Processing Pulses and Oilseeds

Processing Pulses and Oilseeds

Processing Pulses and Oilseeds

Madhuri Jain

Processing Pulses and Oilseeds

Madhuri Jain

ISBN - 9789361525469

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Preface

Edible oil is an essential commodity in India. A collective effort by the Government, policymakers, scientists, extension specialists, farmers, engineers, and industrialists are being made to increase the production of edible oil to meet its requirement in the country. Oilseeds yield oil as well as other co-products and by-products. Deriving maximum value from the different co-products and by-products will help to maximize benefits to the consumers and return to the farmers. The post-harvest system, therefore, has a strong linkage with the technology of processing and marketing of oilseeds.

The book covers in-depth all the available information on the processing of oilseeds starting from threshing to co-products and by-products processing and utilization of 7 major oilseeds grown around the world. Different types of equipment and technologies developed end found suitable at various research organizations, and institutes have been described in detail. Oil expellers, including the traditional as well as improved ghanies for processing of the oilseeds, have been presented in the book with their drawing and descriptions considering the design and development aspects. Applications of research values for individual oilseeds have also been covered. Besides, the book also covers the economically viable and technically feasible technologies suitable for income and employment generation for rural people.

Table of Contents

Introduction 1

1 What is Milling? 2

1.1 Home Scale Milling 4

1.2 Cottage Scale Milling 5

1.3 Commercial-scale Milling 6

1.4 Traditional Milling 6

1.5 Exercise 6

2 Brief about Milling Process 7

2.1 Cleaning and Grading 7

2.2 Pitting 7

2.3 Pre-Milling Treatments 7

2.3.1 Wet Treatment 8

2.3.2 Dry Treatment 8

2.4 Tempering 9

2.5 Drying 9

2.6 Dehusking and Splitting 9

2.7 Polishing 10

2.8 Exercise 10

3 Advances in Milling Technology 11

3.1 Traditional Methods of Dehulling, Splitting and Grinding 12

3.2 Dehulling without Splitting 13

3.3 Dehulling and Splitting 13

3.4 Modern/industrial methods of Dehulling and Splitting 14

3.5 Milling Calculations 15

3.6 Dry versus wet Processes of Dehulling and Splitting 17

3.6.1 Wet Milling 17

3.6.2 Dry Milling 19

3.7 Current and Future trends – improving dehulling and

Splitting Performance 20

3.7.1 Seed Quality Attributes 20

3.8 Manipulation of Milling Variables 21

3.9 Advances in Drying Techniques 22

3.10 Distribution of Pulse Dehulling and Splitting 23

3.11 Modern/industrial methods of Milling Pulse Flours 24

3.12 Particle Size 26

3.13 Substitution of Pulse Flours into other Products 27

3.14 Production of Roasted Pulse Flours 27

3.15 Production of Precooked Pulse Flours and Powders 28

3.16 Production of Germinated Pulse Powders 29

3.17 Production of Pulse Fractions 29

3.17.1 Pantnagar Process (Chemical treatment) 31

3.17.2 Pantnagar Process (Enzymatic treatment) 31

3.18 CIAE Process 32

3.18.1 CFTRI Process 32

3.19 Exercise 33

4 Milling of Individual Pulses 34

4.1 Pigeonpea 34

4.2 Chickpea 35

4.3 Urdbean 35

4.4 Mungbean 36

4.5 Peas 36

4.6 Lentil and Khesari 36

4.7 Exercise 36

5 Methods of Pulse Milling, Domestic and

Commercial Milling 37

5.1 Home Scale Milling of Pulses 37

5.2 Commercial Scale Milling of Pulses 37

5.2.1 Cleaning and Grading 37

5.2.2 Drying of Pulses 38

5.2.3 Loosening of Husk 38

5.2.4 Wet Method 38

5.2.5 Dry Method 39

5.2.6 Removal of Powder/dust 39

5.2.7 Water Polish 39

5.2.8 Buff Polish 39

5.2.9 Nylon Polish 39

5.2.10 Teliya Dal 40

5.3 Exercise 40

6 Process of Oil Refining 41

6.1 Introduction 41

6.2 What are Oilseeds? 42

6.3 Types of Oilseeds 42

6.3.1 Rapeseed (canola) 43

6.3.2 Soybeans 43

6.4 Raw Material Preparation 43

6.5 Oil Extraction Methods 43

6.5.1 Mechanical Expression 43

6.5.2 Hydraulic Press 44

6.5.3 Screw Press 44

6.5.4 Ram Press 44

6.5.5 Oil Extraction 45

6.6 Process of Oil Refining 46

6.6.1 De-odorising 46

6.6.2 Wintering 46

6.6.3 Neutralization 46

6.6.4 Bleaching 46

6.6.5 De-gumming 46

6.7 Exercise 47

7 Composition and Characteristics of Oilseeds and Oils 48

7.1 Composition and Characteristics of Oilseeds and Oils 48

7.1.1 Seed Composition 48

7.1.2 Seed Characteristics 49

7.2 Composition of Oil and their Characteristics 49

7.3 Oilseed Processing 50

7.4 Conditioning and Drying of Oilseeds 50

7.4.1 The Solex Heat Exchanger 51

7.5 Mill (Grinding) 51

7.6 Exercise 52

8 Mill (grinding) 53

8.1 Grinding Laws 53

8.2 Grinding Machines 55

8.3 Ball Mill 55

8.4 Rod Mill 56

8.5 Autogenous Mill 57

8.6 Sag Mill 57

8.6.1 Principle of SAG Mill Operation 57

8.7 Pebble Mill 58

8.8 High-pressure Grinding Rolls 58

8.9 Buhrstone Mill 59

8.10 Tabletop Hammer Mill 59

8.11 Vertical Shaft Impactor Mill (VSI mill) 59

8.12 Tower Mill 59

8.13 Types of Grinding Mills 60

8.14 Exercise 62

9 Horse Mill 63

9.1 Introduction 63

9.2 History 64

9.3 Horse Mill at Beamish Museum 67

1.2 Mill Construction 69

9.4 Horsepower 71

9.4.1 Horse gin at Nottingham Industrial Museum 71

9.5 Horse Gins in the Black Country 74

9.6 Brewers’ House Museum 74

9.7 Horse Mills still in use 74

9.8 Exercise 75

10 TreadWheel and Ship Mill 76

10.1 History 77

10.2 Ship Mill 78

10.2.1 Technology 78

10.2.2 History 80

10.2.3 The Geographical Spread of Ship Mills 81

1.3 Exercise 82

11 Oilseed Press and Principals of Extraction 83

11.1 Oilseed Press Designs 83

11.2 Nutritional Value of Products 86

11.3 Oil Extraction Process 87

11.4 Principles of Oil Extraction 88

11.4.1 Decortication 88

11.4.2 Breaking 88

11.4.3 Cooking 89

11.4.4 Extraction 89

11.4.5 Refining 91

11.5 Basic Processing Steps 93

11.5.1 Seed Cleaning 93

11.5.2 Seed Preparation and Conditioning 93

11.6 Extraction by Cold Press 95

11.7 Exercise 95

12 Oil Expellers 96

12.1 Single-cylinder 97

12.2 Cage-style 97

12.3 Solvent Extraction of Oil 98

12.3.1 Clarification 98

12.3.2 Degumming 99

12.3.3 Refining, Bleaching, and Deodorizing 99

12.4 Oil Packaging and Storage 100

12.5 Oilseed By-products: Meal and Hulls 101

12.5.1 What’s in the Meal? 101

12.6 Exercise 104

13 Post-Harvesting Process 105

13.1 Proteins from Oilseeds 105

13.2 Oilseed Production 106

13.3 Oilseed Usage 106

13.4 Oilseed Processing 107

13.5 Oilseed Meal Consumption 108

13.6 Nutritional Considerations 111

13.7 Other considerations in the Evaluation of Protein Meals 116

13.7.1 Amino Acid Availability 116

13.7.2 Toxic and Antinutritional Factors 116

13.7.3 Functional Considerations 117

13.7.4 Wholesomeness 117

13.7.5 Consistency 117

13.8 The Better Bean Initiative 121

13.8.1 Translating Trait Characteristics into

Estimates of Economic Value 121

13.9 Moving Beyond the Vision 124

13.10 Oilseed Proteins: Now and In The Future 125

13.11 Seed Oil 126

13.11.1 Almond Oil 127

13.11.2 Argan Oil 128

13.11.3 Borage Seed Oil 131

13.11.4 Canola Oil 132

13.11.5 Castor Oil 134

13.12 Seed Oil 137

13.12.1 Cherry Pit Oil 138

13.12.2 Corn Oil 138

13.12.3 Cottonseed Oil 139

13.12.4 Linseed Oil 144

13.12.5 Grape Seed Oil 147

13.12.6 Mustard Oil 149

13.13 Pressed Oil 149

13.14 Essential Oil 150

13.14.1 Neem Oil 151

13.14.2 Rapeseed 154

13.14.3 Sesame Oil 157

13.15 Exercise 164

14 Grains, Pulses, and Oilseeds in Australia 165

14.1 Quality, Safety, and Innovation 165

14.2 Industry Overview 165

14.3 Key Capabilities 166

14.3.1 Products, Varieties, Grades and Provenances

To Suit Every Purpose 166

14.4 Proximity To Market 170

14.5 Customized Purchasing Options 170

14.6 Tailored Product Information and Technical

Support Services 170

14.7 Breeding Programs, Research, and Innovation 171

14.8 On-Farm Production and Quality Improvement 171

14.9 Storage, Handling and Equipment 172

14.10 Food Safety, Traceability, Quality Accreditation, and Biosecurity 172

14.11 Education, Training, Skills and Research 173

14.12 Industry and Research Organisations 174

14.13 Exercise 176

15 Pulse Processing Unit In India 177

15.1 Introduction 177

15.1.1 Current Scenario 177

15.1.2 Status of Pulse Processing in Odisha, India 178

15.2 The Rationale for setting up a Processing unit for Pulses 178

15.3 Raw Material Availability 179

15.4 Need for Infrastructure 179

15.5 Machinery used 180

15.6 Processing of Pulses 180

15.7 Conventional Pulses Milling Process 181

15.8 Products (Main Product and By-Products) 181

15.9 Process Flow for Pulses Processing 182

15.10 Financials 183

15.10.1 Technical Building 183

15.10.2 Plant and Machinery 184

15.10.3 Miscellaneous Fixed Assets 184

15.10.4 Pre-operative Expenses and Security Deposit 184

15.10.5 Total Project Cost 184

15.11 Processed Parameters 185

15.11.1 Cost of Operations 185

15.11.2 Purchase Price of Raw Materials 185

15.11.3 Cost of Gunny Bags 186

15.11.4 Salaries / Wages 186

15.11.5 Administrative and Other Expenses 186

15.12 Means of Finance 188

15.13 Exercise 188

16 Post Harvesting Process 189

16.1 What Constitutes the Post-harvest System? 189

16.2 Post-harvest Profile 189

16.3 Technologies and Phases of the Post-harvest

system for Pulse 191

16.4 Post-harvest Losses 191

16.4.1 Post-harvest System and Losses 191

16.4.2 Extent of Losses 192

16.4.3 Type of Loss at Different Post-harvest Stages 192

16.5 Types of Losses – their Nature and Prevention 193

16.5.1 Losses in Weight 194

16.5.2 Losses in Quality 194

16.5.3 Losses due to Physical Conditions 195

16.5.4 Economic Losses 196

16.6 Total Post-harvest Cereal System General Information 197

16.6.1 Post-harvest Cereal System 198

16.6.2 Harvesting 199

16.6.3 Threshing 199

16.6.4 Winnowing 200

16.6.5 Drying 200

16.6.6 Storage 200

16.6.7 Primary Processing 201

16.6.8 Secondary Processing 204

16.6.9 Raw materials 204

1.4 Proximate Composition of Cereal Grains (FAO, 1999) 207

16.6.10 Paddy Rice 208

16.6.11 Millet 209

16.7 Exercise 209

Appendix 210

Glossary 213

Index 215

Introduction

Fats and oils are one of the five essential ingredients of the human diet, and the others are protein, carbohydrates, minerals and vitamins. In a balanced diet, the oils and fats requirement per person per day is 35 g for vegetarians, 39 g for non-vegetarian and 38 g for the average diet. Oilseeds and animals are the main sources of fat. Historically, the processing of food legumes in developing countries has been done in the home by women as part of their meal preparation. Both small- and large-scale industries have evolved to some extent from these traditional cooking methods; however, they have had only a limited impact and outreach. The greatest potential for providing high-protein legume food products to a large number of people living in developing areas is through adapting and transferring the established home-processing methods to village-scale industries. Also, the identification and recognition of various newer and improved legume processing methods that, for the most part, have been known for some time, can provide the basis for further development of legume processing technology in rural areas. Subsequently, this book discusses a number of methods and techniques for processing and subsequent utilization of grain legumes.

Chapter

1 What is Milling?

The dried seeds that are edible from the cultivated legumes are known as pulses. Pulses are important in a human diet chart, which has lots of nutritional values. They have majority sources of dietary protein and energy. The major pulses are Chickpea, pigeon pea, cowpea, black gram, green gram, lentils, and peas.

These pulses can be consumed in a split or dehusked form, which is also known as dal. The process of milling can be done by three major processes like loosening the husk, de-husking, and splitting of pulses. These pulses are generally consumed in the dal form. The traditional methods for the pulses processing were labor-intensive, time-consuming and incurred losses. Modern technologies for the pulses processing involve two major steps, seed coat or husk loosening and its removal, conversion of seed grain into splits and grinding into flour based on its end-use. For the pulse milling, the various process is involved. Pulses go through some major unit operations during the pulse milling such as cleaning, grading, drying, loosening of the husk, de-husking, splitting and polishing.

The majority of the pulses are consumed in the form of dehusked splits. In the pulse grains, the outer layer of the grain husk is attached to the protein and starch bearing cotyledons. Due to the presence of a layer of gums in between the husk and the cotyledons in some grains like urad bean, pigeon pea, and mung bean, this bonding is strong. These are known as difficult-to-mill pulses. In other grains like Lathyrus chickpea, pea, this bonding is comparatively weaker. These grains can be milled easily and are categorized as easy-to-mill pulses.

Before consumed as dal, this outer husk layer is required to be separated from the cotyledons and subsequently split into two halves. Dehusking is the process of removal of husk from the cotyledons, and the entire process of dehusking and subsequent splitting of cotyledons, its cleaning, polishing and grading are known as milling. Dehusking improves product appearance, texture, product quality, palatability and digestibility. A substantial amount of avoidable loss takes place at different stages of milling. This may vary from 10-15% depending upon the type and quality of grain milled, the process and machinery used for milling and other factors. It is, therefore, important to look at different aspects of milling so that proper process and machinery are used to obtain maximum recovery of good quality dal from the grain and take corrective measures to reduce milling losses to the minimum.

Milling of the pulses is the third large food processing industry after the flour and rice milling. Around 75% of pulses produced are processed for making the dals in the mills of different capacities.

Fig. 1.1 Miling of pulses and oilseeds

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Milling of pulses involves two major steps:

• loosening of the husk, and

• removal of husk and splitting into cotyledons with the help of a suitable machine.

For the ease of husk removal, almost all the pulses need some pre-milling treatment. But, processes and equipment for loosening of the husk, separation of husk from cotyledons and its splitting differ from crop to crop, cultivar to cultivar and place to place. Dehusking is an old practice, which originated at home and later developed into a cottage industry and now has grown into a large-scale organized industry.

1.1 Home scale milling

this home-scale milling is the pounding of grains for dehusking by using a mortar and pestle after mixing with a small quantity of water and drying in the sun for a few hours. Sun-drying after water application helps to loosen the husk from the cotyledons. In mortars, dehusking is achieved due to shearing action between pestle and grains, and the abrasive effect between the grains. Once the pounding is done for several minutes, the husk gets detached from the grains. Winnowing separates husk and split cotyledons are separated from the whole dehusked and unhusked grains by manual sieving. The