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Innovating Healthy Millet-Based Ready-Made Pulav Mix

A PROJECT REPORT

Submitted by
Aapurv Sethi (22BFT10004)
Bhavleen Kaur (22BFT10039)
Akchat Anand (22BFT10001)
Sampurna Thakur (22BFT10049)

in partial fulfillment for the award of the degree of

BACHELOR OF ENGINEERING

IN

FOOD TECHNOLOGY

Chandigarh University

NOVEMBER 2024
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BONAFIDE CERTIFICATE

Certified that this project report “Innovating Healthy Millet-Based Ready-Made

Pulav Mix” is the bonafide work of “ Aapurv Sethi, Bhavleen Kaur, Akchat
Anand and Sampurna Thakur” who carried out the project work under my/our
supervision.

SIGNATURE SIGNATURE
Dr. Naveen Diwedi Dr. Palak Mahajan
HEAD OF THE DEPARTMENT SUPERVISOR
Asst. Professor
Department of Biotechnology and Food Department of Biotechnology and Food
Technology Technology

Submitted for the project viva-voce examination held on

INTERNAL EXAMINER EXTERNAL EXAMINER

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CONTENT

Sl. No. Chapters Page no.

1 Abstract 6
2 Introduction 7-25
3 Review of literature 26-35
4 Material and methodology 36-46
5 Results and discussion 47-58
6 Conclusion and future scope 59-60
7 References 61-65
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LIST OF FIGURES

Figure No. Title Page no.

Fig.2.1 Benefits of consuming millets 28
Fig.2.2 Benefits of freeze-dried carrot 29
Fig.2.3 Benefits of freeze dries beans 30
Fig.2.4 Millet production in India and 32
world
Fig.2.5 Millet market growth rate in % 32
Fig.2.6 Process flow diagram of tray 34
dryer
Fig.2.7 Process flow diagram of freeze 35
dryer
Fig.3.1.1 Chopped carrots and beans 36
Fig.3.1.2 Manna ethnic millets-little 36
millets
Fig.3.2.2.1 Sample of cooked millet 39
Fig.3.2.6.1 Moisture content determination 43
of differently treated millet
samples
Fig.4.1.1 Dried sample of cooked millet 47
Fig.4.1.2 Freeze dried sample of carrots 48
Fig.4.1.3 Freeze dried sample of beans 49
Fig.4.4.1.1 Rehydrated little millet 54
Fig.4.4.1.2 Rehydrated oven dried 54
vegetables
Fig.4.4.1.3 Rehydrated freeze dried 55
vegetables
Fig.4.4.3.1 Final rehydrated pulav mix 57
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LIST OF TABLES

Table Number Title Page No.

Table.2.1 Nutritional composition of millet 31
Table.2.2 Millet production state wise India 33
Table.4.3.1 Moisture content of raw millet 50
sample
Table.4.3.2 Moisture content of roasted millet 50
sample
Table.4.3.3 Moisture content of cooked millet 51
sample
Table.4.3.4 Moisture content of par boiled millet 51
sample
Table.4.3.5 Moisture content of malted millet 52
sample
Table.4.4.1.1 Weight of different samples after 53
rehydration in normal and boiling
water
Table.4.4.1.2 Rehydration ratio of different 53
samples in normal and boiling water
Table.4.4.2.1 Quality attribute analysis of different 56
samples
Table.4.4.1. Sensory evaluation by 10 panelists 58
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ABSTRACT

The intention was to create an RTE mix of little millet, comprising mixed
vegetables, herbs, and spices, which could provide a healthy meal option that is
easy to prepare. Some key ingredients in the formulation included little millet,
freeze-dried carrots and beans, and aromatics like curry leaves, cumin, and
coriander. Since the locale had fresh ingredients, they were pre-treated and
processed for enhanced flavor, texture, and ease of preparation. Various pre-
treatments were involved by soaking, parboiling, cooking, roasting and malting
the millet for better water absorption, texture, and retention of moisture.
Vegetables were prepared by tray drying and freeze-dried, which provided a
comparison of the drying methods from the quality attributes and rehydration
properties. Results of quality tests such as moisture content, water absorption
capacity, and rehydration ratio helped in inferring the results of each
treatment. Among the different methods tested, oven-dried millet and freeze-
dried vegetables came out to be best in rehydration properties, that is, they
looked fairly promising for the final product. Rehydration of oven-dried millet
was firm, yet palatable. Freeze-dried vegetables rehydrated perfectly, retaining
most of their original structure, color, and flavor up to levels near the fresh
vegetable. The sensory evaluation on a 9-point hedonic scale showed an
acceptance score of 7.45 as the panel seemed to favor the flavor and aroma
profile that was achieved due to careful integration of spices and herbs,
mimicking a freshly prepared vegetable pulav. From oven-drying millet and
freeze-drying vegetables, a high-quality RTE pulav mix was produced,
retaining sensory appeal and nutritional value while offering the convenience
of easy reconstitution to meet consumer demands for flavor and health benefits.
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CHAPTER 1
INTRODUCTION

A "ready-to-eat" (RTE) product refers to the merchandise that has been pre-cooked, prepared, and
packaged for immediate consumption without requiring additional cooking or preparation by the
consumer. These products are typically designed for convenience, offering busy individuals or
families an easy meal option with minimal effort. The types of ready-to-eat products range across
various categories including fresh, chilled, frozen, or shelf-stable items.
In the current market there is already an increased demand and production of such
RTE products. There are prepared meals which are full meals, often containing multiple
components (protein, vegetables, grains, etc.), ready to eat after reheating or straight from the
package. Examples include frozen dinners, refrigerated meals, and shelf-stable meals. There is
snacks and light meals which often include grab-and-go items like salads, sandwiches, wraps, and
snack packs that require little or no preparation. Ready-to-drink options such as bottled coffee,
smoothies, fruit juices, and meal replacement drinks. Frozen foods items include frozen pizza,
burritos, lasagna, and other entrees, as well as frozen snacks like nuggets, fries, and dumplings.
There are also shelf-stable products like canned goods, instant noodles, soups, and other packaged
foods that can be stored at room temperature until consumption.
The availability of ready-to-eat products depends on several factors such as region,
consumer demand, and distribution channels. Supermarkets and grocery stores are the primary
retail outlets where ready-to-eat products are widely available. The shelves typically feature a wide
range of products, from fresh salads to frozen meals, and snacks. For on-the-go consumption, many
convenience stores offer a limited selection of ready-to-eat products, such as sandwiches, wraps,
bottled drinks, and snacks. The e-commerce sector has seen a rise in demand for ready-to-eat foods,
with several platforms now offering home delivery services for everything from fresh meals to
frozen foods. Delivery apps such as Swiggy, Zomato, Uber Eats, DoorDash, and Amazon Fresh
are also becoming popular ways to access these products. Specialty food stores offer premium
ready-to-eat products, organic options, or meals tailored to specific dietary needs (e.g., vegan,
gluten-free, keto, etc.). Ready-to-eat products are also available in foodservice outlets, such as
quick-service restaurants (QSRs), and in vending machines that offer packaged snacks and meals.
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There is an increasing consumer demand for ready-to-eat options that are nutritious, low in
preservatives, organic, or cater to special diets (e.g., gluten-free, plant-based). The demand for
sustainable packaging and eco-friendly options is growing, with consumers seeking brands that
prioritize reducing waste through recyclable or biodegradable packaging. The market for ready-
to-eat products is expanding globally, with many brands introducing international flavors or
regional delicacies to cater to a diverse consumer base. The rise of plant-based diets and alternative
protein sources is evident in ready-to-eat foods, with companies launching meat-free, dairy-free,
and other plant-based options. As consumers look for higher-quality products, there is growing
interest in premium or gourmet ready-to-eat meals, often marketed as fresh, artisanal, or chef-
inspired.
For refrigerated and fresh ready-to-eat meals, maintaining shelf life without
compromising taste and nutrition remains a challenge. While convenience is a major draw for RTE
products, the price point can be a barrier for some consumers, especially with premium offerings.
Offering customizable ready-to-eat products (e.g., mix-and-match salads, build-your-own bowls)
could cater to increasingly health-conscious and diverse consumer preferences.
The market for ready-to-eat products continues to expand as consumers demand convenience,
health-conscious options, and diverse meal choices. Whether through traditional retail, online
platforms, or foodservice outlets, ready-to-eat foods are widely available and continue to evolve
to meet modern lifestyle needs. Growing consumer desire for long-lasting, minimally processed,
additive-free food items is anticipated to drive market expansion. Consumers are gravitating
toward meals that are easy to prepare. Due to their busy work schedules, people all around the
world are purchasing ready-to-eat (RTE) food items and meals.
Rising busy lifestyles, working-class individuals, teenagers, hostel residents, and
single people are expected to push the demand for ready-to-eat food. The flavour and convenience
of ready-to-eat food products have led to a trend among young people to replace traditional meals
with ready-to-eat meals. This is anticipated to drive the market's expansion. The food service
industry, including hotels, restaurants, cafes, and bakeries, plays a significant role in driving the
growth of the ready-to-eat food market. These establishments cater to the increasing consumer
preference for convenient and on-the-go food options.
Ready-to-eat food sales grew at a CAGR of 7.1% from 2019 to 2023. By 2034, the worldwide
market for ready-to-eat food is expected to surge at a 9.2% CAGR. The consumer convenience
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factor was a key driver of market growth from 2019 to 2023. Consumers with busy lifestyles were
gravitating toward ready-to-eat options as a quick and hassle-free meal solution. This era
witnessed a wave of innovation in the RTE market. The demand for frozen, prepared foods
increased rapidly. These meals catered to consumers' desire for nutritious and balanced options,
offering convenience and a quality dining experience. The demand for healthy, natural, and
customized foods without sacrificing health goals or ingredients is increasing. Working
professionals are ready to spend money on convenience food without compromising their health.
This trend is creating a market and client base for the high-end convenience and ready-to-eat food
market. Wide Array of RTE products are available in the market, including instant breakfast &
cereals, bakery & confectionery products, and meat products. Further, ready-to-eat vegetables and
salads are becoming highly popular in emerging countries due to the convenience of consumption,
good taste, and growing awareness of the health benefits of vegetables. The below table shows the
estimated growth rates of the top four countries. The United States, India, and China are set to
record high CAGRs of 6.5%, 6.9%, and 7.3%, respectively, through 2034.

India’s ready-to-eat food sales are anticipated to expand at an impressive 6.9%

CAGR, demonstrating the nation's robust demand for quick & easy food options and its promising
future. With leading working populations in the world and rising disposable income, the ready-to-
eat food market in India is gaining traction. Less time for cooking and food preparation due to the
rising urban working cultures and fast-paced lifestyles is fuelling market expansion. Several food
items, such as world cuisines, snacks, and traditional Chinese foods and Soups make up India’s
ready-to-eat food market. This diversity caters to the population's varying interests and
preferences.
Instant Pulav is a ready-to-cook convenience food that combines rice, spices, and
other ingredients (like vegetables, herbs, and seasonings) in pre-measured packs. It offers a quick
and easy way to prepare a flavourful pulav (a type of rice dish) without the need for extensive
cooking time. It's often targeted at people with busy lifestyles or those who want to prepare a quick
meal without compromising on taste. Instant pulav typically contains pre-cooked or dehydrated
rice, along with a spice mix, and possibly dehydrated vegetables or meat. Some may even include
a flavouring packet or oil to enhance the taste. Usually, we just need to add water (or broth), heat,
and cook for a few minutes to have a hot, ready-to-eat dish. Some brands offer microwaveable
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versions for even faster preparation. Instant pulav comes in different flavours, including vegetable
pulav, biryani-style, jeera rice (cumin rice), or even more exotic variants like mushroom pulav or
mixed rice. It's ideal for people who want a home-cooked taste without spending a lot of time
cooking, making it perfect for busy professionals, students, or travellers.
Instant pulav is widely available in markets, both online and offline, especially in
countries like India, Pakistan, and other South Asian nations where rice-based dishes are staple
foods. Internationally, it's also available in supermarkets and grocery stores catering to South Asian
communities. In India, brands like MTR, Knorr, Tasties, and Haldiram's have well-established
instant pulav varieties. These are often found in major supermarkets or convenience stores. Some
local or regional brands may offer even more specific varieties. In countries with a significant
South Asian diaspora (e.g., the UK, UAE, the USA, and Canada), instant pulav can be found in
international grocery stores or through online platforms like Amazon, Big Basket, or local South
Asian marts. The growing trend of e-commerce has made it easier to access instant pulav from a
variety of brands globally. Websites like Amazon, Flipkart, and other regional online grocery
platforms allow consumers to order from the comfort of their homes. Some notable brands offering
instant pulav include- MTR which is known for their wide range of ready-to-eat and instant foods,
including pulav, biryani, and other rice-based dishes. Knorr which offers various instant rice
dishes, including pulav, typically in a seasoning mix form. Shan Foods that is famous for their
spice mixes and ready-to-cook products, Shan offers pulav and biryani kits. Haldiram’s is a major
Indian snack and convenience food brand that also offers instant rice dishes. Tasties is known for
quick meals, including ready-to-cook pulav. Gits is another brand in India providing instant meals,
including various rice dishes. Instant pulav is typically found in the convenience food or instant
meal aisle in large grocery stores. South Asian or international grocery stores are key places for
purchasing instant pulav, especially in markets outside of South Asia. Some grocery delivery apps
also feature these products, especially in cities with large urban populations.
As consumers become more health-conscious, some brands have started
offering healthier versions of instant pulav, such as low-fat, organic, or gluten-free options. There's
a growing market for premium or gourmet instant foods. This includes versions made with exotic
spices, organic rice, or even preservative-free ingredients. In response to environmental concerns,
some companies have started offering packaging that is more eco-friendly or promoting
sustainable sourcing of ingredients. Instant pulav is widely available and growing in popularity
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due to its convenience, especially in markets with a high demand for quick and easy meals. As
lifestyle patterns shift toward more on-the-go eating, the instant pulav market is expected to
continue to expand, offering more variety and options, especially in health-conscious and premium
categories.
The Global Instant Rice Market was valued at USD 1.9 Bn in 2023. It is expected to reach USD
3.3 Bn by 2033, with a CAGR of 5.9% during the forecast period from 2024 to 2033. The Instant
Rice Market encompasses the production, distribution, and sale of pre-cooked rice products that
require minimal cooking time. These products are made through a process that includes blanching,
steaming, and dehydrating regular white rice to a moisture content of 12% or less. The market
features a variety of offerings from both well-established brands and new entrants, catering to the
growing consumer demand for convenient, time-saving meal solutions. The sector is influenced
by factors such as product innovation, quality, and the expanding preference for quick and easy
meal kits preparation options. In 2023, Asia Pacific dominated the Instant Rice Market, capturing
a significant market share of around 55%. This dominance is driven by the region's high rice
consumption and the increasing demand for convenient and quick meal solutions. The growing
urban population, busy lifestyles, and rising disposable incomes have led to a surge in demand for
instant rice products that offer convenience without compromising on taste and nutrition. The
presence of numerous local and international brands, coupled with the expansion of modern retail
channels and e-commerce platforms, further enhances the market's growth in Asia Pacific.
The Instant Rice Market is experiencing notable growth, driven by the increasing demand for
convenient and quick meal solutions. This market is characterized by well-established brands such
as Minute Rice, which was first mass-marketed in 1946, as well as a diverse range of products
from both Asian and American companies. The production process of instant rice involves
blanching, steaming, and dehydrating regular white rice to a moisture content of 12% or less,
significantly reducing cooking time and enhancing convenience for consumers.
The rise in dual-income households and the fast-paced lifestyle of modern consumers are key
factors contributing to the growth of the instant rice market. The convenience of instant rice
products aligns well with the needs of busy individuals and families seeking quick meal
preparation options without compromising on quality and taste. Additionally, the increasing
popularity of ready-to-eat foods and the expansion of retail distribution channels have further
propelled market growth. Product innovation plays a crucial role in this market, with companies
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continuously developing new flavors, packaging, and preparation methods to attract a wider
consumer base. The emphasis on health and wellness has also led to the introduction of healthier
variants, including brown rice, quinoa, and other nutrient-rich grains, catering to the growing
demand for nutritious and wholesome meal options. The instant rice market is benefiting from the
rising trend of home cooking and the growing interest in diverse cuisines. Consumers are
increasingly experimenting with different recipes and flavors, boosting the demand for versatiland
easy-to-prepare rice products.

One of the primary restraining factors for the growth of the instant rice market is the perception
that instant rice has a lower nutritional value compared to regular rice. Many health-conscious
consumers believe that the processing involved in making instant rice can strip away essential
nutrients, vitamins, and minerals, making it a less healthy option. This perception is further
reinforced by dietary guidelines and nutrition experts who often recommend whole, unprocessed
foods. Consumers who prioritize nutrition may opt for traditional rice or other whole grains,
viewing them as more wholesome and beneficial for their health. This negative perception can
hinder market growth by limiting the potential consumer base to those who prioritize
convenience over nutrition.
In 2023, White Rice held a dominant market position in the By Type segment of
the Instant Rice Market, capturing more than a 40% share. This dominance is driven by its
widespread acceptance and preference across various demographics and regions. White rice is
favored for its neutral taste, quick cooking time, and versatility in numerous recipes. It is a staple
in many households, particularly in Asia Pacific, where rice consumption is integral to daily diets.
The convenience of instant white rice, combined with advancements in processing technology that
retain nutritional value, supports its strong market position. Brown Rice is gaining traction due to
its health benefits, including higher fiber content and more nutrients compared to white rice.
Despite its growing popularity among health-conscious consumers, its market share remains
smaller due to a longer cooking time and a distinct taste that may not appeal to everyone. Flavoured
Rice caters to the demand for convenience and variety, offering pre-seasoned options that save
preparation time. Its market share is growing but remains modest as it appeals to a niche segment
looking for quick, tasty meal solutions. Organic Instant Rice is becoming increasingly popular,
driven by the rising consumer awareness of organic and non-GMO products. However, its higher
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price point and limited availability result in a smaller market share compared to conventional white
rice.
In 2023, Supermarkets/Hypermarkets held a dominant market position in the
By Distribution Channel segment of the Instant Rice Market, capturing more than a 45% share.
These retail outlets offer a wide variety of instant rice products, providing consumers with ample
choices and the convenience of one-stop shopping. Supermarkets and hypermarkets often run
promotions and discounts, making them attractive to cost-conscious buyers. Their extensive reach
and established presence in both urban and rural areas ensure a broad consumer base. Convenience
Stores are significant for quick and easy purchases, especially in urban areas. However, their
market share is smaller due to limited product variety and higher prices compared to larger retail
formats. Specialty Stores cater to niche markets, offering premium and unique instant rice products
such as organic or gourmet options. While they attract specific consumer segments, their overall
market share remains modest due to their specialized nature and higher price points.
Online Retail is rapidly growing, driven by the increasing popularity of e-
commerce and the convenience of home delivery. Despite its fast growth, online retail’s market
share is smaller compared to traditional retail channels, as many consumers still prefer to
physically inspect and purchase food items in-store. Rice is an excellent source of carbohydrates,
which provide quick and sustained energy, making it a go-to food for athletes or those needing an
energy boost. It is naturally gluten-free, which makes it a safe option for people with celiac disease
or gluten sensitivities. It can be prepared in a wide variety of dishes and cuisines, from savory
main dishes to sweet desserts, making it adaptable to many dietary preferences. Rice, especially
white rice, is easy on the digestive system, making it a good option for people recovering from
illness or with digestive issues. Brown rice, is a good source of B-vitamins like thiamine, niacin,
and folate, which support metabolism and overall health. It is inexpensive and widely available,
making it a crucial staple for billions of people worldwide. It is naturally low in fat, which makes
it a good option for those looking to maintain or lose weight.White rice has been stripped of its
bran and germ, which means it lacks the fiber found in brown rice. This can contribute to
constipation and a less balanced diet if consumed excessively. White rice has a high glycemic
index (GI), which means it causes rapid spikes in blood sugar. This can be a concern for people
with diabetes or those trying to manage their blood sugar levels. Rice is relatively low in protein
compared to other grains or legumes. While it's a good source of energy, it doesn’t provide a
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complete source of amino acids, which are necessary for muscle repair and overall body function.
Rice, particularly from regions where it is grown in flooded fields, can contain traces of arsenic, a
toxic substance. Long-term exposure to arsenic is linked to health risks, including cancer and
developmental issues. Due to its high carbohydrate content, if rice is eaten in large amounts
without enough protein or vegetables, it may contribute to weight gain. It's important to balance
rice with other nutrients. The refining process removes many of the vitamins, minerals, and fiber
found in the outer layers of rice. Brown rice is a better option for retaining these nutrients.

The India Rice Market size is estimated at USD 52.82 billion in 2024, and is expected to reach
USD 59.46 billion by 2029, growing at a CAGR of 2.40% during the forecast period (2024-2029).
As a cereal grain, rice is the most widely consumed staple food for most people in the country.
Rice is cultivated in a significant acreage of land in the country, which has increased in recent
years. For instance, as per FAOSTAT, the total area harvested for rice in India was 46,278,680
hectares in 2021, which increased to 46,400,000 hectares in 2022. The timely onset of monsoons,
such as the Southwestern and Northeastern monsoons in India, is a major driver for high rice
production. This also results in higher productivity than in other Asian countries such as Thailand
and Indonesia, as these countries are affected by fluctuating rainfall causing floods and drought.
The major rice-producing states in India are West Bengal, Uttar Pradesh, Andhra Pradesh, Punjab,
Haryana, Tamil Nadu, Odisha, and Bihar. Further, the country's increasing food and restaurant
sector is anticipated to promote market growth in the coming years. Likewise, continuous
development in rice mill machinery and attractive packaging enhance product demand among the
people in the country. In addition, the rising demand for specialty rice varieties has increased the
trade for long-grain rice, which, in turn, is driving the market growth. According to the FAO, rice
production in India accounted for 196.2 million metric tons in 2022. Cultivating high-yielding rice
varieties such as IR 64, CR 2301, and Kudrat 5 makes India one of the largest rice producers in
the world, with more than 20% of the global rice production share.
Rice exports from the country have increased significantly in recent years. According to the ITC
Trade Map, India's rice exports touched 22.2 million metric tons in 2022 compared to 21.3 million
metric tons in 2021. The overall rice production in India was ample enough to support exports.
Higher demand for Indian rice in the international market in recent years and good climatic
conditions are supporting the growth of the Indian rice market.With the exponential growth in
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world population, the demand for food produce also increases simultaneously. According to global
consumption drafts, the major staple cereals consumed worldwide for calorie intake was wheat,
maize, and rice. This draft accounts for more than half of the population in the world. Barley,
millets, sorghum and rye finds considerably less consumption. Cereals like rice and wheat have
intensive water requirements. The primary requirement to irrigate such paddy crops depletes the
ground water levels and increases the distance between the ground level and ground water thereby
propelling a significant increase in the area under crop. Remonstrance of increase in dry lands as
well as deepening of ground water level is becoming a major issue in agriculture. This perturbates
for sustainable and commercially alternative of current cereal staples. Through cyclic rotation or
replacing the intensive paddy areas of regions with the alternative cereals like maize, ragi, sorghum
or pearl millet we can lower the water footprint (WFP) by at least 30%, improve production of
protein by 1% and consecutively add certain minerals like iron by 27% and zinc by almost +13%
with only a modest reduction in calories. This consequently increases the nutritional yield as well.
Millets can be a good alternative to wheat especially on acidic soils. Millets are cereal crops and
small seed grasses, mostly these species belong to the tribe Panicea. These coarse grains are widely
used in African and Asian countries. These small crops are used for human consumption and
consequently as fodder for animals. Majorly cultivated in the semiarid tropical regions of Africa
and Asia, around 97 percent of world’s overall millet production happens in these regions. Millets
fall under the group of C4 cereals. C4 cereals take more carbon dioxide from the atmosphere and
convert it to oxygen, have high efficiency of water use, require low input and hence are more
environment friendly. Thus, millets can help to phase out climatic uncertainties, reducing
atmospheric carbon dioxide, and can contribute in mitigating the climate change. The major millets
and their growing conditions in comparison to the staple cereals, i.e., rice and wheat. There is wide
variety of millet produced, few of the major ones consumed are- Barnyard millet which contains
high amount of dietary fibres, assists in intestinal flow and loss of weight, significant in calcium
and phosphate, helps to boost bone mass and yields mature grains 45 days after planting under
perfect weather patterns. Buckwheat millet which is diabetic-friendly, assists in lowering blood
pressure, is advantageous to heart health, promotes weight loss and has anti-cancer characteristics.
Finger millet which is gluten-free, significant in protein intake, assists brain growth in developing
kids, is high in nutrients, supplies with enough iron and other mineral deposit and high amounts
of amino acids that are needed by the body in the antioxidant capacity of traditional Indian food
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products. Foxtail millet which is high in carbs, aids in the control of blood sugar levels in the body,
wherein ron is plentiful and that enhances whole body’s immune system.
Kodo millet which is an amino emulsifier, has a massive effect on central nervous resilience, is an
Important source of Vitamin B, especially niacin, B6, folic, and other minerals and vitamins,
includes minerals like calcium, iron, magnesium, potassium, and zinc, is perfect for coeliac disease
people since it is gluten-free and in postmenopausal women, it can ameliorate cardiac illnesses
like high blood pressure and cholesterol. Little millet is a rich source of vitamin B and minerals
such as potassium, iron, zinc, and calcium and promotes weight loss. Pearl millet that contains
iron, fibre, protein, and mineral deposits like calcium and magnesium. Regular pearl millet intake
can be beneficial for health, such as aiding in combating type 2 diabetes mellitus. Proso millet
helps in balancing blood glucose levels and is a great choice for diabetic patients. It is useful for
nutrient transition. Sorghum millet is widely used in India to make chapatis as well as other baked
goods. It is a good source of iron, protein, and fibre and helps decrease cholesterol attributed to
the prevalence of policosanols. It is a healthier option for people allergic to wheat. It is greater in
antioxidant properties than berries and pomegranates and helps promote metabolic activity.
Millet based products currently available in market comprises of cookies, bread, biscuits, snack
foods, multigrain flour. It also encompasses traditional millet products such as millet porridge
which is a traditional food in Indian, Russian, German and Chinese cuisines. Millets are also used
to replace commonly used cereals in local dishes like idli, puttu, adai, dosa, etc. Other traditional
products like baddis, halwa, burfi, papad have added millet in it. Non-alcoholic products such as
Appalu, Samaipayasam, Korramurukulu have millet based key ingredient in them. There is also
alcoholic millet beverages such as Sur, Madua and Koozh. Millets are packed with essential
nutrients like vitamins (especially B vitamins such as niacin, riboflavin, and folate), minerals (iron,
magnesium, phosphorus, and potassium), and antioxidants. These nutrients help support overall
health, energy levels, and immune function. Millets are high in dietary fiber, which is essential for
digestive health. Fiber helps regulate bowel movements, prevent constipation, and can contribute
to a feeling of fullness, making millets a good option for those trying to manage their weight.
Millets are naturally gluten-free, making them an excellent choice for people with celiac disease
or those following a gluten-free diet. They provide an alternative to wheat, barley, and rye in many
recipes. Millets have a low to moderate glycaemic index, meaning they release sugar into the
bloodstream more slowly than refined grains. This makes them a good option for people with
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diabetes or those trying to manage their blood sugar levels. Due to their high fiber, magnesium,
and antioxidant content, millets can support cardiovascular health. The fiber helps lower
cholesterol levels, while magnesium is important for maintaining healthy blood pressure. Millets
contain minerals like calcium, phosphorus, and magnesium, which are essential for bone health.
Regular consumption of millet-based foods can contribute to stronger bones and help prevent
conditions like osteoporosis. Millets are a good source of plant-based protein, making them a
valuable addition to vegetarian and vegan diets. Protein is essential for muscle repair, growth, and
overall body function. The high fiber content and complex carbohydrates in millets help promote
satiety and prevent overeating. They also stabilize blood sugar levels, which can reduce cravings
and prevent energy crashes that might lead to unhealthy snacking. Millets are rich in antioxidants,
which help combat oxidative stress and inflammation in the body. This can lead to healthier skin
and hair by reducing the risk of acne, premature aging, and hair loss. The fiber in millets acts as a
prebiotic, promoting the growth of beneficial gut bacteria. A healthy gut microbiome is important
for overall health, including immune function and mental well-being. Millets are drought-tolerant
and require fewer chemical inputs than other grains like rice and wheat, making them more
environmentally sustainable. They are a good option for those looking to support environmentally
friendly food choices.
Regulations related to import/export restrictions, tariffs, and non-tariff barriers can limit the global
trade of millet. This can hinder the growth of the millet market and limit access to millet products
in regions where they are not locally produced. Inconsistencies in regulations or standards across
regions or countries can create confusion and challenges for millet producers and traders.
Harmonizing standards can facilitate trade and market growth. Millet is a diverse group of small-
seeded grasses that are grown for their grains, which are used as food. While millets have unique
properties and are valued for their nutritional content and resilience, there are some potential
substitutes available for millet in various culinary applications, such as rice, wheat, barley, oats,
corn, and so on.The Millet Market size is estimated at USD 11.53 billion in 2024, and is expected
to reach USD 14.43 billion by 2029, growing at a CAGR of 4.60% during the forecast period
(2024-2029). Millets comprise various small portions of cereal such as sorghum, finger millet,
pearl millet, barnyard millet, proso millet, and little millet. They are cultivated in adverse and
diverse climates in dry, semi-arid, and sub-humid agriculture areas in over 32 million hectares
worldwide. India, Niger, and China are the largest millet producers in the world, accounting for
 P a g e | 18

more than 55.0% of global production. India is the largest producer of millet in the world.
However, in recent years, millet production has increased dramatically in Africa as many countries
encourage dryland agriculture due to low water availability and sub-tropical climatic conditions
favoring millet production.
The high protein content of these grains makes them ideal for the vegetarian and vegan population,
primarily based in the United States, Europe, and Asia-Pacific. Furthermore, the pandemic has
affected the market positively as many people are including millets in their diet and shifting from
junk foods to nutrient-rich foods like millets and their derivatives to boost immunity and health.
Hence, the demand for millet-based products is growing rapidly in these regions, which is
anticipated to drive the millet market.
The government and organizations promote millet production in India due to its importance in
making a nutritional diet. Due to their nutritional value, millets are notified as Nutri-Cereals by
the Government of India. Furthermore, the Department of Agriculture and Farmers Welfare
(DA&FW) is implementing a sub-mission on Nutri-cereals under National Food Security Mission
to enhance the area, production and productivity of millets. According to Food and Agriculture
Organization (FAO), global millet production was estimated at 28.33 million metric tons in 2019,
which increased to 30.08 million metric tons in 2021. India is the largest global producer, with a
43.0% global market share in 2021 with Sorghum(jowar), Pearl Millet (bajra), Finger millet (ragi),
and other minor millets are grown in the country. According to the Ministry of Agriculture and
Farmers Welfare, millet production in India has increased from 14.52 million tonnes in 2015-16
to 17.96 million metric tons in 2020-21.
The expanding domestic production has further boosted the export of millet. According to Director
General for Commercial Intelligence & Statistics (DGCI & S), the millet exports in India rose by
8% to 159,332.16 metric tons in 2021-22 against 147,501.08 metric tons in 2020-21, which is
anticipated to boost the local millet production. Furthermore, the government of India is promoting
the export of millet due to rising demand in the global market. For instance, Agriculture and
Processed products Export Development Authority (APEDA) has planned 16 programs for the
promotion of millets and millet products in countries such as UAE, Indonesia, the United States,
Japan, the United Kingdom, Germany, South Africa, Australia, Saudi Arabia, etc. to increase the
millet exports of the country. Data on health indicators, published by NFHS (National Family
Health Survey) report 2023 shows that 59.1% of women are anaemic, 35.6% of children are
 P a g e | 19

stunted, and 32.2% of children are underweight. As millet are nutritionally superior to cereals, on-
acid forming, on allergic, easy to digest and rich in protein antioxidants, dietary fibre, there has
been great demand of Millets. The proposal to the United Nations General Assembly (UNGA)
year 2023 has been declared as the International Year of Millets. As Millets helps in maintaining
body weight, improving haemoglobin levels, reducing iron deficiency, fighting anaemia, diabetes,

cardiovascular diseases there has been higher production and productivity of millets across the
globe. Around 70 countries have pledged to engage various stakeholders for promoting the wilder
usage of millets. Farmers have started shifting away from wheat and rice farming in favour of
millet because of the steadily rising demand from Asia Pacific nations, primarily China and India.
Demand for millets products will increase during the projection period as the urban population's
preference for healthy foods grows and as unsustainable rice and wheat production rises. People
decided to switch from eating junk food to renowned rich super foods like millets and derivatives
in order to strengthen their immunity. During the projection period, more consumers are
anticipated to want millets as a healthy option. One of the main drivers of the demand for organic
millet internationally is the change in consumer lifestyles, which has increased their propensity for
healthier foods. High levels of protein and minerals found in organic millets assist prevent ailments
including obesity, diabetes, and cardiovascular issues.
Promotional intervention for millets are government driven in many regions.
The government has provided different kinds of supports like finance, infrastructure, technology
etc. for the various stakeholders. The Minimum Support Price (MSP) for significant millets has
already been announced in most states which has created tremendous opportunities for millet
productions The processing units are placed closer to production sites where at first primary
processing and quality control checks are made and then secondary processing quality control
checks packaging and branding are done at central level in bigger scale. This has helped in
reducing the factory gate pricing of millet products and has generated farm opportunities and better
monetary benefits for millet cultivators.Little millet (scientific name: Panicum sumatrense) is a
small, nutritious grain that is part of the millet family. It is also sometimes referred to as Sama or
Sama Rice in India, where it is commonly consumed. Little millet is native to India and parts of
Southeast Asia and has been cultivated for thousands of years. The grains are smaller than most
other millets, which is why it is called "little millet." The seeds are tiny, round, and light brownish
 P a g e | 20

in colour. The flavour is mild and nutty, making it a versatile ingredient in cooking. When cooked,
little millet has a fluffy, rice-like texture, which is why it's often used as a substitute for rice or
other grains in dishes. Little millet is considered a superfood due to its impressive nutritional
profile. It is high in fibre which helps in digestion and supports a healthy gut. It contains a higher
protein content compared to other grains, making it a good option for vegetarians. It has a low
glycaemic index which is a great option for people with diabetes, as it causes a slower rise in blood
sugar levels compared to refined grains. Little millet is rich in B-vitamins, iron, magnesium, and
calcium, which are important for overall health. Little millet can be used in a variety of dishes,
much like rice or other grains- Upma which is a popular South Indian dish made by cooking little
millet with vegetables and spices. Khichdi which is a comfort food made by combining little millet
with lentils and spices. Pulao that is cooked with vegetables and seasonings, similar to a rice pulao.
Finger millet is sometimes used in the batter for making dosas or idlis. After boiling, little millet
can be tossed with fresh vegetables and dressing for a healthy salad.Little millet is naturally gluten-
free, making it suitable for those with celiac disease or gluten sensitivity. Due to its high fiber
content, it helps keep you feeling full longer, supporting weight loss efforts. The magnesium and
potassium in little millet help in regulating blood pressure and reducing the risk of heart disease.
It is a good source of calcium, which is vital for bone strength.
Little millet has been consumed for centuries in South India, especially in states like Tamil Nadu,
Karnataka, Andhra Pradesh, and Telangana. In these regions, little millet is commonly used in
making dishes like upma, pongal, khichdi, and dosa. In rural areas, little millet is still grown and
consumed as a staple food, though the production volume can vary from year to year due to weather
conditions and market prices. n urban markets, health food stores, organic outlets, and online
platforms (like Amazon, Big Basket, Flipkart, and Organic India) are driving the distribution of
little millet products. Popular millet brands like Millet Mantra, Soulfull, and 24 Mantra Organic
are offering packaged little millet, including ready-to-cook formats like instant upma, millet flour,
millet-based snacks, and more. Online sales are becoming a major distribution channel, with
increasing availability of millet products across India.Vegetables are an essential part of a healthy
diet, providing a wide range of nutrients, vitamins, minerals, and fiber that are necessary for overall
health and well-being. Regular consumption of vegetables has been linked to a lower risk of
chronic diseases, improved digestion, better skin health, and even weight management. Carrots are
rich in Vitamin A (as beta-carotene) which is essential for good vision, skin health, and immune
 P a g e | 21

function. Vitamin K that is important for bone health and blood clotting. Vitamin C that supports
immune function and skin health. Potassium which helps regulate blood pressure. Fiber that aids
in digestion and supports gut health. Antioxidants, particularly, beta-carotene, which helps protect
cells from damage.
Carrots are famously known for supporting good vision due to their high vitamin A content.
Vitamin A is crucial for the proper functioning of the retina and for preventing night blindness.
The antioxidants in carrots, including beta-carotene, help protect the skin from damage caused by
free radicals and UV rays. Carrots can promote a healthy, glowing complexion and may help
reduce the appearance of wrinkles. Carrots contain vitamin C, which strengthens the immune
system and helps the body fight off infections.The fiber in carrots aids in digestion and helps
maintain healthy bowel movements. It can prevent constipation and promote a healthy gut
microbiome. Carrots, being rich in potassium, help manage blood pressure levels. Their
antioxidants also support cardiovascular health by reducing inflammation and improving
cholesterol levels. Some studies suggest that the carotenoids in carrots may help protect against
certain types of cancer, though more research is needed. Carrots can be eaten raw in salads, slaws,
or as a crunchy snack. It can be steamed, roasted, boiled, or sautéed. They are often used in soups,
stews, curries, or as side dishes. Carrots can be juiced or blended into smoothies for an added
nutritional boost. Carrots are a key ingredient in carrot cake and muffins.
Beans (such as kidney beans, black beans, chickpeas, lentils, etc.) are rich in plant-based proteins,
fiber, and essential nutrients, making them an important part of a balanced diet, particularly for
vegetarians and vegans. Beans provides a plant-based alternative to animal proteins. It has fibre
which is important for digestive health, reducing cholesterol, and regulating blood sugar levels. It
has vitamins including folate (important for cell function and tissue growth), vitamin B6
(important for brain health), and thiamine (essential for energy metabolism). Beans are rich in iron,
magnesium, potassium, and zinc, which support overall health and well-being. They contain
flavonoids, polyphenols, and other antioxidants that have anti-inflammatory and anti-cancer
properties.
The high fibre content in beans helps regulate digestion, reduce constipation, and maintain a
healthy gut microbiome. Beans are heart-healthy due to their fiber content, which helps reduce
cholesterol levels, lower blood pressure, and reduce the risk of heart disease. It has a low glycemic
index (GI), meaning they release sugar slowly into the bloodstream, helping to regulate blood
 P a g e | 22

sugar levels. This makes them particularly beneficial for people with diabetes. Beans are high in
fiber and protein, which help keep you feeling fuller for longer. This can reduce overall calorie
intake and assist in weight management. Beans are a good source of magnesium, calcium, and
potassium, which are essential for maintaining strong bones. The antioxidants and fiber in beans
are believed to have cancer-fighting properties by reducing oxidative stress and inflammation,
which are linked to the development of cancer. Beans are often used in various curries, stews, and
soups, especially in vegetarian and vegan cooking. It can be used in salads for added protein and
texture (e.g., chickpea salad, black bean salad). Made primarily from chickpeas (a type of bean),
hummus is a popular dip for snacks or vegetables. Beans are often mashed or pureed for use as a
spread in sandwiches, wraps, or as a filling in tacos and burritos. It is commonly used as the main
ingredient in vegetarian or vegan burger patties, offering a hearty and protein-rich alternative to
meat. Bean flour can be used to make gluten-free pasta, providing a protein and fiber boost to
meals.
Tray drying, also known as batch drying or shelf drying, is a common method used for drying
various materials, especially food, pharmaceuticals, and chemicals. The basic principle behind tray
drying is to remove moisture from the material by exposing it to a controlled flow of hot air,
typically in a large chamber or oven, with the material spread out in trays.
Tray dryers are relatively simple to design, operate, and maintain, making them cost-effective
compared to more complex drying methods like spray drying or freeze drying. With proper airflow
management, tray dryers can achieve fairly uniform drying of products. The material is typically
exposed to air in a consistent manner. Tray dryers can be operated at lower temperatures, which
makes them suitable for drying heat-sensitive products such as certain foods and pharmaceutical
materials.Tray dryers can be used for a wide range of materials, including powders, granules,
fruits, vegetables, herbs, and even medicines.
Freeze drying, also known as lyophilization, is a sophisticated drying process used primarily to
preserve perishable materials like food, pharmaceuticals, and biological samples. The principle
behind freeze drying is to remove moisture from the material while keeping its structure, flavor,
and nutritional content intact by using a combination of freezing and sublimation.
The material to be dried is first frozen at very low temperatures (typically between -40°C to -80°C,
depending on the product). This step converts the water in the product into ice. The freezing
process preserves the physical and chemical structure of the material, as the water freezes inside
 P a g e | 23

the cells, preventing damage to the material's matrix. Under these low-pressure conditions, heat is
gently applied to the frozen product. As a result, the ice in the material sublimates—meaning it
transitions directly from a solid (ice) to a vapor (water vapor) without passing through the liquid
phase.
Once most of the water has been removed during the sublimation phase, any remaining bound
water (water that is chemically or physically attached to the material) is removed by further drying
at a slightly higher temperature under vacuum. This step ensures the material is completely dry
and free of residual moisture. The product is left with minimal moisture content (usually less than
5%), while maintaining its original structure, flavor, and nutrient content.
Freeze drying preserves the integrity of sensitive nutrients, flavors, and aromas. Since the process
occurs at low temperatures and does not involve high heat, heat-sensitive compounds (like
vitamins, enzymes, and antioxidants) are better retained compared to other drying methods. The
low-temperature freezing and sublimation process help retain the shape, texture, and appearance
of the material. This is especially valuable for delicate items like fruits, vegetables, and biological
samples that might otherwise lose their structure when dried by conventional methods. Because
the drying process removes almost all the moisture, freeze-dried products do not require
preservatives, which makes them more natural and appealing to consumers looking for clean-label
products.
Freeze-dried products can be rehydrated easily by adding water. Upon rehydration, the product
generally returns to its original form, with minimal loss in texture, color, or flavor. This is
particularly important for food products, medical formulations, and biological materials where
rehydration is necessary for use. Freeze drying minimizes the damage that can occur to cell
membranes during drying. The process avoids the shrinkage or rupture of cell walls that can
happen with other drying methods, which is important for products like fruits, vegetables, and
biological materials.

The rehydration ratio refers to the amount of water (or other liquid) needed to rehydrate a
dehydrated product to its original or desired consistency. The rehydration ratio is typically
expressed as the ratio of the weight (or volume) of water added to the weight (or volume) of the
dehydrated material.
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Rehydration Ratio = Weight of Water Added

Weight of Dehydrated Product

Moisture content refers to the amount of water present in a substance, typically expressed as a
percentage of the total mass. It is an important characteristic for many materials, especially in food,
agriculture, pharmaceuticals, and manufacturing processes. The moisture content can significantly
affect the quality, shelf life, texture, and stability of products.
Moisture content directly impacts the texture, flavor, and overall palatability of food. For example,
too much moisture can make foods soggy or promote microbial growth, while too little moisture
can make foods excessively dry and unappealing. It plays a role in preservation. Foods with lower
moisture content tend to have longer shelf lives because moisture is a key factor in bacterial and
mold growth. The shelf life of products (e.g., dried fruits, meats, and grains) is heavily influenced
by moisture content, with lower moisture often enhancing preservation.The future scope of ready-
to-eat millet pulao looks bright, driven by a growing focus on health, sustainability, and
convenience. With the right strategies in place—such as educating consumers, expanding flavor
offerings, improving sourcing practices, and leveraging technology—companies can build a strong
market presence. By aligning with global food trends and consumer preferences, ready-to-eat
millet pulao can become a significant player in the growing segment of health-conscious, on-the-
go meals.
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Keeping all the above concerns in mind, our objectives are: -

• Creating a healthy and nutritious ready-to-eat product
• Making the product gluten-free so that celiac patients can consume it
• Adhering to gustatory response and making the product economically viable and
sustainable
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CHAPTER 2
REVIEW OF LITERATURE

In this chapter, a review of literature is presented, examining previous research and various studies
related to Ready-To-Eat products and various treatments used throughout this project. This
overview provides insights into existing knowledge and methodologies, highlighting relevant
findings that inform and support the current work.

Kumar et al., 2011 studied about the impact of gamma irradiation combined with retort processing
on the shelf life and safety of ready-to-eat (RTE) vegetable pulav. Using 60Co, the pulav was
irradiated at various dosages, followed by retort processing. Microbiological, chemical, and
sensory analyses showed that this combination significantly reduced microbial load while
preserving quality, even after one year at room temperature. The findings suggest that a minimum
irradiation dose of 4.0 kGy, combined with a retort processing F0 value of 2.0, is effective in
extending shelf life and enhancing organoleptic properties.

Marathe et al., 2016 worked to create a shelf-stable, ready-to-eat vegetable pulav using radiation
processing. Microbial and sensory analyses over storage indicated that a minimum dose of 7.5 kGy
effectively controlled microbial growth without affecting sensory quality for up to one year at
room temperature. Doses up to 25 kGy did not impact the pulav's proximate composition, and a
slight increase in antioxidant activity and free phenolic content was observed at 25 kGy. GC-MS
analysis showed an increase in aroma compounds like 2-octanol, eugenol, and eugenyl acetate at
doses ≥10 kGy, though these changes were not detected in sensory tests.

In the study of Kumar et al., 2013, it was observed that the work on evaluated the impact of
combining irradiation and retort processing on the shelf life and safety of ready-to-eat chicken
pulav. Using a 60Co gamma source in an air atmosphere at room temperature, the pulav was
irradiated at doses between 2.0 and 5.0 kGy, determined with a Ceric-Cerous dosimeter, followed
by retort processing at an F0 value of 3.0. Microbiological analysis confirmed a significant
reduction in microbial loads (P < 0.05), while chemical and sensory properties showed minimal
 P a g e | 27

changes during storage. This combination processing extended shelf life and enhanced the
organoleptic qualities of the chicken pulav.

Fan et al., 2018 investigated on Microwave heating is increasingly used for drying high-value
solids, offering faster drying times and better product quality. While freeze-drying at cryogenic
temperatures under very low pressure ensures high quality, it is costly and time-consuming.
Microwave-assisted freeze-drying (MFD) combines these methods to accelerate drying while
maintaining product quality, provided that equipment design prevents hot spots. This review
highlights recent advances in MFD modeling and experimental studies, noting that, due to high
costs, its application remains limited to small-scale drying of high-value foods like fruits and
vegetables. Expanded industrial use will require further research to address current process
limitations.

Youchuan MaInstitute et al., 2022 studied on Freeze-drying is a key technology for extending shelf
life and preserving the nutritional quality of high-value, heat-sensitive foods. However, differences
in phytochemical retention across various fruits and vegetables during freeze-drying require
further exploration. This review examines how freeze-drying impacts bioactive compounds and
antioxidant capacity in these foods and assesses the stability of these ingredients during storage.
Additionally, it provides a comprehensive overview of recent advancements and challenges in
freeze-drying techniques and product development.

It was observed that Zhang et al., 2010 did a recent research from the Food Sciences Key
Laboratory of Jiangnan University, Wuxi, China, comparing various drying methods—including
hot air, vacuum, freeze, microwave vacuum, and microwave freeze drying—applied to fruits,
vegetables, and aquatic products. New studies also examined drying extruded restructured chips,
such as potato blended with apple, as a potential future snack. The research evaluated drying
kinetics and key quality parameters like color, texture, nutritional value, and crispness, along with
the microstructural changes unique to each method. The potential for microwave-assisted drying
in industrial-scale applications is also discussed.
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Fig.2.1 Benefits of consuming millets

Huang et al., 2022 made an extensive study on fruits and vegetables are widely regarded as healthy,
most people worldwide still fall short of the WHO’s dietary recommendations. Functional foods
and beverages enriched with health-promoting ingredients are increasingly popular as a convenient
way to boost daily fruit and vegetable intake, delivering essential nutrients and bioactive
compounds. Drying, an effective preservation method for these moisture-rich, perishable foods,
often relies on high temperatures that can diminish nutritional and sensory qualities. This review
focuses on low-temperature drying technologies that better preserve these qualities, enhancing the
potential of fruits and vegetables in functional beverages.

Babu et al., 2018 researched about fresh culinary and medicinal leaves are highly perishable, often
suffering post-harvest losses due to moisture-driven enzymatic and microbial activity, poor
handling, and delays in transport or storage. Effective drying methods are essential to prolong shelf
life, enable off-season availability, and preserve nutrient levels. By reducing moisture to a safe
level, dried leaves achieve improved shelf stability, lighter shipping weight, and lower
transportation costs. Controlled heat treatment is crucial for moisture removal, balancing nutrient
retention and energy efficiency. This review examines key factors affecting water loss, drying
kinetics, methods, and conditions, as well as the impact of drying techniques on nutritional quality.
 P a g e | 29

It also discusses optimal thin-layer drying models for leaves and industry challenges, including
energy conservation, emission reduction, and hot spot prevention, highlighting areas for future
research.

Fig.2.2 Benefits of freeze dried carrot

Hasan et al., 2019 worked on fresh fruits and vegetables, with their high moisture content, spoil
quickly without proper handling. Conventional storage methods like refrigeration and controlled
atmospheres require continuous energy, making them costly throughout the supply chain. Drying
is a more sustainable approach, reducing postharvest losses, easing storage and transport, and
ensuring year-round product availability. Traditional drying methods, like sun drying, are slow
and risk contamination, while advanced techniques—including solar, microwave, vacuum,
infrared, freeze, oven drying, and hybrid methods—are increasingly used worldwide for various
fruits and vegetables. This review examines crop-specific drying methods and their effects on
quality, efficiency, cost, and nutrient retention.
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Fig.2.3 Benefits of freeze dried beans

Joshi at el., 2018 studied on Barnyard millet, known for its superior nutritional value, was used to
create an instant pulav using the PRJ-1 variety, with ingredients like carrot, mint powder, rock salt,
and spices. The pulav was prepared through cooking (13 minutes), dehydration (9 hours at 60°C),
and rehydration (9 minutes). Sensory evaluations showed no significant difference between the
reconstituted and freshly cooked pulav. With a low glycemic index of 34.12, it is suitable for
diabetics. Nutritional analysis revealed protein (11.17g), fat (3.68g), fiber (8.06g), and energy (356
Kcal) per 100g, along with essential minerals. Shelf life studies indicated safe storage for one
month in summer and two months in winter at room temperature.

Tulasiat el., 2020 investigated and researched to develop instant soup and pulav mixes using
millets, dehydrated vegetables, and natural herbs like basil, curry, coriander, mint, and bay leaves,
enhancing the antioxidant properties of both mixes. The millets were pre-processed, milled, and
blended in different ratios to create three formulations (T0, T1, T2). Sensory evaluations identified
T1 as the preferred instant soup mix and T2 as the favored pulav mix, with notable acceptability.
Stored for two months in laminated pouches, the mixes showed no pathogenic contamination at
room temperature. Nutritional analysis indicated that millet and herb enrichment significantly
boosted sensory appeal and health benefits, making this a convenient and nutritious soup mix
option.
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Table 2.1: Nutritional composition of millets

Abegazet al., 2022 worked on small millets that have long been a dietary staple in Asia and Africa,
traditionally prepared as porridge, gruel, flatbreads, dumplings, and various beverages. However,
their popularity declined over time due to the preference for refined grains, the labor-intensive
processing of millets, and the lack of documentation of traditional recipes. Recently, awareness of
their nutritional benefits and advancements in processing techniques have revived interest in small
millets, leading to the development of unconventional products like ready-to-eat and ready-to-
cook mixes, snacks, and novel baked goods. These value-added products not only diversify the
food basket but also offer health benefits and address hunger needs in a growing population.
Kumari et al., 2024 studied dry mix foods, like upma, are widely popular, with upma typically
made from wheat semolina. This study explored the use of four minor millets—proso, barnyard,
little, and kodo—for developing ready-to-cook instant upma mixes using soaking-drying,
autoclaving-drying, and roasting methods. Sensory evaluation identified roasted minor millet
mixes as the best option. The nutritional analysis showed that these instant upma mixes are rich in
protein (6.26-10.68%), ash (3.37-4.27%), iron (7.32-11.28 mg/100g), zinc (3.65-5.73 mg/100g),
and phytonutrients like phenols (1.98-6.07 mg GAE/100g) and tannins (0.45-0.58 mg TAE/100g).
The mixes can be stored for up to 90 days at ambient conditions in LDPE pouches without spoilage
 P a g e | 32

Fig.2.4 Millet production in India and World

According to the work of Yadav et al., 2012 on traditional southern Indian breakfast dish, upma,
was prepared using pearl millet semolina (PMS) instead of wheat. The millet grains underwent
hydrothermal treatment (soaked to 30 ± 2% moisture, then steamed at 1.05 kg cm−2 for 20
minutes) to reduce anti-nutritional factors and inactivate lipase, which was undetectable post-
steaming. Using a central composite rotatable design (CCRD), experiments tested the effects of
vanaspati (vegetable fat), citric acid, and water for rehydration on taste and texture. Optimal
ingredient levels were 46.5 g vanaspati, 0.17 g citric acid, and 244.6 ml water per 100 g PMS,
achieving a sensory desirability of 98.5%. The mix was stable for 6 months at 20–35 °C in
polyethylene pouches (75 μ), with no significant increase in peroxide value, free fatty acids, or
thiobarbituric acid levels.

Fig.2.5 Millet market growth rate in %

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Visvanathan Rangaraju .,2024 investigated on Parboiling of little millet (Panicum sumatrense)

and proso millet (Panicum miliaceum) was optimized by soaking at temperatures of 50 and 60°C
and steaming for 25 and 10 minutes, respectively. The parboiled grains were then shade dried and
polished. Little millet required 9–14 minutes for cooking, with a water uptake ratio of 3.3–4.7,
swelling index of 1.73–2.74, and elongation ratio of 1.69–2.61. Proso millet showed cooking times
of 11–13 minutes, water uptake of 2–4.2, swelling index of 0.7–1.72, and elongation ratio of 1.42–
4.26. These conditions enhanced cooking quality and reduced cooking time for both millets.

Kang at el., 2024 studied on popularity of minor millets, also known as ancient grains, has risen
significantly due to their potential health benefits and sustainable qualities. Once overlooked,
millets are now seen as valuable crops to help achieve food security and sustainable development
goals. This review explores the global distribution of minor millets, highlights the challenges and
opportunities in their production, and examines their nutritional benefits and potential for creating
value-added products.

Table 2.2: Millet production state wise in India

Chabbra & Kaur., 2021 worked extensively meet the growing demand for nutritious, sustainable,
and clean-label foods, this study focused on developing ready-to-cook millet-based khichdi and
upma targeted at health-conscious consumers (LOHAS segment). Using foxtail and little millet,
the grains were dry roasted at 110 °C for 18 minutes to achieve optimal moisture content and
sensory qualities. Nutritional analysis showed these mixes are rich in protein, dietary fiber, and
minerals compared to similar market products. Shelf life tests demonstrated that these
preservative-free products maintain quality at ambient conditions, making them suitable for small-
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scale production and potential women-led enterprises.

Fig.2.6 Process Flow Diagram of Tray Dryer

Nachiket at el., 2023 study focused on creating a convenient, nutritious, ready-to-cook packaged
product using millets, with a process designed for small-scale enterprise production. Batch-scale
trials were conducted to standardize the process, ensuring consistent quality and ease of
reconstitution. The final product offers a healthy, preservative-free option, ideal for small-scale
business models, especially women-led ventures.

Balasubramanian at el., 2014 worked on South Indian breakfast, traditionally made from wheat,
was prepared using pearl millet semolina (PMS) that underwent hydrothermal treatment to reduce
anti-nutritional factors and deactivate lipase. Using a central composite rotatable design (CCRD),
optimal levels of vanaspati, citric acid, and water were determined for rehydration, with sensory
evaluations scoring high for taste, mouthfeel, and acceptability. The final mix, optimized with 46.5
g vanaspati, 0.17 g citric acid, and 244.6 ml water per 100 g PMS, maintained quality and freshness
over six months in polyethylene pouches under ambient storage.
 P a g e | 35

Fig.2.7 Process Flow Diagram of Freeze Dryer

Sahoo at el., 2020 studied about little millet, known for its rich nutritional profile, faces
commercial limitations due to challenging post-harvest processing. This study examined various
pretreatment methods to enhance dehulling efficiency using an abrasive roller. Pretreatments
included soaking and parboiling, followed by either sun drying or hot air drying at 45°C. Results
showed that millet soaked for 4 hours and then hot air dried at 45°C achieved the highest dehulling
and milling efficiencies, at 96.72% and 70.21% respectively, with a head yield of 53.32% and
usable brokens comprising 16.88% coarse and 3.25% fine fractions.

Balasubramanian at el., 2016 investigated on physical properties of foxtail, little, kodo, common,
barnyard, and finger millet were assessed across moisture levels from 11.1% to 25% db. Findings
showed a rise in 1000-kernel weight (2.3 to 6.1 g) and angle of repose (25.0° to 38.2°) as moisture
increased. Bulk density and true density decreased notably from 868.1 to 477.1 kg/m³ and 1988.7
to 884.4 kg/m³, respectively, with a drop in porosity from 63.7% to 32.5%. The static friction
coefficient against mild steel rose from 0.253 to 0.728, while internal friction ranged from 1.217
to 1.964. Grain hardness declined from 30.7 to 12.4 as moisture content increased.
 P a g e | 36

CHAPTER 3
MATERIAL AND METHODOLOGY

3.1 Material
Selectively, the ingredients were chosen in order to procure quality in the development of the
ready-to-eat product. Millet little from Manna Ethnic Millets brand was bought from a supermarket
nearby, which became the primary grain component. Fresh vegetables such as carrots and beans
along with coriander and curry leaves were procured from a vegetable seller locally so that it would
be fresh, hence authentic.

Fig. 3.1.1 Chopped Carrots and Beans

Fig. 3.1.2 Manna Ethnic Millets – Little Millet

Depth of flavor and aroma was attained with multiple whole spices added to the
oil—cumin seeds, bay leaves, peppercorns, and dried red chilies. Powdered spices such as salt,
turmeric, red chilli powder, and coriander powder were added to balance and enrich the overall
flavor profile of the preparation. Fortune Refined Rice Bran Oil was used for sautéing, as it does
not possess any characteristic flavour that will mask the flavours of spices and herbs infusing into
 P a g e | 37

the millet and vegetables.

3.2. Methodology
Our product which is a ready-to-eat Pulav (or Pilaf) is a pre-cooked, packaged millet based dish
that is designed for convenience, allowing consumers to enjoy a flavorful, nutritious meal with
minimal preparation. This methodology outlines the steps involved in preparing Ready-to-Eat
Pulav, from ingredient preparation to packaging and storage.

3.2.1. Pre Treatment of millet

To study the different pre-treatments effects on millet, five different samples were prepared: raw,
par-boiled, cooked, roasted, and malted. Each one of these pre-treatment steps is there to alter the
physical and functional properties of millet in such a manner that they become fit for certain
purposes and testing.

Raw Millet (Untreated):

It relates the study to raw millet-the untreated natural form of the grain-used as a control. This
sample remains with its natural physical structure, nutritional profile, and moisture levels, hence a
superior reference sample compared to the treated samples. The test on the raw sample offers a
benchmark against which the treatment of each sample with the cited pre-treatment is measured.

Par-Boiled Millet:
First, the grains are soaked in water for 15 minutes, then cooked for 8 minutes. Gelatinizing the
starch inside the grains with a partial cooking technique improves digestibility and shelf-life and
helps retain firmness. It is less likely that parboiled millet will crack or leak nutrients during
subsequent processing. This pre-treatment is important because it balances moisture uptake
without cooking the grain completely.

Cooked Millet:
Cooked millet was processed by soaking the grains for 15 minutes, followed by cooking until the
grains were at a soft enough consistency, which took about 15 minutes. Full cooking of the grains
completely breaks down the structure of the grain, increases its water-uptake capacity, and
 P a g e | 38

qualifies it more readily for applications that require a soft, tender texture. This pre-treatment
enhances digestibility and reduces cooking time in end-use thereby making it favorable for ready-
to-eat formulations where minimal rehydration or re-cooking is preferred.

Roasted Millet:
Roasting was carried out by dry heating the millet in an open pan till the grains emitted a mild
aroma and took on a slightly brown colour. This dry roasting develops flavor due to the Maillard
reaction, which gives millet a nutty taste and aroma. Roasting also reduces the moisture content,
thus enhancing shelf life and reducing grain bulk density. Besides the roasted flavor impact, there
is also toasted flavor profile that can be realized with roasting, and this would have potential in
snack applications and for products which require an aromatic quality.

Malted Millet:
The malting of millet was done by steeping the grains in water for 24 hours, allowing them to
germinate over the next 24 hours, then kilning at 60°C for 12-14 hours. Malting activates grain
enzymes that break down tough starch into fermentable sugars, thereby making the millet taste
sweeter and easier to digest. Kilning stops the germination process but preserves the enzymic and
flavor changes, which contribute to the nutrient and sensory content of the grain. Malted millet is
particularly treasured for food products that would be trying to enhance natural sweetness and
digestibility, such as infant foods and health items.

These pre-treated samples will then encompass a wide range of functional and sensory properties
appropriate to various product applications. Testing these samples will enable in-depth analyses
of their physical properties, such as bulk density, 1000-kernel weight, Angle of repose, as well as
properties similar to these, which are critical in determining the suitability of each of these pre-
treatments for food formulations.

3.2.2. Post Treatment of millet

The purpose of post-treatment was to soften the small millet for use in the ready-to-eat product. It
was subjected to controlled cooking and drying methods that enhanced its texture, flavor, and
shelf-life. The following steps were undertaken:
 P a g e | 39

Soaking
For the above operation, 500 grams of small millet were soaked in water for 30 minutes. Soaking
allows the grains to absorb water, which further softens the grain structure and partially hydrates
it. It saves time and energy that is used later in cooking since it will provide an overall and balanced
softening in the grain. Later, soaking helps in removing any surface dust or impurities affixed to
the millet; therefore, it will also raise its cleanliness and quality.

Cooking
The soaked millets were cleaned and cooked in boiling water to a time of 15–17 minutes, when
millets became soft. Cooking further gelatinizes the starch of the millet. This also helps in making
the grain soft a bit, ready for uniform drying. In the next steps, moisture will be reduced better.

Fig. 3.2.2.1 Sample of cooked millet

Drying by Hot Air Oven

The millet was spread on trays lined with aluminum foil, sprayed lightly with oil, to prevent
sticking. Millet-drying process was carried out in a hot air oven at a temperature of 60–65°C, for
24 hours. Controlled drying removed moisture from the millet, thus lowering its water activity;
this hereby restricted microbial growth and enhanced shelf-life. The relatively low temperature
 P a g e | 40

ensured retention of the grain's texture and nutritional qualities while properly drying it to the
desired moisture level.

This post-treatment process yields a shelf-stable, pre-cooked millet that can be rapidly
reconstituted in the final ready-to-eat product; the convenience, retention of flavour, and soft
texture on reconstitution are assured.

3.2.3. Drying of Vegetables

Pre-treatment of beans and carrots was involved in preparation for drying with multiple steps to
conserve quality and enhance the character of the vegetables to be incorporated into the final
product. The highly detailed methodology follows:

Preparation: Cleaning, Cutting/Cubing, Blanching, Salting

Cleaned, unblemished fresh beans and carrots were cleaned thoroughly to get rid of impurities,
diced to the same size for uniform drying. Pre-processing involved blanching of the diced
vegetables in muslin cloth to a boiling water at 80°C for 3–5 minutes, where blanching kills
enzymes that degenerate colors and nutrients after the vegetables' intended cooking, thus ensuring
retention of good appearance and flavor. The vegetable samples immersed after blanching in a 2%
salt solution. This salting step helps in inhibition of microbes, shelf-life extension, as well as in
retention of color and texture of the vegetables after storage and subsequent rehydration.

Tray Dryer Drying

The same number of prepared vegetable samples was dried in a tray dryer maintained at 60°C. The
working of a tray dryer is based on convection. In this case it dries uniformly using heated air
blown over the samples. However, the direct heat exposure when drying from a tray induces a
certain amount of shrinkage along with loss of color and nutrients, hence resulting in a denser,
more compact product by the end. Though very efficient for the reduction of moisture content, it
might mar the quality of rehydration.

Freeze Drying
The other half was frozen in a deep freezer until the water content solidified. These are freeze-
 P a g e | 41

dried in a lypholizer for almost 4 days. Freeze drying removes moisture through the process of
sublimation, whereby ice turns straight into vapor under low temperature and pressure. This
process gives very porous, lightweight dried vegetables with minimal shrinkage and great retention
of color, flavor, and nutrients. The freeze-dried vegetables rehydrate well, restoring much of the
fresh like qualities of vegetables and making them ideal for ready-to cook applications.

3.2.4. Drying of Herbs and Roasting of Whole Spices

For fresh herbs and spices, preparation within the ready-to-eat product consisted of a controlled
drying of herbs and dry roasting of whole spices. Both methods were used to ensure preservation
of flavor and aroma of the ingredients and sustain shelf stability of these ingredients until the end
product, which had been guaranteed for sensory appeal.

Drying of Herbs (Curry Leaves and Coriander Leaves)

Pre-treatment
Fresh curry leaves and coriander leaves are washed properly so that all dirt or impurities get
removed from them. The leaves were then picked with utmost care in a way that was done
uniformly while plucking the leaves. The drying time will be less as well because the moisture
will be held inside by the stems that delays the procedure of drying.

Drying on Tray
The leaves were spread evenly on trays in a thin layer of oil to prevent sticking of the leaves, which
allows them to dry evenly. Then, the trays are placed in a tray dryer and subjected to controlled
drying for 12–14 hours at 60°C.

Dry Roasting of Whole Spices

Whole Spices Selection and Preparation
The whole cumin seeds, bay leaves, dry red chilies, and black peppercorns dominated the
aromatics. Each of these was chosen in its whole form. Roasting the spices whole would release
the ultimate flavor and aroma in the recipe.
 P a g e | 42

Roasting Procedure
Dry-roast whole spices in an open pan over low to medium heat until they give off natural aromas
and become slightly darker and emit a change of color like cumin seeds become darker or the bay
leaves get brittle. Be careful not to burn because this will give you a bitter flavor.

By drying the herbs and roasting the spices, both ingredients were properly prepared to be given
their quality and to provide the flavor, aroma, and stability in the final product.

3.2.5. Water Absorption Capacity

Water absorption capacity, which stands for WAC, is an important parameter in the preparation of
ready-to-eat products. Since WAC also determines texture, rehydration time, and acceptance of
the final product, it is perceived that ingredients like grains and millets should have a high WAC
to ensure suitable moisture retention capacity, thereby giving a desirable, tender texture upon
reconstitution or cooking. This would be quite imperative for products rehydrated before
consumption, thus adding to the satisfaction of the consumer.
In this experiment, 50 grams of small millet were used and left to soak in water for
15 minutes. This soaking enables to hydrate and softening the grains thus reducing time for
cooking due to breaking some antinutrients present in the grain hence increasing nutrient
bioavailability. After soaking, the millet was placed in boiling water, then cooked until it became
soft, it consequently took about 14 minutes. The sample was weighed using a balance after excess
water had been strained off from the cooked millet.
The WAC was calculated using the following formula:
WAC = (Final weight of cooked sample - Initial weight of raw sample / Initial weight of raw
sample) * 100

3.2.6. Moisture Content Determination

Determination of Moisture Content Determination of the moisture content of raw materials is very
important in the development of stable, quality ready-to-eat products. Moisture contents in such
ingredients like little millet influence not only the shelf life and texture of the final product but
also the efficiency with which processing and cooking methods can be carried out. The
understanding of the raw and processed millet's moisture characteristics helps the developers tailor
 P a g e | 43

the techniques of processing to achieve the desired texture and stability in the final product.
Preparation of samples included five types of little millet: raw, parboiled, cooked,
roasted, and malted. About 5 grams of each type were accurately weighed on sterilized Petri plates
in triplicate to get this accuracy and sterility. Samples placed in a hot air oven kept at 80°C were
dried for the first 3 hours. Immediately after primary drying, the samples were withdrawn, cooled
a little, and weighed for moisture loss. To ensure all moisture has been removed, samples were put
back into the oven for two drying cycles of 30 minutes each with weight obtained at the end of
each cycle. The moisture content for each sample variety was thus calculated based on differences
in weights obtained at each drying stage.

Fig. 3.2.6.1 Moisture Content Determination of differently treated millet samples

Moisture content = (Initial weight of sample before drying – final weight of sample after drying /
initial weight of sample before drying) * 100

3.2.7. Development of RTE product

The development of an RTE product requires a series of methodical tests and quality assessments,
to obtain convenience, nutrition, and consumer acceptability. Thus, the key tests will involve
assessment of water absorption capacity, measuring moisture content and re-hydration ratio - all
important factors for optimizing texture, shelf stability, and ease of preparation. The components
 P a g e | 44

are cooked and processed into a dry mix, whereby every ingredient is subjected to analysis for
quality attributes like flavor, color, and texture. Sensory evaluation is carried out with a taster panel
to get an overall acceptability and knowing where consumer expectations of the final product lie.
This is the way one ensures that the RTE product can meet the expectations of industry standards
as well as consumer expectations towards taste and ease of convenience.

3.2.7.1. Rehydration Ratio

Re-hydration ratio is one of the critical quality parameters for dried food products, especially when
they are ready-to-eat or have any quick preparation requirement. This imparts the reconstitution
ability to the dried samples that can accept water into them and consequently influences the texture,
flavor release, and palatability of the final product. High re-hydration ratios in the case of dried
foods entail that these foods can regain moisture excellently, closely resembling the fresh
counterpart in terms of texture and mouth feel. This aspect plays a critical role in acceptance by
consumers and the appeal of the final product can be highly affected.
Sample preparation - To compare the re-hydration properties of different methods,
three types of dried samples were prepared: little millet by using the hot-air oven, chopped beans
and carrots freezed, and chopped beans and carrots tray-dried. All received distinct drying
treatments whose purpose was to retain quality at minimal moisture content: moderate heat hot-air
oven drying, reversible removal of moisture with retention of cellular structure and color for freeze
drying, and tray drying for the most efficient method without compromising nutrient retention.
Each dried sample was weighed to about 10 g and packed into tight-fitting airtight stainless steel
containers in such a way that all samples were uniformly consistent. Re-hydration was measured
under two sets of conditions: room temperature water (35°C) and boiling water (70°C). In each
condition, water was added just above the level of the sample so that the sample is fully submerged
for optimal reconstitution. The airtight containers were sealed; and samples, therefore, underwent
soaking for a total of 5 minutes to permit absorption of water.
After soaking, the samples were removed and their final weights obtained to compute
the rehydration ratio. Quality attributes of soaked samples were also evaluated to determine what
method of drying was able to preserve more quality of the product.
Rehydration Ratio = Final weight of sample after absorption of water / Initial weight of dried
samples
 P a g e | 45

3.2.7.2. Quality attributes

One of the key quality attributes that ensure rehydration performances of rehydrated dry food
products has been texture; color flavor and structural properties. Ideally, these ought to evaluate
its freshness as a pointer of effective dehydration and rehydration processes involved in their
productions.
Assessment of sample and associated rehydration, characteristics for both treatments
were accordingly conducted on;
1. Texture: Texture influences mouth feel as well as acceptability. Each sample was scored for
softness, firmness, and adhesion. The hot-air oven-dried millet was checked for tenderness, and
both the freeze-dried and tray-dried vegetables were examined for integrity. Texture was also
compared before and after rehydration in tap water and boiling water.
2. Color: Color shows freshness. Color match was done visually where the color of each sample
after rehydration with fresh and dry state samples is considered. Freeze-dried samples should retain
a bright color as compared to tray- and oven-dried samples, where fading might have happened.
Difference between the two rehydration conditions also observed with regard to possible color loss
in boiling water condition.
3. Flavor and Aroma: These should enhance the overall appeal. Each sample was scored for
intensity of flavor and aroma, as well as off-flavors. Freeze-dried samples retain aromas better
than other technologies, but any differences between room temperature and boiling water should
be noted.
4. Structural Integrity: To check on structural integrity, which is important for chopped-vegetable
items, samples were examined for retention of their shape without becoming mushy. Freeze-dried
samples should retain their shape better than tray- or oven-dried samples, and effects of both
rehydration conditions are to be compared for differences on stability.
Following these determinations, the hydration ratio may be assessed based on weight gain as the
criterion for quantitatively measuring the efficiencies of hydration with a variety of drying methods
and temperatures. With this determination of rehydration, one may know which method of drying
and rehydration is of better quality if the quality becomes an issue to better prepare ready-to-eat
products of high quality.
 P a g e | 46

3.2.7.3. Combining and cooking of components to make the RTE product

A mix of ingredients had been carefully chosen to prepare this ready-to-eat product, lightly sautéed
to enhance flavor and aroma. There are roasted whole spices like cumin seeds, dried red chilies,
whole peppercorns, and bay leaves and dried herbs like curry leaves and coriander leaves, added
in for depth of flavor. Dry little millet was the main grain base with added texture and nutrition,
and freeze-dried vegetables assisted in bringing back the color and flavors of the product and also
other facets of nutrients. To maintain a stable flavor, powdered spices of salt, red chili powder,
and coriander powder were added into the formulation.
Each ingredient is measured and mixed in various compositions to maximize both
flavor and rehydration efficiency. The mixture is then lightly sautéed using rice bran oil. This is
done so that the natural oils and aromas of the spices can be released to acquire a better flavor
profile. When sautéed, the mixture was cooled to help preserve quality and prevent moisture
accumulation in the product. Then, the cooled product was put up in airtight containers to ensure
fresh content and not absorbed moisture.
Testing the Final RTE Product: Measuring and placing a part of the mixture in an
airtight steel container, then covering it with boiling water up to just the level is the next step. Place
the lid on the container and let rest for 5 minutes, allowing the hot water to rehydrate the millet,
vegetables, and spices. After 5 minutes, the product was evaluated for rehydration quality, texture,
and flavor to meet the standards of ready-to-eat meals.

3.2.7.4. Sensory Evaluation

Sensory evaluation is crucial for testing the general acceptability of the ready-to-eat product such
that consumer expectations on flavor, texture, aroma, and appearance are met. A 9-point hedonic
scale was used wherein panelists ranked different sensory attributes using a scale where 1 point
was "like extremely" and 9 points was marked as "dislike extremely." This scale is directly
measurable and provides standardization in measuring the overall appeal of the product.
The sensory panel consisted of different faculty members from our department and
a couple of students so that we may get a good spread of feed backs. The panelists were asked to
appraise the RTE product on a variety of parameters, such as taste, texture, color, aroma, and
overall acceptability. Each panel member was given the rehydrated product after boiling water had
been added and the answer provided by them was noted by the hedonic scale.
 P a g e | 47

CHAPTER 4
RESULTS AND DISCUSSION

The different outcomes of drying treatments of millets, vegetables, and other ingredients are
discussed in the context of moisture content, water absorption capacity, and the ready-to-eat (RTE)
product. Effects on quality and rehydration of ingredients are discussed through oven drying with
hot air, freeze-drying, and tray drying. Formulation aspects of the RTE product would include
sensory attributes and overall acceptability.

4.1. Drying of millet, vegetables, whole spices and herbs

The drying process was most effective on millets, and dried grain weights were stable and uniform
post-drying. This indicated that thorough moisture removal occurred. The grains did not
structurally collapse, and they could easily be processed further to be prepared as the ready-to-eat
product.

Fig. 4.1.1 Dried sample of cooked millet

The effects for the vegetables were different for various drying methods. Vegetables
dried in tray dryers resulted in wide shrinkage and loss of nutritive and sensory properties since
 P a g e | 48

direct heat for too long leads to serious dehydration, significant losses in color, texture, and volatile
nutrients, thus causing overall deterioration. But the dried vegetables obtained by freeze-drying
procedure retained their structural integrity and sensory attributes. Freeze-drying had preserved
the cell structure, so the vegetables remained intensely colored, flavored, and nutritionally valued.
After drying, these vegetables appeared porous and weightless, indicating that all the water
molecules had evaporated without damaging the texture and quality of the vegetables. Freeze-dried
vegetables were much more suitable for use in ready-to-eat product.

Fig. 4.1.2 Freeze Dried sample of carrots

The drying of herbs like curry leaves and coriander leaves in a tray had successfully
maintained their aroma and flavor, thus making an essential contribution to the overall taste of the
ready-to-eat product. Dry roasting whole spices enhanced their aroma and removed its raw
sharpness for a better balanced and aromatic flavor profile.
 P a g e | 49

Fig. 4.1.3 Freeze Dried sample of Beans

4.2. Water Absorption Capacity

The WAC of the cooked millet was 298.74%. It really absorbed nearly three times its weight in
water, showing that it holds a lot of moisture and can expand upon rehydration. With such high
WAC, the millet presents suitable choice for ready-to-eat products where moisture retention relates
strongly with the texture and consumer acceptance of the final food product.

4.3. Moisture Content Determination

The results of moisture content determination for various millet samples, providing insight into
the drying efficiency are as follows-
The millet samples showed a considerable variation in the outcomes regarding moisture content
determination with the processing methods used. The highest moisture content was that of cooked
millet at 70.56%. This is consistent with the fact that cooking releases bound water and absorption
occurs from the surrounding to soften the grain and increase its digestibility. Millet that was par-
boiled retained less water than the fully cooked sample but more than the others and provided a
balance between partial hydration and structural firmness at 51.16%. Malted millet had the lowest
moisture content at 21.11% as compared to the other samples, showing that the kilning process
reduced the water content effectively without affecting the enzymatic modification and nutritional
benefits of the grains. Dry-heat process led to the roasted sample having the lowest moisture
 P a g e | 50

percent at 9.28%, meaning that dry heat was very effective in giving off water molecules and
concentrating flavor. Finally, the raw sample contained 10.49% moisture content was set as the
control, representing no pretreatment, therefore at pre-treatment level of water. The results clearly
depict how different pre-treatments affect moisture content, therefore texture, shelf life, and
suitability in food application.

Table 4.3.1. Moisture content of Raw Millet Sample.

Sl. Weight of Weight of Weight of Weight of Weight of Weight of Moisture
No. empty Petri plate Sample Petri plate Petri plate Petri plate Content
Petri plate + Sample (g) + Sample + Sample + Sample (%)
(g) before after after after
drying (g) drying (3 drying (+ drying (+
hrs) (g) 30 mins) 30 mins)
(g) (g)
1 45.659 50.625 4.966 50.452 50.239 50.103 10.51 %
2 42.265 47.286 5.021 46.952 46.856 46.739 10.89 %
3 42.695 47.70 5.005 47.402 47.372 47.195 10.08 %

Table 4.3.2. Moisture content of Roasted Millet Sample.

Sl. Weight of Weight of Weight of Weight of Weight of Weight of Moisture
No. empty Petri plate Sample Petri plate Petri plate Petri plate Content
Petri plate + Sample (g) + Sample + Sample + Sample
(g) before after after after
drying (g) drying (3 drying (+ drying (+
hrs) (g) 30 mins) 30 mins)
(g) (g)
1 44.9 50.12 5.22 49.92 49.79 49.65 9.00 %
2 42.62 47.73 5.11 47.43 47.32 47.24 9.58 %
3 43.57 48.63 5.06 48.41 48.24 48.16 9.28 %
 P a g e | 51

Table 4.3.3. Moisture content of Cooked Millet Sample.

Sl. Weight of Weight of Weight Weight of Weight of Weight of Moisture
No. empty Petriplate of Petriplate Petriplate Petriplate Content
Petriplate + Sample Sample + Sample + Sample + Sample
(g) before (g) after after after
drying (g) drying (3 drying (+ drying (+
hrs) (g) 30 mins) 30 mins)
(g) (g)
1 43.439 48.49 5.05 45.56 44.97 44. 89 71.28 %
2 43.55 49.07 5.52 48.005 47.067 45.23 69.56 %
3 42.72 47.98 5.26 46. 23 45.04 44. 24 71.10 %

Table 4.3.4. Moisture content of Par Boiled Millet Sample

Sl. Weight of Weight of Weight of Weight of Weight of Weight of Moisture
No. empty Petriplate Sample(g) Petriplate Petriplate Petriplate Content
Petriplate + Sample + Sample + Sample + Sample
(g) before after after after
drying (g) drying (3 drying (+ drying (+
hrs) (g) 30 mins) 30 mins)
(g) (g)
1 44.525 49.527 5.002 47.872 47.349 47.034 49.84%
2 43.99 49.574 5.584 47.326 46.981 46.769 50.23 %
3 44.94 50.247 5.307 48.561 47.963 47.412 53.42 %
 P a g e | 52

Table 4.3.5. Moisture content of Malted Millet Sample

Sl. Weight of Weight of Weight Weight of Weight of Weight of Moisture
No. empty Petriplate of Petriplate Petriplate Petriplate Content
Petriplate + Sample Sample + Sample + Sample + Sample
(g) before (g) after after after
drying (g) drying (3 drying (+ drying (+
hrs.) (g) 30 mins) 30 mins)
(g) (g)
1 43.96 49.291 5.331 48.984 48.468 48.261 19.32 %
2 43.62 48.87 5.25 48.120 47.93 47.72 21.90 %
3 44.285 49.475 5.190 48.971 48.452 48.326 22.136 %

4.4. Development of RTE product-

4.4.1. Rehydration Ratio

The rehydration ratio results as follows: samples rehydrated much better in boiling water (70°C)
compared to normal room temperature water (35°C). In boiling water, the structure of the food
matrix expands at a higher temperature, which hastens the absorption process for quicker water
penetration. In normal water, it goes slow because of the lesser temperature that stops the swelling
and opening of the inner food structure.
The rehydration ratio was particularly high for millet, jumping nearly threefold in
warm water versus normal water. This suggests that higher temperatures help revive millet to its
smooth, wet structure, as the expanded composition allows the grain to absorb more water with
ease.
In the dried vegetable samples, it was close between the rehydration ratio of normal
and boiling water although the percentage of rehydration was still higher in boiling water. Another
aspect of the drying technique rehydration of freeze-dried vegetables ranged from 4.5 to 7 times
their dry weight while tray-dried samples showed only 2-3.5 times rehydration. Therefore, these
structural alterations that occur during the drying process account for this considerable size
difference. Freezing will desiccate through water sublimation, which means the porous,
lightweight matrix will suck up water in rehydration to restore the texture and patterns of fresh
 P a g e | 53

vegetables. Tray-dried products depend absolutely on direct heat, resulting in shrinkage and
compaction of the cell structure to influence the speed and efficiency of water absorption.

Table 4.4.1.1 Weight of different samples after rehydration in normal and boiling water
Sample Initial Weight Final weight Final weight
(g) after soaking after soaking in
in normal boiling water (g)
water (g)
Dried Millet 10.05 22.36 32.76
Freeze Dried Carrot 3.31 14.86 16.45
Freeze Dried Beans 3.5 21.32 24.83
Oven Dried Carrots 3.51 8.13 9.82
Oven Dried Beans 3.05 10.52 11.02

Table 4.4.1.2 Rehydration Ratio of different samples in normal and boiling water
Sample Rehydration Ratio in normal Rehydration Ratio in boiling
water water
Dried Millet 2.22 3.25
Freeze Dried Carrot 4.48 4.96
Freeze Dried Beans 6.09 7.09
Oven Dried Carrots 2.31 2.79
Oven Dried Beans 3.44 3.61

The rehydration ratios obtained for the three samples revealed that huge differences exist between
absorption of water and quality recovery of the three samples. Furthermore, the rehydration ratio
for the dry millet appeared remarkably high; this indicates a good, excellent capacity of water
absorption to reach a texture close to fresh millet. The high rehydration capacity defines the
potential of ready-to-eat products to have a fine texture when reconstituted to satisfy consumers'
expectations.
It was observed that freeze-dried vegetables have high rehydration ratio though
slightly lower than that of millet. Freeze-drying basically did an excellent job maintaining the cell
 P a g e | 54

structure which enabled rehydration, thus recovering much of the color, shape, and texture of these
vegetables. Therefore, it is reasonable to deduce that freeze-dried vegetables are ideal for
applications that require rehydration with minimal losses in quality. On the other hand, oven-dried
vegetables had a poor rehydration ratio since they exhibited significant shrinkage and damage in
cell structure due to direct application of heat. The vegetables could not absorb much water and
were consequently harsh and did not recover color or appearance. This low rehydration ratio
suggests the limitations of oven drying for products that must be included in RTE meals with good
quality rehydration.

Fig. 4.4.1.1 Rehydrated little millet

Fig. 4.4.1.2 Rehydrated Oven dried Vegetables

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Fig. 4.4.1.3 Rehydrated Freeze dried Vegetables

4.4.2. Quality Attributes

Color, texture, flavor and aroma, and structural integrity of rehydrated millet and dried vegetable
samples varied as a function of treatments during evaluation of quality attributes.

Colour
The rehydrated millet retained a color close to that of its fresh state, though it did look a bit duller.
Freeze-dried vegetables kept an appearance close to that of fresh vegetables. They kept their
brilliant colors as all drying took place gently. Tray dried vegetables showed a considerably
different color-with a brownish tinge that detracted from the look as fresh, probably because of the
great heat exposure in tray drying.

Texture
The rehydrated millet was only slightly firmer than its original texture, showing good retention of
water without becoming mushy. The freeze-dried vegetables, when rehydrated, were similar in
texture to the fresh commodity, being almost chewy. The tray-dried vegetables were much firmer
and dryer with an extremely tight, dense feel from the compacting effect of high-temperature
drying.

Flavor and Aroma

Millet flavor and aroma remained very close to the original after rehydration. Freeze-dried
vegetables had a fresh, natural aroma and flavor and were close to the fresh produce at face value
 P a g e | 56

because the impact of freeze drying on volatiles is almost nil. In contrast, the tray-dried vegetables
were more flavor burnt, and there was no detectable aromatic value from the loss of volatile
compounds and flavor breakdown due to a direct heat effect.

Structural Integrity
Rehydrated millet flowered less; it maintained forms but wasn't as extensively expanded as when
fresh, fully hydrated. Freeze-dried vegetables almost matched the structural integrity of their fresh
sample, maintaining shape and form due to the nature of gentle drying involved that had retained
their cellular structure. Tray-dried vegetables had shrunk considerably and reduced in dimension,
therefore exemplifying colossal structural breakdown and compactness upon exposure to heat.

Freeze dried better with the color, texture, flavor, and structure of vegetables, where oven drying
had resulted in a major loss in quality for all these attributes, and for millet, it retained most of its
qualities with slight differences in firmness and appearance.

Table 4.4.2.1 Quality Attribute Analysis of different samples

Attributes Millets Freeze Dried Oven Dried
Vegetables Vegetables
Colors Close to fresh Close to fresh Brownish and pale
Texture Slightly firm Close to fresh, chewy Firm and dense
Flavor and aroma Very close to fresh Slightly salty due to Burnt and no aroma
blanching yet close to
fresh
Structural Integrity Flowered less Retained Shrunk and reduced

4.4.3. Combining and cooking of components to make the RTE product

The spices and herbs blend well with the millet as well as the vegetables within the cooking
process, thus blurring together relatively well. Sautéing ingredients over low heat using rice bran
oil prevents the spices and herbs from burning while their natural oils and aromas are released into
the dish, thereby increasing the flavor and fragrance. This mixed the pungent flavor of the spices
with the millet and vegetables in such a way that no uncooked or overpowering flavor from the
 P a g e | 57

spices could be detected. All these ingredients absorbed the aromatic oils and spice blend of the
millet and freeze-dried vegetables during cooking and really gave them a rich flavor profile. Warm,
earthy spices with subtle herbaceous notes came from the curry and coriander leaves, giving
balance to the dish that rounded out the sensory experience.

Fig. 4.4.3.1 Final Rehydrated Pulav mix

4.4.4. Sensory Evaluation

The developed RTE product received an acceptance score of 7.45 for liking by the panelists on the
9-point hedonic scale through sensory evaluation. Flavor and aroma, particularly the spice and
herb blend, contributed to an authentic and appealing taste profile like freshly prepared pulav.
There were some minor problems with the texture of the dish found by panelists, who thought it
was a bit less ideal than freshly prepared pulav. Therefore, there are suggestions for changes that
would make it softer and better in mouthfeel for the future.
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Table 4.4.4.1 Sensory Evaluation by 10 panelists

Panelist Sl. Taste Aroma Appearance Texture Overall
No. Acceptability
1 7 8 7 7 7.25
2 6 9 8 6.5 7.37
3 7.5 8 7 7.5 7.5
4 6 7.5 7 7 6.87
5 9 8 8.5 8 8.37
6 7.5 8 8.5 7.5 7.62
7 7 7.5 7 7 7.12
8 8 7 7.5 8 7.62
9 7.5 7.5 7 8 7.5
10 6.5 7.5 7.5 7.5 7.25
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CHAPTER 4
CONCLUSION AND FUTURE SCOPE

This product develops a healthy RTE millet-based food product that tastes like a newly prepared
vegetable pulav. The entire research started with the preparation and pre-treatment of major
ingredients like little millet, vegetables, herbs, and spices. Various pre-treatments were carried out
on millet samples for functionality improvements like soaking, par-boiling, cooking, roasting, and
malting. All of these treatments affected the texture, taste, and moisture content of millet, which,
in turn, impacted its final appearance. Both tray drying and freeze-drying of vegetables (carrots
and beans) allowed us to observe how the differences in the drying methods affect texture, color,
retention of nutrients, and quality after rehydration. Herbs were tray-dried to help preserve the
aroma. More robust ingredients, such as cumin seeds, bay leaves, and dry chilies, were dry roasted
thus helping develop their aroma and flavor in the final food product.

Quality tests were run on every ingredient for treatment effects. Parameters tested
included water absorption capacity, moisture content determination, rehydration ratio, and bulk
density to understand how much the ingredients released water and retained their original structure.
These factors would directly influence the texture, flavor release, and appearance of the final
product. Sensory evaluations scored with a 9-point hedonic scale indicated scores were mostly
positive in relation to taste, texture, and aroma, indicating that the product had a pleasing quality
and authenticity of a freshly prepared pulav. The millet that was treated hydrated well; the freeze-
dried vegetables rehydrated well and retained some structure, and the roasted spices gave a rich,
tempting aroma. The RTE product thus had expectations of convenience, nutrition, and appearance
to deliver a balance of flavor and texture with easy reconstitution.

Future Scope
Based on these findings, some options for improving and diversifying this RTE product are
available. Future work could range from having various profiles of flavors, such as with regional
spices or global seasonings, to increase consumer appeal. Other prospects involve developing both
vegetarian and non-vegetarian versions to cater to a larger market. Varieties could include plant-
 P a g e | 60

based proteins or dehydrated meats to present more variety for the diversified needs and
preferences of consumers.

Further testing could include a comprehensive suite of physiochemical analyses to fine-tune

stability and shelf life of the product. Such parameters may comprise pH, texture profile analysis,
and water activity to get the optimal safety and longevity of the product while ensuring quality
over time. The expansion of the nutritional analysis will also be helpful for the health-conscious
consumer; in addition to simple macronutrient content (protein, carbohydrate, and fat), retention
of micronutrients, vitamin content, fiber, and potential allergens like gluten could create a very
extensive nutritional profile. Other tests, such as mineral analysis, antioxidant levels, and
measurements for glycemic index, may reinforce the selling point of the product for specific
markets targeted for gluten-free, low-glycemic index, or high-fiber foods.

Lastly, sustainable packaging is an area where research is still called for. Lightweight, compact,
rugged, and consumer-friendly biodegradable or recyclable packaging may be available and align
with the demand of green products. Easy-open and reclose packaging designs can make customers
more convenient and save waste. Single-serve, portioned packaging may appeal to consumers who
opt for speedy healthy meal options.

In a nutshell, this product allows the foundation of a flexible, healthy, and easy RTE product.
Further evolution in the development of this product can be brought about with even more flavors,
ingredients, and nutrition testing alongside adopting an eco-friendly type of packaging to
accommodate all the diverse diets and benefit from consumer trends that are ever more picking
toward healthy and sustainable food choices.
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