, the Middle East, Latin America, and
the West Indies. It is the grain with the second highest worldwide production, after maize (corn).

j


Milk is defined as the lacteal secretion, practically free from colostrum, obtained from the
complete milking of one or more healthy cows.

D

D


 
  

c 0
c 
°V 100 g Red parboiled Rice
°V 400 ml Milk
°V 50 g Sugar
°V 5g Vanilla
°V 2.5 g Cinnamon
°V Ice
°V Water

D D 
 
  
Place the rice in a bowl with enough hot water to cover. Let the rice sit overnight. Next day,
remove the water. Place 50ml of water, and 200ml milk in a blender. Blend until rice is all
ground up. Mix in 25g sugar, 2.5g vanilla, and 1.25 g cinnamon. Do the same with the other half
of the ingredients. Strain through cheesecloth (or whatever). Serve over ice. Makes 600ml of
drink. Add sodium benzoate 50 ppm before packing into glass bottles.


 D
  

 

 

Incoming Incoming c
  c
  c
  Water

sugar Milk red raw Va a
 a
r
e

IQC IQC IQC IQC IQC Water

pur
at
pr
ess

Temporary Temporary Temporary Temporary Temporary

storage storage storage storage storage Temporary
storage

R
e saked
 ht water Heating
r 6hrs of water
(80oC)

Blending of
rice, water
and milk

Mixing Sugar,
Vanilla,
Cinnamon
(15mins)

Filtration
IQC = Incoming quality checking
Pasteurization
(HTST method)

Filling

Bottling
and capping
 c  

  
This section deals on the quality factors that should be checked during incoming quality
checking. If the given values deviate from the standards it should be rejected or should bring to
an accepted parameters.



Purified and crystallised sucrose (saccharose) with a polarisation not less than 99.7 ºZ.

  


 


Sulphated ash (% m/m ) N/A

Conductivity ash (% m/m) V0.04
Invert sugar content (% m/m)VVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVV0.04 VVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVV
Sucrose plus invert sugar content (% m/m expressed as sucrose) N/A
Loss on drying (% m/m) UV0.1
Starch content (% m/m)VVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVN/A
Colour (ICUMSA units) VU60
pH (for 10% m/m) N/A

c  j


!



j

j"
!

Copper 0.05 mg/kg
Iron 0.2 mg/kg

# 0$%&c'%#0
Maximum free fatty acids (% m/mas
oleic acid) 0.3

Maximum peroxide value (milli- 0.3

equivalents of oxygen/kg fat)

Taste and odour Acceptable for market requirements after heating a sample to 40---
45°C

Texture Smooth and fine granules to liquid, depending on temperature

c   
V
 c%&#jD#cc#%
$%&c'%#0

V


( 

Rice shall be safe and suitable for human consumption.

Rice shall be free from abnormal flavours, odours, living insects and mites.




( 
j
 

15% m/m max
Lower moisture limits should be required for certain destinations in relation to the
climate, duration of transport and storage. Governments accepting the Standard are
requested to indicate and justify the requirements in force in their country.
"
 

: is defined as organic and inorganic components other than kernels of rice.



: impurities of animal origin (including dead insects) 0.1% m/m max

#
   "
 

such as foreign seeds, husk, bran, fragments of straw, etc.
shall not exceed the following limits

Milled Parboiled Rice 0.5% m/m

c   "
 

such as stones, sand, dust, etc. shall not exceed the following
limits

Milled Parboiled Rice 0.1% m/m

#%jc%

!


The products covered by the provisions of this standard shall be free from heavy metals in
amounts which may represent a hazard to human health.

D 
   
Rice shall comply with those maximum residue limits established by the Codex Alimentarius
Commission for this commodity.

' c  
It is recommended that the product covered by the provisions of this standard be prepared and
handled in accordance with the appropriate sections of the 0
    
 
 

   
 


  (CAC/RCP 1-1969), and other Codes of Practice
recommended by the Codex Alimentarius Commission which are relevant to this product.

To the extent possible in good manufacturing practice, the product shall be free from
objectionable matter.
When tested by appropriate methods of sampling and examination, the product:
± shall be free from micro-organisms in amounts which may represent a hazard to
health;
± shall be free from parasites which may represent a hazard to health; and
± shall not contain any substance originating from micro-organisms, including fungi, in amounts
which may represent a hazard to health.

Ô 


)



Husked rice or parboiled husked rice with a length/width ratio of 2.1±3.0.

  




Medium grain rice has a kernel length of 6.2 mm or more but less than 6.6 mm.

%* 
 
  



 
 

)



j   has a kernel length of more than 5.2 mm but not more than 6.0 mm and a
length/width ratio of less than 3

c  + 



Codex has not yet established standards. Therefore basic hygiene parameters should be checked.

c    




Should maintain WHO portable water standards

(ref: http://www.who.int/water_sanitation_health/dwq/gdwq3rev/en/index.html)

0  

1000kg of red parboiled rice is filled into soaking tank and water at 80 oC is filled into tank that
is enough to cover the rice. ( about 1003 lit) and kept for about six hours to stand.

0


 ,. Most rice is perfectly cooked when the final moisture content is
between 58% and 64% moisture. At lower moisture contents, the rice is firmer. The final
moisture content is a matter of preference and preference can differ with the type of rice and
final cooked application. The math is very simple; 100 grams of rice with a starting moisture
content of 12% needs 110 grams of water to be fully cooked at 58% moisture. 100 grams of rice
with a starting moisture of 12% needs 145 grams of water to be fully cooked at 64% moisture.

V
 
  . Soaking the rice reduces the cooking time of the rice and improves the final
texture. Rice is not done until the center is cooked. Moisture does not transfer easily through
rice. It take about 15 minutes in boiling water to get water and heat to the center of the kernel. So
the outside of the kernel has been cooked for 15 minutes while the center has been cooked only a
minute or so. The more the outside of the kernel cooks, the more starch leaches out and the
mushier it gets. Soaking rice allows moisture to get to the center of the kernel.

-
   . The rice needs to cook in hot water in order to get additional moisture into the
rice and transfer the heat necessary to gelatinize the starch.

-
  
Remove the water by decanting it and add 1000 liters of rice and 4000l of milk to blender and
blend until the rice is fully ground. Then add 500Kg sugar, 50 kg Vanilla, 25 kg of cinnamon
and mix well for 15 minutes.

c 

j"  -
 

These used to mix or blend a wide range of materials used in different industries including
the food, chemical, pharmaceutical, plastic and mineral industries. They are mainly used to mix
different materials using different types of blades to make a good quality homogeneous mixture.
Included are dry blending devices, paste mixing designs for high viscosity products and high
shear models for emulsification, particle size reduction and homogenization.

Industrial mixers range from laboratory to production line scale, including Ribbon Blender, V
Blender, Cone Screw Blender, Screw blender, Double Cone Blender, Double Planetary High
Viscosity Mixer, Counter-rotating, Double & Triple Shaft, Vacuum Mixer, Planetary Disperser,
High Shear Rotor Stator and Dispersion Mixers, Paddle, Jet Mixer and Mobile Mixers.
The Banbury mixer is effective at mixing or kneading viscous materials.

They can operate at different temperatures and pressures for mixing different solutions and can
also have internal or external heating systems added to them. Options also exist where spray
nozzles, CIP, PLC and pneumatic or electric systems can be used. Systems can come equipped
withhydraulic or electronic soft start mechanisms so that they start and stop smoothly.
 j
V V



V   V


V j
V
V
V

  V

 VVV
V
 VV V
j 
 V




 
This is done to remove the remaining debris of rice cinnamon and other unwanted particles.




 
Filtration is the removal of insoluble solids from a suspension (or µfeed slurry¶) by passing it
through a porous material (or µfilter medium¶). The resulting liquor is termed the µfiltrate¶ and
the separated solids are the µfilter cake¶. Filtration is used to clarify liquids by the removal of
small amounts of solid particles.

 
When a suspension of particles is passed through a filter, the first particles become trapped in the
filter medium and, as a result, reduce the area through which liquid can flow. This increases the
resistance to fluid flow and a higher pressure difference is needed to maintain the flow rate of
filtrate. The rate of filtration is expressed as follows:
Rate of filtration =driving force (the pressure difference across the filter)_
resistance to flow
Assuming that the filter cake does not become compressed, the resistance to flow
through the filter is found using

where 0(m_2) _ resistance to flow through the filter, _ (N s m_2) _ viscosity of the liquid, 
(m_2) _ specific resistance of the filter cake, (m3) _ volume of the filtrate, c _ the fractional
volume of filter cake in the feed liquid volume, , (m2) _ area of thefilter and _ equivalent
thickness of the filter and initial cake layer.
For constant rate filtration, the flow rate through the filter is found using
where () (m3 s_1) = flow rate of filtrate, (Pa) = pressure difference and (s) = filtration
time. This equation is used to calculate the pressure drop required to achieve a desired flow rate
or to predict the performance of large scale filters on the basis of data from pilot scale studies.
In constant-pressure filtration, the flow rate gradually decreases as the resistance to flow, caused
by the accumulating cake, increases. Equation (6.5) is rewritten with constant as:

If ____ is plotted against _, a straight line is obtained .The slope and the intercept are used
to find the specific resistance of the cake and the equivalent cake thickness of the filter medium:

If the filter cake is compressible (that is the specific resistance changes with applied pressure) the
term is modified as follows

where V Vis the specific resistance of the cake under a pressure difference of 101 V103 Pa
and =the compressibility of the cake. This is then used in equation . Derivations of the above
equations and further details are given by Earle (1983), Jackson and Lamb (1981) and Toledo
(1999a).


Gravity filtration is slow and finds little application in the food industry. Filtration
equipment operates either by the application of pressure to the feed side of the filter bed
or by the application of a partial vacuum to the opposite side of the filter bed. Centrifugal
filtration using a basket centrifuge is described above. Filter aids are usually applied to
the filter or mixed with the food to improve the formation of filter cake.
D    
Two commonly used pressure filters are the batch 
   
  and the 



  

 . In the plate-and-frame design, cloth or paper filters are supported on vertical
plates. Feed liquor is pumped into the press and liquid passes through the filter cloths and flows
down the grooved surfaces of the plates to drain through an outlet channel in the base of each
plate. A layer of cake builds up on the cloths until the space between the plates is filled.

In operation, the pressure is increased to a pre-determined value and the plates are then back-
washed with water. The press is dismantled and the cake is removed, ready to begin another
cycle. The filter press has relatively low capital costs, high flexibility for different foods, it is
reliable and easily maintained. It is widely used for the production of apple juice and cider (for
example Jones 
, 1983). However, it is time consuming and highly labour intensive.

The 


  
 is used to overcome the problems of high labour
costs and lack of convenience of plate-and-frame presses. It consists of mesh µleaves¶,
which are coated in filter medium and supported on a hollow frame which forms the
outlet channel for the filtrate. The leaves are stacked horizontally or vertically inside a
pressure vessel, and in some designs they rotate at 1±2 rev min_1 to improve the
uniformity of cake buildup. Feed liquor is pumped into the shell at a pressure of
approximately 400 _ 103 Pa. When filtration is completed, the cake is blown or washed
from the leaves. This equipment has a higher cost than plate filters and is best suited to
routine filtration of liquors which have similar characteristics.

D
.
 
Pasteurization is a relatively mild heat treatment, in which food is heated to below 100ºC.
In low acid foods it is used to minimize possible health hazards from pathogenic micro-
organisms and to extend the shelf life of foods for several days. In this process minimal changes
are caused to the sensory characteristics or nutritive value.
 
The sensible heat required to raise the temperature of a liquid during pasteurization is
found using

where (W) =specific rate of heat transfer, (kg s_1)= mass flow rate,
(kJ kg_1 ºC_1)= specific
heat capacity and =temperature change.
The extent of the heat treatment required to stabilise a food is determined by the value of the
most heat-resistant enzyme or micro-organism which may be present milk. pasteurisation is
based on 60 and a 12 logarithmic cycle reduction in the numbers of   (Harper, 1976),
As flavours, colours and vitamins are also characterised by values, pasteurisation conditions
can be optimised for retention of nutritional and sensory quality by the use of high-temperature
short-time (HTST) conditions. For example in milk processing the lower-temperature longer-
time process operating at 63ºC for 30 min (the 
 process) causes greater changes to flavour
and a slightly greater loss of vitamins than HTST processing at 71.8ºC for 15 s and it is less often
used. Higher temperatures and shorter times (for example 88ºC for 1 s, 94ºC for 0.1 s or 100 ºC
for 0.01 s for milk) aredescribed as higher-heat shorter-time processing or µflash pasteurization¶.

D

   


Swept surface heat exchangers (Barclay 
, 1984) or open boiling pans are used for small-
scale batch pasteurisation of some liquid foods. However, the large scale pasteurisation of low
viscosity liquids (for example milk) usually employs plate heat exchangers.

The 
  consists of a series of thin vertical stainless steel plates, held tightly together in a
metal frame. The plates form parallel channels, and liquid food and heating medium (hot water
or steam) are pumped through alternate channels, usually in a counter-current flow pattern . Each
plate is fitted with a synthetic rubber gasket to produce a watertight seal and to prevent mixing of
the product
Counter-current flow through plate heat exchanger: (a) one pass with four channels per
medium; (b) two passes with two channels per pass and per medium.
(Courtesy of HRS Heat Exchangers Ltd.)

and the heating and cooling media. The plates are corrugated to induce turbulence in the liquids
and this, together with the high velocity induced by pumping, reduces the thickness of boundary
films to give high heat transfer coefficients (3000±11 500Wm_2K_1). The capacity of the
equipment varies according to the size and number of plates, up to 80 000 l h_1.
In operation ,food is pumped from a balance tank to a µregeneration¶section, where it is pre-
heated by food that has already been pasteurised. It is then heated to pasteurising temperature in
a heating section and held for the time required to achieve pasteurisation in a holding tube. If the
pasteurising temperature is not reached, a flow diversion valve automatically returns the food to
the balance tank to be re pasteurised. Thepasteurised product is then cooled in the regeneration
section (and simultaneously preheats incoming food) and then further cooled by cold water and,
if necessary, chilledwater in a cooling section.
The regeneration of heat in this way leads to substantial savings in energy and up to 97% of the
heat can be recovered. Heat recovery is calculated using:

The advantages of heat exchangers over in-bottle processing include:

‡ more uniform heat treatment
‡ simpler equipment and lower maintenance costs
‡ lower space requirements and labour costs
‡ greater flexibility for different products
‡ greater control over pasteurisation conditions



 
The selection of an appropriate filling machine depends on the nature of the product and the
production rate required. Gravity, pressure and vacuum fillers are each used for liquid foods and
are described in detail by Osborne (1980). In each case an airtight seal is made between the
container and the filling head, and liquid is filled until it reaches a vent tube, which is set to give
the correct fill-weight or volume.
Volumetric fillers commonly used for liquids, pastes, powders and particulate foods. The filling
heads are either in line or in a µcarousel¶ (or rotary) arrangement.


D 

Packaging may be defined in terms of its protective role as in µpackaging is a means of achieving
safe delivery of products in sound condition to the final user at a minimum cost¶ or it can be
defined in business terms as µa techno-economic function for optimizing the costs of delivering
goods whilst maximising sales and profits¶.
The functions of packaging are:
‡ Containment ± to hold the contents and keep them secure until they are used
‡ Protection ± against mechanical and environmental hazards encountered during
distribution and use
‡ Communication ± to identify the contents and assist in selling the product. Shipping
containers should also inform the carrier about the destination and any special
handling or storage instructions. Some packages inform the user about method of
opening and/or using the contents
‡ machinability ± to have good performance on production lines for high speed filling,
closing and collating (1000 packs per min or more), without too many stoppages
‡ convenience ± throughout the production, storage and distribution system, including easy
opening, dispensing and/or after-use retail containers for consumers (Paine, 1991).

The main factors that cause deterioration of foods during storage are:
‡ climatic influences that cause physical or chemical changes (UV light, moisture
vapour, oxygen, temperature changes)
‡ contamination (by micro-organisms, insects or soils)
‡ mechanical forces (damage caused by impact, vibration, compression or abrasion)
‡ pilferage, tampering or adulteration .
Packaging provides a barrier between the food and the environment. It controls light
transmission, the rate of transfer of heat, moisture and gases, and movement of microorganisms
or insects. In addition the package should not influence the product (for example by migration of
toxic compounds, by reactions between the pack and the food or by selection of harmful micro-
organisms in the packaged food. Other requirements of packaging are smooth, efficient and
economical operation on the production line, resistance to damage such as fractures, tears or
dents caused by filling and closing equipment, loading/unloading or transportation, and not least,
minimum total cost.

&

Light transmission is required in packages that are intended to display the contents, but is
restricted when foods are susceptible to deterioration by light (for example by oxidation
of lipids, destruction of riboflavin and natural pigments). The amount of light absorbed
by food in a package is found using:

where a (Cd) =intensity of light absorbed by the food, i (Cd)= intensity of incident
light, p =fractional transmission by packaging material, 0p = the fraction reflected by
the packaging material and 0f= the fraction reflected by the food.

The fraction of light transmitted by a packaging material is found using the Beer±
Lambert law:

where t (Cd) _ intensity of light transmitted by the packaging, ’ =the characteristic

absorbance of the packaging material and (m) = thickness of the packaging material.
The amount of light that is absorbed or transmitted varies with the packaging material
and with the wavelength of incident light. Some materials (for example low-density
polyethylene) transmit both visible and ultraviolet light to a similar extent, whereas
others (for example polyvinylidene chloride) transmit visible light but absorb ultraviolet
light. Pigments may be incorporated into glass containers or polymer films, they may be
over-wrapped with paper labels to reduce light transmission to sensitive products, or they may be
printed Alternatively, clear packs may be contained in fibreboard boxes for distribution and
storage.
 

The insulating effect of a package is determined by its thermal conductivity and its reflectivity.
Materials which have a low thermal conductivity (for example paperboard, polystyrene or
polyurethane) reduce conductive heat transfer, and reflective materials (for example aluminium
foil) reflect radiant heat. However, control over the temperature of storage is more important
than reliance on the packaging to protect foods from heat. In applications where the package is
heated (e.g. in-container sterilisation or microwaveable ready meals), the packaging material
must be able to withstand the processing conditions without damage and without interaction
with the food.

j
 
Moisture loss or uptake is one of the most important factors that controls the shelf life of
foods. There is a micro-climate within a package, which is determined by the vapour
pressure of moisture in the food at the temperature of storage and the permeability of the
packaging. Control of moisture exchange is necessary to prevent microbiological or
enzymic spoilage, drying out or softening of the food, condensation on the inside of
packages and resulting mould growth.

j  

 

The suitability of a package to protect foods from mechanical damage depends on its
ability to withstand
, caused by stacking in warehouses or vehicles,  
caused by rubbing against equipment or during handling, 
 or  
 caused
by impacts during handling or by  during transport. Some foods (for example
fresh fruits, eggs, biscuits, etc.) are easily damaged and require a higher level of
protection from a package, including cushioning using tissue paper, foamed polymer
sheets, or from paperpulp that is formed into shaped containers for individual pieces (e.g.
egg cartons, fruit trays). For other foods, protection is provided by a rigid container and/
or restricted movement by shrink- or stretch-wrapping or by using plastic packages that
are tightly formed around the product.
Wooden crates and barrels or metal drums have a long history of use as shipping containers
as they provide good mechanical protection. These are now being replaced by cheaper
composite intermediate bulk containers (IBCs) made from fibreboard and polypropylene.
Examples of IBCs include a seamless, 6±9 ply corrugated fibreboard container, capable of
withstanding 20 tonnes compression. It can be lined with a multi-ply film for liquids and,
because no metal or wood is used in the construction, it is biodegradable and more easily
recyclable (Anon., 1998). IBCs are claimed to carry 20% more product than drums in a given
space and because they are flat when empty, save 80% on storage space. The rapid expansion
in the use of polymer pots, trays and multi-layer cartons (Sections 24.2.5 and 24.2.6) has also
increased the degree of protection that is available for specific foods.
The strength of polymer and paper or board materials can be assessed by measuring
the stress that results from an applied force to give the following .
‡ the tensile strength
‡ Young¶s modulus
‡ the tensile elongation
‡ the yield strength
‡ the impact strength

Each of these factors is influenced by the temperature of the material and the length of time that
the force is applied (Briston and Katan, 1974a). The molecular structure of polymer films may be
aligned in different ways depending on the type of film and method of manufacture. Orientation
of molecules in one direction (uniaxial) or in both directions (biaxial) improves the mechanical
properties of some films (for example polyethylene, polypropylene, polyethylene terephthalate
and polystyrene ).

Type of Packaging material used for the product is glass bottle. since Glass jars and bottles are
made by heating a mixture of sand (73%), the main constituent being silica (99% SiO2), broken
glass or µcullet¶ (15±30% of total weight), soda ash (Na2CO3) and limestone (CaCO3 or
CaCO3.MgCO3) to a temperature of 1350±1600ºC.Alumina (Al2O3) improves the chemical
durability of the glass, and refining agents reduce the temperature and time required for melting,
and also help remove gas bubbles from the glass. Colourants include chromic oxide (green), iron,
sulphur and carbon (amber), and cobalt oxide (blue). Flint (clear) glass contains decolourisers
(nickel andcobalt) to mask any colour produced by trace amounts of impurities (e.g. iron).

Glass containers have the following advantages:

‡ they are impervious to moisture, gases, odours and micro-organisms
‡ they are inert and do not react with or migrate into food products
‡ they have filling speeds comparable with those of cans
‡ They are suitable for heat processing when hermetically sealed
‡ they are transparent to microwaves
‡ they are re-useable and recyclable
‡ they are resealable
‡ they are transparent to display the contents and can be decorated
‡ they can be moulded into a wide variety of shapes and colours
‡ they are perceived by the customer to add value to the product
‡ they are rigid, having good vertical strength to allow stacking without damage to the
container.

The main disadvantages of glass include:

‡ higher weight which incurs higher transport costs than other types of packaging
‡ lower resistance than other materials to fracturing and thermal shock
‡ more variable dimensions than other containers
‡ potentially serious hazards from glass splinters or fragments in foods.

Although glass can be made into a wide variety of shapes, particularly for marketing
high-value products such as liqueurs and spirits, simple cylindrical shapes are stronger
and more durable. Sharp corners and abrasion of glass surfaces weaken the container, and design
features such as a protruding µshoulder¶ which
minimises contact between containers during handling, or protection by a plastic sleeve
are used to reduce the risk of damage.
Alternatively glass surfaces may be treated with titanium, aluminium or zirconium
compounds to increase their strength and also enable lighter containers to be used.
Developments in glass-making technology, including reductions in wall thickness
(lightweighting) and computer design of containers, are described by Lomax (1987). Louis
(1998) describes potential advances in glass-making technology using plasma-arc
crucibles to melt raw ingredients. The molten glass could then be co-extruded in a similar
way to that currently used for plastic containers to produce jars or bottles of any shape,
size or thickness.

j*
  
The law of conversion of mass states that µthe mass of material entering a process equals
the mass of material leaving¶. In case this has can apply for the mixing step.In general a mass
balance for a process takes the following form:

Mass of raw materials in= mass of products and wastes out+ mass of stored materials+ losses

Many mass balances are analysed under steady-state conditions where the mass of stored
materials and losses are equal to zero. Mass balances are used to calculate the quantities of
materials in different process streams, to design processes, to calculate recipe formulations, the
composition after blending, process yields and separation efficiencies.

*
   




water loss due to evaporation is 2%

For soaking
Mass of raw materials in= mass of products and wastes out+ mass of stored materials+ losses
Mass of rice + Mass of H20 = Mass of H20 removed+ mass of stored materials + water loss due
to evaporation

1000 Kg + 1003 kg = 503 kg+ mass of stored materials + 200

Mass of stored materials = 1300 kg

For blending and mixing

Mass of raw materials in= mass of products and wastes out+ mass of stored materials+ losses
Mass of rice + Mass of H20 + Mass of milk + Mass of vanilla + Mass of Cinnamon+ Mass of
Sugar= Mass of ungrounded particles + Mass of cinnamon +Mass stored in material + Water loss
due to evaporation

1300 kg + 1000 kg + 4000 kg+ 50Kg +25Kg+500Kg = 1Kg +25 kg+ Mass stored in material+
46 kg

Mass stored in material =6803 Kg

 *
  
An energy balance states that µthe amount of heat or mechanical energy entering a process= the
total energy leaving with the products and wastes+ stored energy + energy lost to the
surroundings¶. If heat losses are minimised, energy losses to the surroundings may be ignored for
approximate solutions to calculation of, for example, the quantity of steam, hot air or refrigerant
required. For more accurate solutions, compensation should be made for heat losses.
j   

  
 
 heat transfer takes place when there is a constant temperature difference between
two materials. The amount of heat entering a material equals the amount of heat leaving, and
there is no change in temperature of the material. This occurs for example when heat is
transferred through the wall of a cold store if the store temperature and ambient temperature are
constant, and in continuous processes once operating conditions have stabilised. However, in the
majority of food-processing applications the temperature of the food and/or the heating or
cooling medium are constantly changing, and  
 heat transfer is more commonly
found.
Calculations of heat transfer under these conditions are extremely complicated but are simplified
by making a number of assumptions and using prepared charts and computer models to give
approximate solutions.

/

 
 
The rate at which heat is transferred by conduction is determined by the temperature difference
between the food and the heating or cooling medium, and the total resistance to heat transfer.
The resistance to heat transfer is expressed as the conductance of a material, or more usefully as
the reciprocal which is termed the thermal conductivity.
Under steady-state conditions the rate of heat transfer is calculated using

Where (J s_1) = rate of heat transfer, (Jm_1 s_1K_1 or Wm_1K_1) = thermal conductivity, 
(m2) =surface area, (oC or K) _ temperature difference and (m) = thickness of the
material. is also known as the temperature gradient.
The thermal conductivity of foods is influenced by a number of factors concerned with the nature
of the food (for example cell structure, the amount of air trapped between the cells, and the
moisture content), and the temperature and pressure of the surroundings. A reduction in moisture
content causes a substantial reduction in thermal conductivity.
$ 
/

 
 
During processing, the temperature at a given point within a food depends on the rate of
heating or cooling and the position in the food. The temperature therefore changes
continuously. The factors that influence the temperature change are:
‡ The temperature of the heating medium
‡ The thermal conductivity of the food
‡ The specific heat of the food.
Thermal diffusivity is related to the thermal conductivity, specific heat and density of a food by
where (m2 s_1) =the thermal diffusivity, VVVVVVV(kgm_3) = density,
(J kg_1K_1) = specific heat
capacity and (Wm_1K_1) = thermal conductivity.
The basic equation for unsteady-state heat transfer in a single direction () is

where d_/d=change in temperature with time.

 ! 
 
Forced convection takes place when a stirrer or fan is used to agitate the fluid. This reduces the
boundary film thickness to produce higher rates of heat transfer and a more rapid temperature
redistribution. Consequently, forced convection is more commonly used than natural convection
in food processing. Examples of forced convection include mixers and liquids pumped through
heat exchangers.
When liquids or gases are used as heating or cooling media, the rate of heat transfer from the
fluid to the surface of a food is found using


The  
   
 
 is a measure of the resistance to heat flow, caused by the
boundary film, and is therefore equivalent to the term /in the conduction equation. It is higher
in turbulent flow than in streamline flow. Heat transfer through air is lower than through liquids
and higher rates of heat transfers are obtained by moving air than still air. Larger heat exchangers
are therefore necessary when air is used for heating or cooling compared to those needed for
liquids. Condensing steam produces higher rates of heat transfer than hot water at the same
temperature and the presence of air in steam reduces the rate of heat transfer. The surface heat
transfer coefficient is related to the physical properties of a fluid (for example density, viscosity,
specific heat), gravity (which causes circulation due to changes in density), temperature
difference and the length or diameter of the container under investigation. The formulae which
relate these factors are expressed as dimensionless numbers as follows:
where 
(W m_2 K_1) =convection heat transfer coefficient at the solid-liquid interface, 
(m) =the characteristic dimension (length or diameter), (W m_1 K_1) = thermal con ductivity of
the fluid,
(J kg_1 K_1) = specific heat at constant pressure, (kg m_3) = density, (N sm_2) =
viscosity, (m s_2) = acceleration due to gravity, _ (m m_1 K_1) =coefficient of thermal
expansion, __ (K) _ temperature difference and (m s_1) =velocity.

For streamline flow through pipes

For turbulent flow through pipes,

where = 0.4 for heating or  0.3 for cooling, when Re > 10 000, viscosity is measured at the
mean 
temperature and other physical properties are measured at themean bulk temperature
of the fluid.
The Grashof number is used for natural convection when there is no turbulence in the fluid.
Formulae for other types of flow conditions and different vessels are described by Loncin and
Merson (1979), Jackson and Lamb (1981) and Earle (1983).

% 00 %j 
Most soft drink factories further install water treatment plants.The objectives of water treatment
are ««.
* A uniform water at all seasons of the year
* Removal of colloidal and suspended matter
* Removal of colour
* Removal of off tastes and odours
* Reduction of alkalinity to a set level
* Freedom from micro ± organism
* Removal of residual Cl2 from water (Use of carbon filler)
Mostly used combination of chemicals for the treatment of water is Ca(OH)2 , FeSO4 and
NaOCl

 %
%0
% 00 %j D&%

Water treatment almost universally applied for the production of carbonated soft drinks is to hold
the water in a tank and add a coagulant (FeSO4) and chlorine together with lime to reduce
alkalinity if necessary.
A gelatinous precipitate is formed, which absorbs foreign organic matter chlorine has both a
beneficial oxidizing and a microbiocidal effect. The water is subsequently passed through a sand
filter, then a carbon bed for removal of the chlorine and finally through a polishing filter.

NaOCl HOCl OCl- + H+

To aid the chemical treatment of the water super chlorinating with doses above 2 mg / Ltr. Must
be used.
Cl2 + H2O HCl + HOCl
HOCl H+ + OCl-
Cl2 + H2O 2HCl + O (free Radical)
Organic matter O (free Radical) Oxidized organic matter

Alkalinity is reduced by the removal of the bicarbonate iron and a blanket of floc consisting
of isoluble calcium carbonate, magnesium hydroxide and ferric-hydroxide is formed at the
base of the reaction tank through which the water has to pass.


 0
Both Ferric hydroxide and Aluminium hydroxide are colloids of variable composition. In hard
waters the floc they form is weighted down with the mixture of pecipitated calcium and
magnesium salts. Here no trouble of maintaining the bed of floc at the base of the coagulation
tank and for some waters a stirrer is essential to prevent the floc bed from solidifying.
In soft waters the floc is much lighter and skill is required to prevent the bed breaking up and
floating over into the clear well or on to the sand filter.The addition of diatamacious earth or ke
sulger will help to form a more solid bed floc.

Ca(OH)2 + Ca(HCO3)2 2CaCO3 + 2H2O
2 Ca(OH)2 + Mg(HCO3)2 2CaCO3 + Mg(OH)2 + 2H2O
FeSO4 + Ca(OH)2 2 Fe(OH)2 + CaSO4
Oxidation
Fe2O3nH2O

$ #. :
Some use Ozone as disinfectant in the water treatment process.Compared to Cl2, O3 has certain
advantages. It does not require removal of residual O3 . Little residual O3 help to maintain the
sterility of the water during the soft drink bottling.O3 is very efficient at removing colour,
oxidising organic matter & removing some odours & tastes. V




*
:
Occationally in clear drinks a faint flocculant precipitate is formed a few days after bottling. This
will disappear in shaking but reform after a little while. This is due to a polysaccharide
liberated from microcystis and it can survive the standard water treatment. Acidifying and
heating solves this problem.






-


 
Empty glass bottles are returned to a soft drink plant in different conditions of cleanliness. Some
may even contain greese, cement and various chemicals in addition to traces of syrup and insects
which is usually found. All these bottles must be delivered to the filling machine in clean, sterile
and undamaged condition,
Washing and sterilizing of thousands of bottles per hour is an important and complex operation.
Bottle washing machine is the largest and most expensive single equipment in the soft drink
plant. It consists of various compartments where bottles are exposed to a combination of soaking
jetting with caustic solutions at various temperatures. Most bottle washers have the capability of
label removal. Before the detergent section a pre rinse with water and after detergent a final
rinse with warm and cold water is given to remove caustic residues.The cleaning and sterilization
of bottles depends on,
Contact time
Caustic strength
Temperature of detergent

Germicidal efficiency of bottle washing solution not necessarily linked to it¶scleaning efficiency.
Eg : A solution containing 0.3% caustic soda at 750 C with a contact time of 15 minutes has the
same germicidal efficiency as a solution containing 2.6% C.S at 450 C with same contact time.
The cleaning efficiency of the second process will be superior.
Phases in a typical bottle washing cycle :

D % & %c #% jD,

% cj 
Pre rinse Water 10 ± 60 sec 27 ± 380 C
Jetting & soak 2-4 Sec. 0.5 ± 2.5 % 15 min. 710 C
Label removal NaOH

Warm water Water 15 ± 60 sec 38 ± 430 C

Final rinse Water 1 5 ± 60 sec Ambient

Temperature gradients should be controlled carefully otherwise bottles can crack due to the
thermal shock. When a hot climate exists it is necessary to use extremely high caustic levels.
Eg : 4 ± 5 % During rainy seasons algae formation can take place due to collection of rain water.
This can remain even after washing and get loosen only after reaching the market.

 jc%&$
c-#& % c 

Caustic Soda form basis of bottle washing detergents. But it lacks certain properties desired in a
good detergent such as ;
Emulsification power
Wetting power
No sequestering ability



%
 
 
  0
Sequestering agents
Wetting agents
Defoaming agents
Corrosion inhabitors
Often a bactericide (NaOCl) is also added to the rinse water.

 
  
  *


 
Alkalis ± (NaOH, Soda ash)
* Emulsification and saponification of fats.
* Swelling, proteolysis and hydrolysis of proteins.
* Dissolving of carbohydrates.
* Dispersing of insoluble matter.
* Control microbial population.
* Promotes label removal from bottles.

  
 %
:
Mostly chelating agents. E.g. : Polyacrylate, EDTA
* Removal of scale forming metal ions
* Can remove already formed scale
* Can remove rust ring from metal capped bottles
* Removal of final layer of dirt from bottles


 %

Non ionic polymers of alkylene oxides.
Lowers the surface tension of bottle washing solution and enable the solution to penetrate soil
material and labels.
 c *

Phosphonate salt of methylene phosphoric acid.
Prevents corrosion of the metals of the washing plant. (Abalance must be maintained between
scale prevention and corrosion)

‡  c *
0
Phosphonate salt of methylene phosphoric acid.
‡ Prevents corrosion of the metals of the washing plant. (A balance must be maintained between
scaleprevention and corrosion)

 %
0
Food grade silicones.
Mechanical action of the detergent like the chemical action help to remove soil, labels, etc..
Surface active material in detergent result in forming. This reduces the mechanical action,
different.
0    
ADAMS, H. W. and YAWGER, E. S. (1961) Enzyme inactivation and colour of processed peas.


r , 314±317.
ANON. (1983a) Ñ

 
 
. EC 4549/12.83. Electricity Council, London SW1P
4RD.
ANON. (1983b) Ñ

 
   

. Technical Information Ind 43.
Electricity Council,London SW1P 4RD.
ANON. (1983c)  

 
. Technical Information Ind 18. Electricity Council,
LondonSW1P 4RD.
ANON. (1983d)   
. EC 4401/3.83. Electricity Council, London SW1P 4RD.
ANON. (1996) The Pearson Square ± common calculations simplified. , r
, (March),
fromITDG Broughton Hall, Broughton on Dunsmore, Rugby CV23 9QZ, UK.
ANON. (1998)  
  

. Institute of Food Science and
Technology(IFST), Cambridge Court, London W6 7NJ, UK.
BEEVERS, A. (1985) How to save energy. 
, 41±43.
BENDER, A. E. (1978)  
 . Academic Press, London, pp. 3±57.
BENDER, A. E. (1987) The nutritional aspects of food processing. In: A. Turner (ed.) 



  
Ñ  . Sterling Publications International, London, pp. 273±275.
VAN DEN BERG, C. (1986) Water activity. In: D. MacCarthy (ed.) 
 

.Elsevier Applied Science, Barking, Essex, pp. 11±36.
BLANSHARD, J. M. V. (1995) The glass transition, its nature and significance in food
processing. In: S. T Beckett (ed.) 

 


 
. Blackie
Academic and Professional, London, pp. 17±48.
BOARDMAN, J. (1986) Effecting efficient energy usage.  
. May 29±31.
BOURNE, M. C. (1978) Texture profile analysis. 


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BOURNE, M. C. (1982)   

. Academic Press, New York.
BRENNAN, J. G. (1984) Texture perception and measurement. In: J.R. Piggott (ed.) 



. Elsevier Applied Science, London, pp. 59±92.
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 , Royal Society of Chemistry,
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!" #, October 106±107.
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 $  
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. The Global Hygiene Forum, Helsinki.
 #%&# #&c0c 
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,&,+,D c0c

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)

Food process engineering



Introduction

Production process (lab scale)

Production process Flow chart (industrial)

Incoming Quality checking

Blending of rice

Filtration

Pasteurization

Filling

Packaging

Mass balances

Energy balances

Water treatment

Bottle Washing