Introduction

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 is 184,064,880 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.

RiceRice is whole and broken kernels obtained from the monocot plant  species Oryza sativa 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).

Milk

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

PRODUCTION PROCESS ( LAB SCALE)

INGREDIENTS 100 g Red parboiled Rice 400 ml Milk 50 g Sugar 5g Vanilla 2.5 g Cinnamon Ice

Water

PREPARATION (LAB SCALE)

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.

Production process Flow chart (industrial)

IQC = Incoming quality checking

Incoming sugar Incoming Milk

Incoming red raw rice

Incoming cinnamon

Incoming Vanilla

Water

IQC IQCIQCIQC IQC

Temporary storage

Temporary storage

Temporary storage

Temporary storage

Temporary storage

Water purification process

Temporary storage

Rice soaked in hot water for 6hrs

Heating of water (80oC)

Blending of rice, water and milk

Mixing Sugar, Vanilla, Cinnamon (15mins)

Pasteurization (HTST method)

Filling

Bottling and capping

Filtration

Incoming Quality checking

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.

White sugar

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

Composition and quality factors White sugar

Sulphated ash (% m/m ) N/A

Conductivity ash (% m/m) 0.04 Invert sugar content (% m/m) 0.04

Sucrose plus invert sugar content (% m/m expressed as sucrose) N/A

Loss on drying (% m/m) 0.1

Starch content (% m/m) N/A

Colour (ICUMSA units) 60

pH (for 10% m/m) N/A

Incoming Milk

Heavy metals

Metal Maximum level Copper 0.05 mg/kg

Iron 0.2 mg/kg

OTHER QUALITY FACTORS Maximum free fatty acids (% m/mas oleic acid)

0.3

Maximum peroxide value (milli-equivalents of oxygen/kg fat)

0.3

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

Incoming red raw

ESSENTIAL COMPOSITION AND QUALITY FACTORS

Quality factors – general Rice shall be safe and suitable for human consumption.

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

Quality factors – specific Moisture content 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.

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

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

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

Milled Parboiled Rice 0.5% m/m

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

Milled Parboiled Rice 0.1% m/m

CONTAMINANTS

Heavy metals 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.

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

HYGIENE 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 Recommended International Code of Practice – General Principles of Food Hygiene (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.

Kernel length/width ratio

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

The kernel length

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

A combination of the kernel length and the length/width ratio

Medium grain rice 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

Incoming Vanilla

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

Incoming cinnamon

Water

Should maintain WHO portable water standards

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

Rice Soaking

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.

Ratio of water to rice. . 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.

Soaking the rice. 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.

Blanching rice. 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.

Blending of rice

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.

Industrial Mixers and Blenders 

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.

Model: BFJ

Brand: SAIBAINUO

Origin: Made In China

Category

:

Industrial Supplies / Food,

Beverage & Cereal

Machine

Filtration

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

FiltrationFiltration is the removal of insoluble solids from a suspension (or ‘feed slurry’) by passing it through a porous material (or ‘filter medium’). The resulting liquor is termed the ‘filtrate’ and the separated solids are the ‘filter cake’. Filtration is used to clarify liquids by the removal of small amounts of solid particles.

TheoryWhen 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 flowAssuming that the filter cake does not become compressed, the resistance to flowthrough the filter is found using

where R (m_2) _ resistance to flow through the filter, _ (N s m_2) _ viscosity of the liquid, r (m_2) _ specific resistance of the filter cake, V (m3) _ volume of the filtrate, Vc _ the fractional volume of filter cake in the feed liquid volume, V, A (m2) _ area of thefilter and L _ equivalent thickness of the filter and initial cake layer.For constant rate filtration, the flow rate through the filter is found using

where Q (V/t) (m3 s_1) = flow rate of filtrate, P (Pa) = pressure difference and t (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 P constant as:

If t__V_A_ is plotted against V_A, 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 r is modified as follows

where r is the specific resistance of the cake under a pressure difference of 101 _ 103 Paand s =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).EquipmentGravity filtration is slow and finds little application in the food industry. Filtrationequipment operates either by the application of pressure to the feed side of the filter bedor 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 tothe filter or mixed with the food to improve the formation of filter cake.Pressure filtersTwo commonly used pressure filters are the batch plate-and-frame filter press and the shell-and-leaf pressure filter. 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 et al., 1983). However, it is time consuming and highly labour intensive.

The shell-and-leaf pressure filter is used to overcome the problems of high labourcosts and lack of convenience of plate-and-frame presses. It consists of mesh ‘leaves’,which are coated in filter medium and supported on a hollow frame which forms theoutlet channel for the filtrate. The leaves are stacked horizontally or vertically inside apressure vessel, and in some designs they rotate at 1–2 rev min_1 to improve theuniformity of cake buildup. Feed liquor is pumped into the shell at a pressure ofapproximately 400 _ 103 Pa. When filtration is completed, the cake is blown or washedfrom the leaves. This equipment has a higher cost than plate filters and is best suited toroutine filtration of liquors which have similar characteristics.

Pasteurization

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.TheoryThe sensible heat required to raise the temperature of a liquid during pasteurization isfound using

where Q (W) =specific rate of heat transfer, m(kg s_1)= mass flow rate, c (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 Dvalue of the most heat-resistant enzyme or micro-organism which may be present milk. pasteurisation is based on D60 and a 12 logarithmic cycle reduction in the numbers of C. burnetii (Harper, 1976), As flavours, colours and vitamins are also characterised by D 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 holder 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 ‘flash pasteurization’.

Pasteurisation of unpackaged liquidsSwept surface heat exchangers (Barclay et al., 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 plate heat 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 permedium; (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 ‘regeneration’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

FillingThe 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 ‘carousel’ (or rotary) arrangement.

Packaging

Packaging may be defined in terms of its protective role as in ‘packaging 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 ‘a 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 duringdistribution and use• Communication – to identify the contents and assist in selling the product. Shippingcontainers should also inform the carrier about the destination and any specialhandling or storage instructions. Some packages inform the user about method ofopening 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 easyopening, 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, moisturevapour, 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 lighttransmission, the rate of transfer of heat, moisture and gases, and movement of microorganismsor 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.

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

where Ia (Cd) =intensity of light absorbed by the food, Ii (Cd)= intensity of incidentlight, Tp =fractional transmission by packaging material, Rp = the fraction reflected bythe packaging material and Rf= the fraction reflected by the food.

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

where It (Cd) _ intensity of light transmitted by the packaging, ∞ =the characteristicabsorbance of the packaging material and x (m) = thickness of the packaging material.The amount of light that is absorbed or transmitted varies with the packaging materialand with the wavelength of incident light. Some materials (for example low-densitypolyethylene) transmit both visible and ultraviolet light to a similar extent, whereasothers (for example polyvinylidene chloride) transmit visible light but absorb ultravioletlight. Pigments may be incorporated into glass containers or polymer films, they may beover-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. Heat

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 interactionwith the food.

MoistureMoisture loss or uptake is one of the most important factors that controls the shelf life offoods. There is a micro-climate within a package, which is determined by the vapourpressure of moisture in the food at the temperature of storage and the permeability of thepackaging. Control of moisture exchange is necessary to prevent microbiological orenzymic spoilage, drying out or softening of the food, condensation on the inside ofpackages and resulting mould growth.

Mechanical strengthThe suitability of a package to protect foods from mechanical damage depends on itsability to withstand crushing, caused by stacking in warehouses or vehicles, abrasioncaused by rubbing against equipment or during handling, puncturing or fracturing causedby impacts during handling or by vibration during transport. Some foods (for examplefresh fruits, eggs, biscuits, etc.) are easily damaged and require a higher level ofprotection from a package, including cushioning using tissue paper, foamed polymersheets, 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 thatare tightly formed around the product.Wooden crates and barrels or metal drums have a long history of use as shipping containersas they provide good mechanical protection. These are now being replaced by cheapercomposite intermediate bulk containers (IBCs) made from fibreboard and polypropylene.Examples of IBCs include a seamless, 6–9 ply corrugated fibreboard container, capable ofwithstanding 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 easilyrecyclable (Anon., 1998). IBCs are claimed to carry 20% more product than drums in a givenspace and because they are flat when empty, save 80% on storage space. The rapid expansionin the use of polymer pots, trays and multi-layer cartons (Sections 24.2.5 and 24.2.6) has alsoincreased the degree of protection that is available for specific foods.The strength of polymer and paper or board materials can be assessed by measuringthe 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 ‘cullet’ (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 thecontainer.

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 marketinghigh-value products such as liqueurs and spirits, simple cylindrical shapes are strongerand more durable. Sharp corners and abrasion of glass surfaces weaken the container, and design features such as a protruding ‘shoulder’ which

minimises contact between containers during handling, or protection by a plastic sleeveare used to reduce the risk of damage.Alternatively glass surfaces may be treated with titanium, aluminium or zirconiumcompounds 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-arccrucibles to melt raw ingredients. The molten glass could then be co-extruded in a similarway to that currently used for plastic containers to produce jars or bottles of any shape,size or thickness.

Mass balancesThe law of conversion of mass states that ‘the mass of material entering a process equalsthe 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.

For blending soaking and filtration

water loss due to evaporation is 2%

For soakingMass of raw materials in= mass of products and wastes out+ mass of stored materials+ lossesMass 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 + 200Mass of stored materials = 1300 kg

For blending and mixingMass of raw materials in= mass of products and wastes out+ mass of stored materials+ lossesMass 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

Energy balancesAn energy balance states that ‘the 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.Mechanisms of heat transferSteady-state 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 unsteady-state 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. Steady-state conductionThe 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 Q (J s_1) = rate of heat transfer, k (Jm_1 s_1K_1 or Wm_1K_1) = thermal conductivity, A (m2) =surface area, (oC or K) _ temperature difference and x (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.Unsteady-state conductionDuring processing, the temperature at a given point within a food depends on the rate ofheating or cooling and the position in the food. The temperature therefore changescontinuously. 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 a (m2 s_1) =the thermal diffusivity, (kgm_3) = density, c (J kg_1K_1) = specific heat capacity and k (Wm_1K_1) = thermal conductivity.

The basic equation for unsteady-state heat transfer in a single direction (x) is

where d_/dt =change in temperature with time.

ConvectionForced 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 surface heat transfer coefficient is a measure of the resistance to heat flow, caused by the boundary film, and is therefore equivalent to the term k/x 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 hc (W m_2 K_1) =convection heat transfer coefficient at the solid-liquid interface, D

(m) =the characteristic dimension (length or diameter), k (W m_1 K_1) = thermal con ductivity of the fluid, cp (J kg_1 K_1) = specific heat at constant pressure, (kg m_3) = density, (N sm_2) = viscosity, g (m s_2) = acceleration due to gravity, _ (m m_1 K_1) =coefficient of thermal expansion, __ (K) _ temperature difference and v (m s_1) =velocity.

For streamline flow through pipes

For turbulent flow through pipes,

where n = 0.4 for heating or n= 0.3 for cooling, when Re > 10 000, viscosity is measured at the mean film 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).

WATER TREATMENTMost 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.

THE STANDARD WATER TREATMENT PLANTWater 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 abeneficial 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 + HOClHOCl 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 consistingof isoluble calcium carbonate, magnesium hydroxide and ferric-hydroxide is formed at thebase of the reaction tank through which the water has to pass.Coagulation :Both Ferric hydroxide and Aluminium hydroxide are colloids of variable composition. In hardwaters the floc they form is weighted down with the mixture of pecipitated calcium andmagnesium salts. Here no trouble of maintaining the bed of floc at the base of the coagulationtank 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 andfloating 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 + 2H2O2 Ca(OH)2 + Mg(HCO3)2 2CaCO3 + Mg(OH)2 + 2H2OFeSO4 + Ca(OH)2 2 Fe(OH)2 + CaSO4

Oxidation Fe2O3nH2O

Use of Ozone :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.

Water related problems :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 polysaccharideliberated from microcystis and it can survive the standard water treatment. Acidifying and heating solves this problem.

Bottle Washing

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 insectswhich 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 finalrinse with warm and cold water is given to remove caustic residues.The cleaning and sterilization of bottles depends on,Contact timeCaustic strengthTemperature 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 :

PHASE CLEANING CONTACT TEMP. AGENT TIMEPre rinse Water 10 – 60 sec 27 – 380 CJetting & soak 2-4 Sec. 0.5 – 2.5 % 15 min. 710 CLabel removal NaOH

Warm water Water 15 – 60 sec 38 – 430 CFinal 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.

CHEMICALS USED IN BOTTLE WASHING Caustic Soda form basis of bottle washing detergents. But it lacks certain properties desired in a good detergent such as ;Emulsification powerWetting powerNo sequestering ability

Additional chemicals used are :Sequestering agents

Wetting agentsDefoaming agentsCorrosion inhabitorsOften a bactericide (NaOCl) is also added to the rinse water.

Functions of chemicals used in bottle washing 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.

Sequestering Agents :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 bottlesWetting Agents Non ionic polymers of alkylene oxides.Lowers the surface tension of bottle washing solution and enable the solution to penetrate soil material and labels.Corrosion Inhibitors Phosphonate salt of methylene phosphoric acid.Prevents corrosion of the metals of the washing plant. (Abalance must be maintained between scale prevention and corrosion)

• Corrosion Inhibitors :Phosphonate salt of methylene phosphoric acid.• Prevents corrosion of the metals of the washing plant. (A balance must be maintained between scaleprevention and corrosion)Defoaming Agents :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.

Reference

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NON ALCOHOLIC RICE DRINK

T.L.V. PEIRIS

GS/MSc/Food/3630/08

Food process engineering

Content

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