PM FME - MAHUA PROCESSING

PM Formalization of

Micro Food Processing Enterprises (PMFME)

Scheme
HANDBOOK

OF

MAHUA

AATMANIRBHAR BHARAT
National Institute of Food Technology Entrepreneurship and Management
Deemed to be University (De-novo Category) under Section 3 of the UGC Act, 1956
An Autonomous Institution under Ministry of Food Processing Industries, Government of
India, Sonepat, Haryana, India
Website: www.niftem.ac.in
Email: [email protected]
Call: 0130-2281089

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CONTENTS
CHAPTER 1 : INTRODUCTION

1.1 Introduction...................................................................................................................03-04

1.2 Climate and soil............................................................................................................04-05

1.3 Harvesting and post harvesting management.....................................................................05

1.4 Nutritional aspects..............................................................................................................05

1.5 Uses og Mahua..............................................................................................................05-08

1.6 Mahua seeds meal/cake.................................................................................................08-10

1.7 Healt benefits................................................................................................................10-12

1.8 Nutritional properties of mahua flowers.......................................................................12-13

CHAPTER 2 : PACKAGING

2.1 Introduction........................................................................................................................14

2.2 Systems approach...............................................................................................................15

2.3 Packaging house operations..........................................................................................16-17

2.4 Types of packaging.......................................................................................................17-26

2.5 Marketing...........................................................................................................................26

2.6 Conclusion....................................................................................................................26-27

CHAPTER 3: FSSAI

3.1Food Safety and Regulatory Requirements for Mahua Processing...............................28-29

3.2 HACCP procedures......................................................................................................29-30

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CHAPTER 1

1.1 Introduction
Mahua is deciduous tree of dry region and native of India. A multipurpose tree,
mostly grown on wastelands in North and Central part of the country where generally
tropical and subtropical climates prevail. It grows in Eastern Uttar Pradesh, Chhattisgarh,
Maharashtra, Bihar, Jharkhand, Orissa and Andhra Pradesh.
Madhuca latifolia is a medium sized to huge deciduous tree, distributed in Andhra
Pradesh, Gujarat, Madhya Pradesh, Orissa, Bihar and Uttar Pradesh. Madhuca
longijolia is a large evergreen tree found in South India, and in the evergreen forests of the
Western Ghats from Konkan Southwards

Mahua is one of the most important trees of Central India. The Mahua trees have
large spreading root system, though many of them are superficial. Wood is hard to very
hard withlarge sapwood. Hardwood is reddish brown in colour. It is large and deciduous
trees with a short Bole and rounded crown. Mahua has a special status among NTFPs as it
is linked to thetribal livelihood systems in different ways. Apart from meeting food and
other requirements, itis also an important source of seasonal income. Its flowers are used to
brew country liquor which is very popular in the tribal areas of the country. The tree has
religious and aesthetic value in tribal culture. Mahua flowers and seeds, which have
medicinal and nutritional properties, are collected and dried. One single mature tree can
provide an income of about Rs.1500 from its flowers and seeds, in addition to various other
tangible and intangible benefits. Mahua provides livelihood security to poor households who
collect it both for self consumption and for sale the income is used to purchase daily
household items. However, in most tribal areas, Mahua gatherers rarely get the true value
of produce, which they usually barter for daily grocery items .
Mahua, the Indian Butter Tree (Madhuca longifolia (Koenig) J.F. Macribide) is an
important tree having vital socioeconomic value and growing throughout the tropical and
subtropical region of the Indian subcontinent. It is a deciduous tree that grows widely under
dry tropical and subtropical climatic conditions. It is very hardy and thrives well on rocky,
gravely, saline and sodic soils, even in pockets of soil between crevices of barren rock
.Mahua (Madhuca indica J.F. Gmel. syn. Madhuca latifolia Macb.) belonging to the family
Sapotaceae. It is one of those multipurpose forest tree species that provide an answer for
the three major Fs i.e food, fodder and fuel Fruits are eaten as raw or cooked. The fruit pulp
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may be utilized as source of sugar, whereas the dry husk makes a good source of alcoholic
fermentation. Seeds are good source of oil (Singh et al, 2005). The tree, known under the
name of mahua, produces edible flowers and fruits. The leaves of Mahua tree contain saponin,
an alkaloid glucoside. Sapogenin and other basic acid have been found in the seeds. Mahua
flowers are well known for their high reducing sugar and nutrient content. Flowers of the
plant are edible. The corolla commonly called as mahua flowers is a rich source of sugar
containing appreciable amount of vitamins and minerals .The flowers are also used in
preparation of distilled liquor, portable spirits, vinegar and feed for livestock reported that
the fresh flowers of Mahua (B. latifolia Roxb.), that emit fragrance contain 2
acetyl1pyrroline (2AP), the compound responsible for pleasant aroma in basmati and other
scented rice. It was found that 2AP gets synthesized only in fleshy corolla of mature flowers
.They are edible and used as a sweetener in preparation of many local dishes like halwa,
kheer, puri and burfi .in the mahua production belt of India. However, due to the lack of
proper scientific investigation and post harvest processing technologies, they are collected
and subjected to open yard sun drying till about 80% moisture is lost, before storage .

1.2 Climate and soil:

Mahua prefers tropical climate. It can withstand drought admirably. This tree does not survive
under waterlogged conditions. Since it is a very hardy tree, it can grow even in pockets of soil
between crevices of barren rocks. Trees even grow on degraded rocky areas including salt-
affected soils. However, for its better growth and productivity, well drained, deep loam
soil is ideal.
Cultivation and Collection - This plant can be cultivated or self sown. Flowering of this
medium sized tree take place during the season of March to April, in every years.
Botanical Description and Identification Features - A medium sized to large
deciduous tree, usually with a short, hole and large rounded crown found throughout the
green forest part of India up to an altitude of 1,200 meter and of 12 to 15 meter height,
bark thick dark colored cracked, inner bark dark red, milk, trunk short, branches numerous

(Behl and Sriwasrawa, 2002) [9]. Leaves are 10-30 centimeter long, are thick and leathery
most of leaves pointed at the tip, clustescent glabrred near end of branches, epileptic
or elliptic oblong 7.5 to 23 cm into 3.8 to 11.5 cm. coriaceous pubeand when young almost.
Flowers are small and fleshy, dull or pale white in color and in define fascicles near end of

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branches. Corolla tubular, freshly pale, yellow aromatic and caduceus (Variers and

Vaidyarathanam, 1995) [40]. Fruits are 2-6 cm long, fleshy and greenish

1.3 MATURITY HARVESTING AND POST-HARVEST MANAGEMEN-

Fruits are ready for harvest by 3rd week of May to 3 rd week of June. Maturity
standards in different genotypes of Mahua under different conditions were observed
that fruit growth was faster initially and slowed down while reaching towards
maturity. Total soluble solids, total and reducing sugars increased as fruits reached
towards maturity. Titratable acidity increased during initial period of fruit development,
then declined.

1.4 NUTRITIONAL ASPECTS OF MAHUA

Constituents Fresh Flowers Dry Flowers

1 Moisture 73.6-79.82 11.61-19.8 (%, w.b)
(%, d.b.)
2 pH 4.6 …..
3 Ash (%) 1.5 1.4-4.36
4 Total sugars (g/100 g) 47.35-54.06 41.62
5 Total Inverts (%) 54.24 …..
6 Cane sugars (%) 3.43 …..
7 Reducing sugars 36.3-50.62 28.12
(g/100 g)
8 Proteins (%) 6.05-6.37 5.62
9 Fats (%) 1.6 0.09-0.06
10 Fibers (%) 10.8 …..
11 Calcium (mg/100 g) 45 0.14-8
12 Phosphorus (mg/100 g) 22 0.14-2
13 Carotene (μg/100 g) 307 …..
14 Vitamin-C (mg/100 g) 40 7

1.5 Uses of Mahua

Used in tribal medicine: In diarrhoea a cup of infusion of bark is taken orally twice
a day by the tribals. Besides the stem bark is used in chronic tonsillitis, leprosy and
fever . It is commonly used for the treatment of snakebite as antidote for southern part of

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Tamilnadu, India . Decoction of stem bark is used to cure skin disease, hydrocoel and skin
disease . Powdered bark is employed for the treatment of scabies. Madhuca longifolia
leaves are expectorant and also used for chronic bronchitis and Cushing’s disease . The
leaves are applied as a poultice to relieve eczema.
Traditional uses of mahua
• Flower bearing period of mahua is March-April, as it is an annual bearing tree. Flower
sheds when it gets mature at dawn. Fresh mahua Flowers are sweet in taste and
contain different phytochemicals. Traditionally, the fresh flowers are collected and
dried under direct sunlight for 2-3 days and stored in gunny bags in normal
environment
Use of mahua leaves
• Leaves of Mahua are of very high nutritive value for cattle, goat and sheeps.
Trees are lopped for fodder in almost every states, where ever it is grown
specially during summer when there is scarcity of fodder. The chemical
constituents of Mahua leaves are given in following table

1 Crude protein 9.4-10.02

2. Digestible crude protein 0.03

3. Total digestible nutrients 37.04

4. Crude fibre 19.5-0.35

5. Calcium 1.66

6. Phosphorus 0.1-0.2

Traditional medicinal uses of mahua flowers

medicinal uses way of consumption remarks

Used as tonic Flower juice Flower juice having high.

amount of protein so it

is used as tonic

Cure skin Flower juice rubbed on skin

diseases for oleation to relieve

from itching

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Cure eye Flower juice is used for

diseases treatment of eye diseases.

Cure Raktapitta Flower juice is used to

arrest bleeding

Cure headache Flower juice is used

due to "pitta" as nasal drops

Cure diarrhoea Flower powder Flower act as an astringent

and colitis to cure diarrhoea and colitis

Increases Raw flowers Flowers act as a galactogouge

lactation which can help in augmentation

of breast milk.

Cure cough Roasted flowers ……

and bronchitis

Cure impotency Flower mixed with ……

milk

and general debility

Cure piles Flowers fried in ghee Mahua flower act as a cooling agent
Use of Mahua flower
The flowers of Mahua tree are fermented to produce an alcoholic drink called
Mahua, country liquor. Tribals of Bastar in Chattisgarh and Orissa, Santhals of
Santhal Paraganas (Jharkhand) and Tribals of North Maharashtra, consider the tree
and the Mahua drink as part of their cultural heritage. Tribal people, men and
women, consume this drink and is an obligatory item during celebrations and
evening activities. The main ingredients used for making Mahua are the Chhowa
Gud (Mollasses in granular form) and dried Mahua flowers
Use of fruits

Fruits of mahua are also utilized for human consumption as food. Unripe
fruits are used for vegetable preparation in following way: Flesh of mahua fruit
covering hard seeds are first peeled off to remove outer thin portion and then

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remaining portion are cut into pieces and fried in small amount of mustard oil along
with onion and garlic paste Take appropriate amount of mixed spices powder and
cook till complete softening of fruit pieces and also to prepare a concentrated curry of
mixed spices. In the rural areas of Eastern UP, this vegetable is sometime used as
substitute of jack fruit. Fruits contain 55 to 65 percent husk, 10 to 15 percent sugar,
1.8 to 2.4 percent minerals, 51 to 74 mg vitamin C and 586 to 890 IU vitamin A per
100 gram. Because of these above mentioned qualities of fruits these are eaten afresh
after ripening in tribal areas and poor of rural areas.

1.6 MAHUA SEED MEAL/CAKE

• After the extraction of oil from oil bearing seeds a major portion of the raw
materials is left over as the oilseed cake. Oilseed cakes are good and cheap source
of proteins and the market value of the cake is governed by its protein contents
and quality of its proteins.
• Mahua seed meal is the product left after extracting oil from Mahua seeds.
Seeds yield 30-40 % oil and hence 60-70 of total seed production yields is Mahua
seeds meals. Two types of meals are available in the market, Mahua seed meal is
used as a detergent and fertilizer. It is also used as manure either alone or in
mixture with other cakes and ammonium sulphate.
Value addition of mahua

• Recently Orissa University of Agriculture and Technology, Bhubaneshwar have

developed many value-added products from dry mahua flowers like candy, cake,
RTS, toffee, squash and ladoo.
• Other value-added products like candied flower, glazed flower and mahua bar are also
developed from dried mahua flowers.
Because of having high amount of fermentable sugars, mahua flowers are utilized for
making wine by various researchers scientifically using Saccharomyces cerevisiae

• Freshly prepared mahua wine has been fortified with traditional Indian herbs (Black
pepper, cinnamon, clove, cumin, fenugreek, nutmeg, fennel and Indian cassia) for

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development of new value-added product, called mahua vermouth

• Dry flowers are also utilized to make fermented products like brandy, acetone, and
lactic acid. Beside that all mahua flowers can be successfully used as a substrate for
surface fermentation using Aspergillus niger for production of citric acid .
• The complete detail of the utilization of mahua flower recently by various researchers
for preparation of value added products is given in table 5 along with them specific
remarks
value-added products of mahua flowers
Non-fermented flowers

1 Puree & Sauces Fresh flowers Fresh flowers are crushed into puree after
2 Juice Fresh flower removal of stamens manually and processed
to make puree.
Used as a sweetener in bakery

3 Concentrates juice and confectionary.

Mahua Jam Pulp of ripe Jam is made with addition

4 Jelly flowers of citric acid.

Combined with guava to

5 Marmalade reduce astringency of mahua flower.

By addition of citrus peels.

7 Glazed flowers

8 Mahua bar

9 Mahua candy

10 Mahua toffee

11 Mahua cake Dry flowers

12 Mahua squash

13 Mahua ladoo

14 Mahua RTS Mahua flower RTS blended with ginger extract

15 Antioxidant rich and @ 10 (%) have TSS of 18° Brix and with
fennel extract @
5 (%) have TSS of 14.8° Brix. The blend

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showed TPC of 15.94

Beverage Amla juice (mg GAE/ml) and 91.22 (%) DPPH radical
scavenging activity.

Fermented flowers

16 Mahua Fermentation of flower Fermentation at 16° C favours wine

wine juice quality and increase alcohol content (up to
9.9 %). Sensory evolution reported that
addition of yeast during fermentation is
acceptable but tannin addition is not
required.

1.7 Heath benefits of Mahua seed

Anti-inflammatory activity: Ramchandra et al. evaluated the ethanol extract and
saponin mixture of seeds of Madhuca longifolia for anti-inflammatory activity using
acute (carrageenan-induced inflammation), sub-acute (formaldehyde-induced
inflammation), and chronic (cotton pellet granuloma) models of inflammation in rats. The
ethanol extract and saponin mixture at a dose level of 10 and 15 mg/ kg and 1.5 and 3
mg/kg significantly reduced the edema induced by carrageenan in acute model of
inflammation, inhibiting both phases of inflammation. Both the extracts had a more
effective response than the reference drug diclofenac sodium in the sub-acute
inflammation model. Results longifoliated a significant anti-inflammatory activity by
Madhuca longifolia saponins in cotton pellet granuloma.
Antihyperglycemic activity: The ethanolic extract of seeds of Madhuca longifoliawas
effective in reducing the plasma glucose level in normal albino rats in a dose dependent
manner, producing hypoglycemic effect by stimulating the release of insulin from the β-
cells and or increasing the uptake of glucose from the plasma

Antibacterial activity: Antibacterial activity of fruits of Madhuca longifolia tested

against Bacillus subtilis and Klebsiella pneumonia in ulcer index compared to vehicle, and
was near to that of lansoprazole used at a dose level of 40 mg/kg, while crude alkaloid
extract exhibited no significant gastroprotective effect
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Anticancer activity: Bhaumik et al. studied the in-vitro anticancer activity of different
extract of fruit seed of Madhuca longifolia against human cancer cell line (HeLa) and
used MTT assay to analyze the cell growth inhibition. Results of Tables 10-14 showed
that the various extracts of fruit-seeds of Madhuca longifolia have a very good to
moderate anticancer activity

Sugar syrup: There are several reports on preparation of sugar syrup from dry
Mahua flowers, as its sweet property isutilized in the fermentation process, The water
extract of dried flower is decolorized with differentde colorizing agent like slacked lime
and activated charcoal before concentrating it to the desired concentration. Activated
charcoal at a concentration of 3.5-5.0 % was found to be the best agent for the
preparation of the Mahua sugar syrup The syrup thus obtained from the flower of
Mahua is employed in the different purpose, either in the manufacturing of chocolate or
as a sweetening agent
Fermented products: Dried mahua flowers are an attractive source of fermented products
due to the high sugar content. Prepration of mahua wine from fresh flowers. Various
products like alcohol, brandy, acetone, ethanol, lactic acid and other fermented products
have been prepared from the dry mahua
Utilization of mahua for processing of different food products Sugar syrup: Sugar
syrup from dry mahua flowers, which can be further use as a sweeting agent in different
food products with addition of citric acid. The pulp is also converted into marmalade or
syrup, which is used as food material. Jelly is also made from the pulp alone or combined
with guava to modify the astringent flavor. The pulp is also pickled. Major quantity of

flowers is used in the preparation of distilled liquors (Wealth of India, 1962) [3].
Patel, 2008 prepared the mahua jam and jelly by using fresh flowers. The developed
products were tested for their colour, flavor, taste, texture and overall acceptability, using
hedonic test. According to the findings of hedonic test all the developed Mahua
products were found to be highly acceptable.
Nutritional and Medicinal Use: The Mahua tree is having lots of nutritional value in it.
It produces fruit which is valued for its seed which yield high quantity of fat commercially
known as Mahua butter or mowrah butter, many edible and medicinal applications and it is
also used as a biodiesel. Its fat has been used as substitute for cocoa butter and ghee. It is

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one of the single largest sources of natural hard fat. The fat which is thus obtained from
Mahua fruit oil is used in cooking, frying and manufacturing chocolates. The seed fat has
emulsion property so it mostly used as an emulsifying agents in few pharmaceutical
industries. It is generally applied as massage oil in many part of the country, as it is very
good to moisturize skin. Besides edible and medicinal uses, Mahua has industrial
application as it can be utilized in the manufacture of laundry soaps and lubricants.
Moreover, the seed cake is reported to have insecticidal and pesticide property and used
as organic manure in crops like rice, sugarcane etc. The medicinal properties which are seen
in this plant are stimulant, demulcent, emollient, heating. Skin disease, rheumatism,
headache, laxative, piles, and sometimes as galactogogue astringent and many more. Review
of literature based on chemical composition of mahua flower reveals its high nutritional
value. Apart from being a rich sours of sugar and protein, the flowers also contain
essential minerals like Ca, p, Fe, and K. Calcium is a major component of the bone and
assists in teeth development phosphorus is next in importance to calcium as utilization of
Ca is closely related to it. Most of the Calcium in the body is deposited as the calcium
Phosphate.
1.8 Nutritional Properties of Mahua flower (Source: Kureel et al., 2009)

Constituents Flower
Moisture (%) 19.8
Protein (%) 6.37
Fat (%) 0.50
Total Sugar (%) 54.06
Calcium (%) 8.00
Phosphorus (%) 2.00 2.00
Ash (%) 4.36

Tree-Borne Oilseed Mahua: Seeds of many tree species contain high levels of oil and
their use for bioenergy generation has been a topic of interest for long (Raina, 1986).
Mahua oil is also edible and is used by tribal communities. All the TBOS are
multipurpose in their utility, making them what is desired for agroforestry systems.
However, caution is necessary in assessing whether all the uses will be realized at the same

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time Mahua seed oil: Mahua seeds contain about 40% pale yellow semi-solid fat. The seed
oil is commonly known as “Mahua Butter”. The oil content of the seed varied from 33 to
43% weight of the kernel. For the tribals of India, Mahua oil is by far the most important
tree seed oils. Fresh Mahua oil from properly stored seeds is yellow in colour with a not
unpleasant taste. The oil is used as cooking oil by most of the tribes in Odisha, Chhattisgarh,
and Maharashtra etc.

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CHAPTER 2
PACKAGING OF MAHUA PRODUCE

2.1 INTRODUCTION
Indian Food Industry is in the thrones of a major revolution, thanks to the
economic liberalisation. Demand for fresh produce is increasing in internal market as
well as other countries due to globalisation. India is one of the largest producer of
horticulture produces both in terms of number of varieties and quantities. Nearly 20-
25% of total production is lost every year due to poor handling, storage and
transportation methods. The main purpose of packaging is to provide produce with the
attributes necessary to survive a number of different hazards which can be expected
during storage, transportation and distribution. In recent days, entrepreneurs in India are
showing greater interest for the internal marketing as well as export of fresh produce.
The trade is attractive but is not an easy enterprise; a high degree of organisation and
professionalism is necessary to export fresh produce successfully, especially to the
sophisticated markets of Europe. It can make good use of indigenous horticultural skills.
The combined requirements of fresh produce and of its transport environment often
impose unusually severe conditions on the packaging employed. As a result, higher
package quantity is usually needed for fresh fruits and vegetables for manufactured
goods of the same weight. For designing of a package for a specific product and
particular target market a clear picture of distribution system should be drawn up, as
hazards involved in transportation are different for different modes (i.e. packaging
requirements for ship transportation are total different than that by air transportation).
The models may be used depending upon the characteristics of the produce and the
market. Fresh produces are lining tissue, high in 'water content and diverse in termsvof
morphology, composition and physiology. So package design should be based on
requirement of the product in terms of mechanical fragility, susceptibility to or benefits
at high or low relative humidity, limitations or benefits at high or low temperatures and
optimum atmospheric composition.

Some of the commodities with high sensitivity to ethylene gas, hence the need to
avoid gas build up in transit, which allow for effective external air ventilation (e.g.
avocados and package may protect from moisture loss). Certain commodities have
special treatments
e.g. sulphur dioxide treatment of grapes. The package assist in protection of commodity
against damage, the appropriate design of package and fittings should reduce the chance
ofbruising.

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2.2 SYSTEMS APPROACH

A systems approach to modern fresh produce processing and distribution
organisations includes all the information required for packaging it reproduce, whereby
the produce and the package become together the produce sold in the market. This may
be grouped into the following :

I. Protection requirement and constraints of the product:

1. Mechanical fragility of the product; ability to sustain prolonged compression
shocksand vibration in transit.
2. Susceptibility to or benefits at high or low relative humidity.
3. Tolerance or benefits at high and low temperatures; contaminant hazards.
4. Atmospheric composition conducive to better preserving the quality, or its
damagepotential.
II. Marketing requirements of the product:
1. Number of products and number of product (types/grades) in the same container.
2. Weight of the container (gross and net).
3. Means of handling, storage and transportation environment (chain from
productionto consumption).
4. Modes and types of wholesale and retail outlets.
5. Modes of quantizing (by weight, by count, by volume, etc.).
6. Modes of coding and labeling (prices, dates, health hazard warnings,
utilizationinstructions, etc.).

III. Requirements and constraints of the package:

1. Types of packaging materials, types and construction of containers,
standardisation requirements and types of closures. Modes of package
manufacturing (in-plant versus contacting suppliers).
2. Modes of empty container storage (in knocked down form?)
3. Feeding containers into the packaging line.

IV. The processing and packaging line in the packaging house:

1. Type and sequence of processing and packaging stages (mechanized, semi-
mechanized, manual), number of workers and their skills at each station, etc.
2. Unitizing methods, master containers, bundling, strapping, palletizing, shrink
wrapping or stretch wrapping of pallets, airline or maritime containerization, etc.
V. Quality criteria of alternative packaging systems available:
1. Total packaging cost per unit product.
2. Containment and protective qualities, marketability and salability.
3. Disposal or recycling possibilities of the package.

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2.3 PACKAGING HOUSE OPERATION:

The packaging line begins with unloading harvested produce. Bulk bins of
200-500 kg capacity are used for big packaging houses but in India reusable plastic crates
are used. Freshly harvested produce stacked up for interim storage. Interim storage may
serve several purposes, depending on the type of produce. Latest damage, sustained
during harvesting, will appear as visual defects several hours later and can be detected.
Storing field-warm produce for few hours in a cool place, such as cold storage corridors,
whereby produce temperature is reduced by several degrees before processing will help
reducing subsequent spoilage and damage in the packaging line.

The most important process in fresh produce is respiration, a biochemical

oxidation of all living cells. Respiration rate is proportional to temperature,
approximately doubling for every 10°C. Due to high respiration, heat build up will be
more, which in turn increases the temperature and respiration of produce. This reduces
shelf-life of the produce. The heat produced may be calculated by
1 mg CC>2/kg hr. = 61.2 k.cal/metric ton. day = 220 BTU/ton.day.

The term precooling refers to several practices whereby the temperature of the
freshly harvested produce is quickly lowered to shorten the period of initial high
respiration rates as well as to reduce the loads on the long-term cold storage facilities.
Success of efficient precooling depends upon fast removal of field heat from all fruits,
preferably within 2 to 3 hours. Regular cold storage room with about 150 air changes per
hour gives best result, but with danger of excess moisture loss.

Hydrocooling consist of drenching field-warm produce with stream of cold water

taking care of chilling injury suitable for leafy vegetables. There are three types of
hydrocoolers. Immersion, flooding and spraying. Another precooling method suitable for
lettuce is vacuum cooling. This system uses hermetically sealed vacuum chambers
whereby the pressure is reduced until the vaporising temperature of water is near O°C
(4.6 mm Hg), removes moisture uniformly from all tissues, not just from the surfaces.
The produce are subjected to a cleaning process, which begin with soaking tank, where
dirt clods and pesticide residues are softened and diluted by warm or cold solution of
water detergents and disinfectants. The fruit is thoroughly washed by piece of cloth
or soft brushes with water spray. The produce is then treated with fungicide treatment if
any. Before processing further, produce is dried by air steams from overhead fans. In the
next stage the undersized produce called as culls, is eliminated can be sent for
converting, called as presizer stage.
The grading process next follows to segregate the produce into quality groups, such as

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ripe fruits which must be marketed immediately, grade A,B,C, export grade or culls.
Before or after grading, high quality fresh produce processing may be included a waxing,
operation, especially when long shelf-life is desired. Most produce has a natural wax
layer on its rind or skin which protects it from excessive moisture loss while allowing
free metabolic gas exchange. This wax is largely removed by the cleaning operation. By
applying an artificial wax, the keeping quality of produce is reinstalled or even bettered,
which includes chemical additives to inhibit spoilage or to add gloss to colour for sales
appeal. Sizing is an additional sorting operation whereby sorting attribute is size. Now
uniformly sized and graded produce is ready to be packaged. Depending upon produce
type and grade, distance to markets, cost and availability of packaging materials, the
produce may be packed in a large variety of shipping containers.

The packaging operation usually includes set up of container, before quantitizing

of produce, filling and container closure. Quantitizing may be by count or by weight or a
combination of the two. Accurate sizing provides proportional link between count and
weight whereby only 'check-weighing' is required after filling by count. Container fill
may be random or pattern packed. Pattern packed increases protection of produce, by
minimising contact pressure by increasing number of contact points until its maximum of
12, is emphasized and maximising volume utilisation. Sometimes the produce is pre-
packed in packaging house in consumers pack, mostly different types of plastic bags or
overwrapped trays. The final packaging operation is container closures which may be
performed by gluing, stapling, strapping. Unitization and palletization may be done
according to the container requirement and market need.

2.4 Types of packaging: Packaging can be classified in number of ways; the most
importantone is by stages of distribution system for which it is primarily intended.
• Consumer or unit packaging,
• Transport packaging;
• Unit load packaging.

Consumer packaging
The package in which consumer receives the produce is called consumer packaging. The
term prepackaging of produce in consumer units prior to its presentation to the final
consumer. Prepackaging may be undertaken at any stage throughout the distribution
chain from the field to the retailers premises, depending upon, need of produce for
protection, expected transport and storage time, required shelf-life, packaging material
costs and costs of packaging and sorting at different points, transport and storage cost

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and latest knowledge of the market requirements.Types of consumer package:

Bags :

Bags are most common and favoured retail packs because of its low material and
packaging cost. In terms of cost to strength ratio 25 - 40 micron low density polyethylene
or 12.5 micron high density polyethylene bags are most suited. Net bags are used to
provide desired ventilation and allow free air moment for the produce such as citrus
fruits, onions potatoes etc. The bags can be made of paper, perforated polyethylene or
polypropylene film, plasticor cotton nets.

Net bags Perforated bags

Tray:

Tray packs made of foamed polystyrene or PVC or PP are overwapped with heat
shrinkable or stretch films. A tight wrap immobilizes the fruits and keep them apart.
Trays of moulded pulp, card board, thermoformed plastic or expanded polystyrene are
used.

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Sleeve packs:
Combine the low cost of bags and protective qualities and sales appeal of tray packs.
Wraps of plastic film such as polyethylene or PVC, in the form of shrink-wrap, stretch
film or cling film. Regular net stocking or expanded plastic netting can also be used. The
traditional fruits and vegetable retail trade packs the produce in the presence of
consumers and in the qualities and quantities required by them. The package normally
used is a simple wrap of paper or a paper or polyethylene bag. Sleeve packs can be
fabricated to contain from one to as many as ten fruits. The main advantage in sleeve
packs is that they immobilize the produce at a fraction of cost of tray packs and produce
can be observed from all sides without damage to the fruit.
Transport packaging:
The transport packaging for fresh produce may be divided into two size groups:
i) The predominant size group, suitable for carrying by man, is in the range of 15 to 25 kg.
ii) The other group, recently becoming increasingly popular is in 200-500 kg range
suitablefor fork lift handling refers to as pallet container.

Wooden boxes:
Includes natural wood and industrially manufactured wood-based sheet materials.
Timber used must be inexpensive and easily worked. All wood that is used for the
production of the packaging should be well dried in order to prevent cracks and mould
growth later. Manufactured wood based sheet materials include ply wood, hard board
and particle board. Plywood is usually made from birch. It is rigid and strong, though
perhaps somewhat less resistant to splintering than poplar, but is smoother and flatten so
suitable for direct printing. Hard board is dark in colour but its appearance can be
improved with decorative printing, but deforms after long storage in high relative
humidity. Particle board is thicker and rigid but relatively brittle.

Corrugated fibreboard boxes:

Corrugated fibreboard boxes are the most commonly used shipping containers where
cartons, glass, cans and pouches are the unit containers. The popularity of CFB as a
container in food industry as well as in other industrial packaging is for the
followingreasons:
1. Low cost to strength and weight ratio.
2. Smooth, no abrasive surface.
3. Good cushioning characteristics.
4. Excellent printability.
5. Easy to set up and collapsible for storage, and
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6. Reusable and recyclable market.

Corrugated fibreboard boxes

The most commonly used material for plastic corrugated box is polypropylene and
HOPE. Its advantage over CFB is low weight to strength ratio and its reusability. The
printability is also excellent when compared to CFB boxes. But CFB has edge over
plastic fibreboard boxes when cushioning properties are taken into consideration. The
disadvantages are ultraviolet degradation and temperature resistant.

Plastic crates
Plastic crates are usually made up of HOPE or Polypropylene by injection moulding has
been replacing wooden and wire crates. These crates must have good resistant properties
to ultraviolet degradation and shock damages.

Sacks:
These are flexible shipping containers which are generally used in food industries to
bring to raw materials viz. fruits and vegetables from the field. If the weight of content is
more than 10 kg then it is called sack otherwise bags. The commonly used materials for
sacks are cotton, jute, flan, plastics (HOPE, Polypropylene). These sacks are
advantageous to use as it cost less, high strength, reusability and requires small space for
the empties. Disadvantage of plastic woven sack is poor stackability due to low
coefficient of friction.

Palletization:
Pallets have been standardised keeping in view of the standard package sizes and sea
containers. The size of the pallet take on a strategic importance since they correspond
directly to the sizes of the various types of containers, ship cargo compartments, trucks,
fork trucks, etc. Most commonly used pallet sizes are 120x80 cm (Euro pallet) and
120x100 cm (Sea pallet). Sea pallets are most commonly used outside the Europe.

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Palletized loads are used in order to reduce handling costs by allowing the substitution of
mechanical handling for manual methods.
• A decrease in sorting.
• Redraw labelling requirement.
• Better utilization of storage space.
• A reduction in mechanical strains and damages.
• A reduction of the total distribution time.
• A better maintenance of product quality.

Two principles are used in the assembly of pallet loads.

1. The modular principle, in which all package are oriented in the same direction.
2. The two-way principle, in which the packages in each tier form a pattern such that
some packages are oriented lengthwise and other cross wise on the pallet.

Unitization :
Corner posts made with plastic or wood or Moulded paper boards is generally used as
columns for unitization. The boxes are held together by means of strapping around the
boxes as shown in below.

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Modified Atmosphere Packaging (MAP)

A modified atmosphere is the initial alteration of the gaseous environment in the immediate
vicinity of the product, permitting the packaged product interactions to naturally vary
their immediate gaseous environment.

A controlled atmosphere is a process by which the gaseous environment is modified to a

desired level and controlled at this level, with strict limits, throughout storage and is usually
applied to bulk storage.Normal composition of air 20% O2, 79% N2, 0.03% CO2.

Smart packaging
To be able to control the package structure to deliver controlled atmosphere within
packages is a major accomplishment that truly deserves the name "smart packaging." The
term "smart" packaging was coined about fifteen years ago to describe package structures
that allegedly sensed changes in the internal or surrounding environment and altered some of
their relevant properties in response. Simultaneously, academics and true researchers,
concerned that the term was too juvenile, invented the term "interactive" packaging to
describe the same entities and later shortened it to "active" packaging, the nomenclature
employed today. The problem with too much active packaging today is that it is not very
intelligent, i.e., it does not really change with environment but rather functions in a less
passive fashion than "ordinary" "barrier" packaging.

Intellipac™ polymeric package materials, manufactured by Landec Corp., Menlo Park,

Calif., are side-chain-crystallizable (SCC) polymers with the ability to effectively and
reversibly melt as the temperature increases and thus foster increased gas transmission
through them. SCC polymers are acrylics with side-chains independently of the main chain.
By varying the side- chain length, the melting point can be altered. By making the
appropriate copolymers, it is possible to produce any melting point from 0 to 68 0 C., well
within the extreme distribution temperature range of minimally processed foods. SCC
polymers are unique because of their sharp melting transition and the ease with which it is
possible to produce melting points in a specific temperature range. When elevated to the
switch temperature, SCC polymers become molten fluids which are inherently high in gas
permeability. The permeation properties may be modified by inclusion of other polymers to
change the carbon dioxide to oxygen permeability ratios, for example. The resulting
materials can permit the packaging technologist to achieve the lowest oxygen concentration

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without going anaerobic within the

package. Thus, the optimum gas concentration may be employed from the outset of
distribution with minimum concern for elevated temperatures. In addition to the reversible
temperature sensitivities, the materials are generally capable of 100 times greater oxygen
permeability than mainstream polyethylene films without compromising the carbon
dioxide to oxygen permeability ratio. This is accomplished by coating a porous substrate
with a proprietary SCC polymer and applying the membrane as a package label over an
aperture on an otherwise reasonably well sealed package. Membranes with high carbon
dioxide to oxygen ratio selectivity are best for products with carbon dioxide-sensitive
contents to allow the carbon dioxide to escape at rate faster than oxygen can enter.
Conversely, membranes with low ratios are more applicable to products in which high
carbon dioxide values can inhibit microorganisms. Thus, the materials can be tailored to the
exact requirements of the package contents. Package materials structures are capable of
satisfactorily containing high- respiratory-rate fresh and fresh-cut produce. Despite their
relatively high cost, Landec materials were commercialized during the 1990s and are being
employed for many fresh produce items, where they are the package medium of choice.

Oxygen scavenging
Oxygen is such a broadly effective agent of deterioration in foods that a substantial industry
has been established to provide a wide range of alternative means of oxygen removal from
package headspaces to reduce chemical deterioration. Such deterioration processes include
discolouration of meats or rancidity development due to lipid oxidation.

The choice of method of oxygen removal depends upon both economic factors and upon the
properties of the particular food. In practice the application of a short inert-gas flush
coupled with use of a scavenger is likely to be an attractive combination.

The performance of oxygen scavenging sachets depends strongly on the equilibrium relative
humidity of the food and the range of sachets available. The inclusion of iron-based
scavenging compositions in sachets has been improved by development of adhesive
scavenging labels for the inner wall of packages.

Technologies for thin films typically used in MAP systems need an additional feature to
prevent premature reaction if they are to provide maximum scavenging capacity. The
transition-metal-catalyzed (optionally light-activated) process patented by W.R. Grace, Inc.

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approaches this by pre-planned activation involving generation of full capacity by

consumption of antioxidants. Amoco Chemicals have reported some performance data for
their Amosorb®, water-activated, masterbatch for blending into a variety of plastics. No
compositional detail is yet provided but the masterbatch and plastics incorporating it are
stable at relative humidities below 40%.

Co2-scavengers and emitters

Co2 is formed in some foods due to deterioration and respiration reactions. The produced
Co2 has to be removed from the package to avoid food deterioration and/or package
destruction. Co2-absorbers might therefore be useful. The 02 -and Co2 -scavenging sachet
FreshLock® or Ageless® E is used in coffee to delay oxidative favour changes and absorb
the occluded 602 which if not removed would cause the package to burst . The active
compound Ca(OH)2 of FreshLock® reacts at suffciently high humidity with the Co2 to
produce CaCoa. Multiform Desiccants patented a Co2 -absorbent sachet including a porous
envelope containing CaO and a hydrating agent such as silica gel on which water is
adsorbed.

In some cases, however, high 602 -levels (10-80%) are desirable for foods such as meat and
poultry because these high levels inhibit surface microbial growth and thereby extend shelf-
life . Fresh meat, poultry, fish and cheese can benefit from packaging in a high Co2 -
atmosphere. Removal of 02 from a package by use of 02 -absorbers creates a partial
vacuum which may result in a collapse of flexible packagings. Also, when a package is
flushed with a mixture of gases including €02, the Co2 dissolves partly in the product and
creates a partial vacuum. In such cases, the simultaneous release of Co2from inserted
sachets which consume 02 is desirable. Such systems are based on either ferrous carbonate
or a mixture of ascorbic acid and sodium bicarbonate. The 02 -absorbers/Co2 -generators
are mainly used in products where package volume and package appearance are critical.

Antimicrobial packaging
Substantial recent research has been directed at determining how the surfaces of plastics
can be made not only sterile but also capable of having an antimicrobial effect on the
packaged food or beverage. This type of effect has already been achieved in outer layers of
laminates by use of modified printing presses.
Horseradish extract on a cyclodextrin carrier has been used in a drip sheet for fish or in a
film wrap for lunches in Japan.

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Approaches to antimicrobial packaging can be classified as either of two types. The first
consists of binding an agent to the surface of packages and this would require a molecular
structure large enough to retain activity on the microbial cell wall even though bound to the
plastic. Such agents are likely to be limited to enzymes or other antimicrobial proteins. The
second approach involves the release of agents into the food or beverage or localized
removal of a food ingredient essential for microbial growth.

prepackaging
The package in which consumer receives the produce is called consumer packaging. The
term prepackaging of produce in consumer units prior to its presentation to the final
consumer. Prepackaging may be undertaken at any stage throughout the distribution chain
from the field to the retailers premises, depending upon, need of produce for protection,
expected transport and storage time, required shelf-life, packaging material costs and costs
of packaging and sorting at different points, transport and storage cost and latest
knowledge of the market requirements. The experiments carried out at CFTRI showed the
extended shelf-life of different fruits, vegetables and cut flowers are shown in table:

Labelling:
Handling
information.
This side up-
symbol.
Fragile-symbol.
Temperature symbol min. 12°C., max. 14°C.
Produce information on "produce short side".
Origin : Country

Optional : District or regional or local place name

Produce : Mangoes

Variety : Name of variety.

Net weight : in kg.

Count : Number of fruits in the package.
Size : Optional

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Packed : Date of
packaging.Produce information "other short
side"

Tare : Tare weight in kg. (Max. + deviation in %)

Packer or : Name and address

dispatcher
Grower : Name and address

2.5 MARKETING
• Mahua being essentially a forest crop, there is lack of organized marketing
process. In forest areas the proportion of flowers and seed collection is much
less than the areas around . villages. However local middlemen purchase the
dehulled kernels of mahua from villagers and supply it to wholesale markets.
It ultimately reached to expellers from wholesale market.
• About 75 % of farmers sell their produce at farm level to the village merchants,
retailers, big producers or to pre harvest contractors. They cannot afford to
transport their produce to distant markets on account of non availability of
transport facilities, expensive transport, and malpractices in market.
Information regarding demand, supply, price, market outlook, knowledge of
consumer's preference, marketing channels are important for marketing of
produce.

2.6 Conclusion

• The research workers have to come along with the people of tribal community, so they
may have more and valuable knowledge. In coming next generation the importance of
plant and mahua tree is going to be increase because of their effectiveness, easy
availability, low cost and comparatively being devoid of toxic.
• Plants are the important economical source of a number of well established drugs looking
upon wide prospects and potential of Madhuca Indica for various purposes; it is

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worthwhile to cultivate this plant on large scale especially on unproductive and

wasteland. This will help in financial full support of poor and landless families. Generally
this plant Madhuca Indica is known only for its liquor making purpose, but one have to
come forward to change the thinking of unaware people
• The research workers have to come along with the people of tribal community, so they
may have more and valuable knowledge. In coming next generation the importance of
plant and mahua tree is going to be increase because of their effectiveness, easy
availability, low cost and comparatively being devoid of toxic.
• Plants are the important economical source of a number of well established drugs looking
upon wide prospects and potential of Madhuca Indica for various purposes; it is
worthwhile to cultivate this plant on large scale especially on unproductive and
wasteland. This will help in financial full support of poor and landless families. Generally
this plant Madhuca Indica is known only for its liquor making purpose, but one have to
come forward to change the thinking of unaware people

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CHAPTER 3

3.1 Food Safety and Regulatory Requirements for Mahua Processing

• Any food business operation to function in India should adhere to certain product specific
standards, safety and hygienic parameters.

• The food safety regulations are laid down by Food Safety & Standards Authority of
India, came into existence in 2006.

• Other agencies involved in standardization and quality certification are Bureau of Indian
Standards (BIS), AGMARK, Codex.

• FSSAI replaces the then existed laws like Prevention of Food Adulteration Act (1954),
Fruit Products Order, Milk & Milk Products Order, Export (Quality Control &
Inspection) Act, Meat Products order, Agricultural Produce (Grading & Marketing) Act

• Every food business operator involved in the manufacture, processing, storage and
distribution and sale of food products must compulsorily obtain FSSAI Registration or
License.

• It is a 14-digit registration of a license number which is printed on all the food packages.
The 14-digit registration number gives details about the assembling state, producer’s
permit.

FOOD SAFETY AND STANDARDS AUTHORITY OF INDIA (FSSAI)

• The Food Safety & Standards Authority of India is the principal Government
Authority responsible for preparing specific regulations under the Act. FSSAI is an
autonomous body established under the Ministry of Health & Family Welfare,
Government of India

• FSSAI has been established under the Food Safety and Standards Act, 2006

• Came in to action- August 2011

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• FSSAI is responsible for protecting and promoting public health through

the regulation and supervision of food safe.

• Businesses having annual turnover above 20 crore can apply for FSSAI central license.

• 1. Rental Agreement of Business Premises.

• 2. ID Proof of the Concerned Person (Aadhaar Card / Driving License / Passport / Voter
ID)

• 3. If any Government Registration Certificates ( Company Incorporation Certificate /

Firm Registration / Partnership Deed / Pan card / GST / Shop & Establishment / Trade
License)

• 4. If the applicant is private limited company or partnership firm then they should provide
MOA & AOA or Partnership deed copy.

• 5. IE Code (Import Export Code) Certificate (for the category of export and import IE
code is compulsory)

• 6. Authority letter from the company letterhead to the concerned person stating that he is
authorized to file FSSAI application.

• 7. List of food category desired to be manufactured (In case of manufacturers).

3.2 HACCP PROCEDUER

Appropriate to the nature and size of the operation and sufficient to assist the business to verify
that the HACCP controls are in place and being maintained.

Documentation shall include (as a minimum) the following:

• HACCP team composition;

• Product description;

• Intended use;

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• Flow chart;

• Hazard analysis;

• CCP determination;

• Critical limit determination;

• Validation process; and

• HACCP plan

The HACCP plan shall include the following information for each identified CCP:

• Food safety hazard(s) to be controlled at the CCP;

• Control measure(s);

• Critical limit(s);

• Monitoring procedure(s);

• Corrections and corrective action(s) to be taken if critical limits are exceeded;

• Responsibilities and authorities for monitoring, corrective action and verification;

Record(s) of monitoring

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