TRADITIONAL DAIRY PRODUCTS

Lesson 30. CONVENIENCE FORMULATIONS FOR TRADITIONAL DAIRY PRODUCTS

Module 12. Innovative processes for traditional dairy products

Lesson 30
CONVENIENCE FORMULATIONS FOR TRADITIONAL DAIRY PRODUCTS

30.1 Introduction

Consumer convenience along with safety is the key to value addition in dairy and food processing industries. In this context, technology development for process upgradation of certain traditional dairy products is obviously the topical area of research geared to cater to the need of the consumer. Empirical evidences suggest that the composition of an average Indian’s food basket is gradually shifting towards value added products. A survey (February 2006) conducted by the Confederation of Indian Industry also suggests that demand for ready-to-eat foods is growing at the rate of 20%. Some of the Convenience formulations for traditional dairy products are dealt in this chapter.

30.2 Khoa Powder

Khoa powder can be prepared in three different ways. Khoa, made from standardized buffalo milk by traditional method is grated into flakes and subjected to heat treatment to evaporate moisture before grinding in a small scale laboratory grinder. The ground khoa is uniformly distributed over an aluminium tray and dried in a vacuum and atmospheric hot air oven at 70°C. In the second process, grated khoa was dried in a fluid bed drier with an inlet air temperature of 98°C. In the third process, drum drying process is standardized for medium scale operation. Buffalo milk is adjusted to 6 percent fat and 9 percent SNF and heat treated to develop a typical cooked flavour in the final product. The heated and partly concentrated milk is drum dried after adjusting the steam pressure, flow rate of milk and speed of roller drums. Spray drying technology is considered suitable for large scale production of khoa powder. Concentrated milk with 30 percent T.S. is prepared from standardized buffalo milk followed by heat treatment to develop cooked flavour. The heated, concentrated milk was instantly dried in the spray drier with an inlet temperature of 190°C and outlet temperature of 78°C.

On reconstitution with water, this can be utilized directly for the preparation of burfi, milk-cake, kalakand and gulabjamun. Khoa powder packaged in tin containers under nitrogen gas can be stored for up to 10 months at 30°C.

30.3 Rasogolla Mix Powder

Rasogolla mix powder has been successfully developed employing ultrafiltration process. Cow skim milk is first subjected to ultrafiltration process to attain 3 fold concentration. The retentate contains milk proteins, part of the minerals and lactose as obtained in channa. However excess of the mineral and lactose were removed through diafiltration to make the composition of the retentate identical to chhana. The pasteurized cream is then mixed into diafiltered retentate and subsequently spray dried under standard drying conditions. The dried retentate is blended with selected additives to produce desired flavour and texture.

For manufacture of Rasogolla, an equal quantity of water is mixed to the mix powder and held for about 5 min for rehydration of proteins. The channa dough is shaped into circular balls of about 7 g size in a manner such that no cracks appear on the surface. The balls were first cooked in sugar syrup of 60% concentration for 15 min and later transferred into hot sugar syrup of about 40% concentration.

30.4 Gulabjamun Mix Powder(GMP)

The Gulabjamun Mix Powder, based on roller dried skim milk powder (SMP), consists of SMP, maida, semolina (suji), hydrogenated vegetable fat, baking powder and cardamom in definite proportions. All the ingredients are dry blended in a power driven mixer such that the ingredients are uniformly mixed. The vegetable fat is added in molten state intermittently to ensure thorough mixing with the dry ingredients. The GMP packaged in laminate pouches and stored in dry place remains acceptable upto 6 months at room temperature. Process has also been standardized for manufacturing Gulabjamun from the GMP. It generally requires preparation of dough of suitable consistency (50-55 ml water for 100g mix), which could be made into smooth balls of uniform size and shape and deep fat fried in vegetable oil (Dalda) at about 125°C for 15-20 min. The properly fried balls acquire brown colour which are subsequently transferred into hot sugar syrup of 60° brix. Even when SMP and vegetable fat were completely replaced with whole milk powder in the GMP formulation, product characteristics remained largely unchanged. Use of spray dried SMP in place of roller dried SMP was not found acceptable as it led to case hardening of balls during deep fat frying and prevented the sugar syrup penetration thereby resulting in unacceptable product. However certain alterations in the ingredients viz., use of high heat SMP, increase in fat content from 15% in roller SMP based formulation to about 18% in spray based SMP, use of additives such as CMC and sodium citrate and/or addition of dried whey protein concentrates (1-2% of SMP) to the mix, helped in improving the textural properties of the product and resulted in highly acceptable product. However GMP based on spray dried SMP requires certain modifications in manufacturing procedure such as increase in the holding time of dough and frying at slightly lower temperature.

30.5 Instant Kheer Mix

Production of Instant Kheer mix involves spray drying of admixture of milk concentrate and rice flour (preheated to partially pre-gelatinize the rice starch) along with sugar followed by fluidized bed drying to make the powder which has excellent reconstitution properties. Rice grains which could be readily rehydrated were obtained by a technology which involved partial cooking of rice, it’s conversion into a paste, subsequent extrusion and dehydration in air dryer. This form of instant rice was rehydrated in about 5 min. Alternatively, quick cooking rice can also be obtained by drying of partially cooked rice in a fluidized bed dryer. The rice thus obtained could be cooked in hot water in about 10 min.

Spray dried Kheer powder mixed with instant rice is packed in metalized polyester laminates and could be stored at room temperature without any loss of quality for a period of 6 months.

30.6 Instant Kulfi Mix

Manufacture of Kulfi mix powder involves preparation of a mix from milk fat (11%), MSNF (16%), sucrose (15%) and isabgol husk (0.2%). The total solids concentration of the mix is adjusted and only 25% of the total sugar required in the final mix is added before drying. The mix is homogenized at 6.83/3.43 MPa, heated at 100°C for 10 min in a tubular heat exchanger followed by cooling to 4°C. The mix is spray dried. The remaining sugar in ground form is dry blended with the powder and packaged in tin cans. The proximate chemical composition of kulfi mix powder is fat 25.41%, MSNF 36.98%, Isabgol 0.46%, Sugar 34.65% and moisture 2.52%. The product has a shelf-life of 7 months at 30°C in tin cans. The shelf-life can be extended up to 10 months with the addition of butylated hydroxy anisole (BHA) and nitrogen gas flushing. Kulfi mix powder can be instantly reconstituted and frozen to get kulfi of consistently good quality all the year round at an affordable price. It ensures the production of pathogens-free frozen product.

30.7 Ready-to-Reconstitute Rasmalai Mix

The process comprised of preparation of syrup mix powder and dehydrated patties to be mixed into an instant rasmalai mix. The syrup mix powder is prepared by dry blending of sweetened milk solids powder, whole milk powder (WMP) and sugar powder. To the dry mix, saffron is added and packed in co-extruded multilayer plastic pouches. The sweetened milk solids powder is prepared from standardized buffalo milk (fat: SNF ratio of 0.35) by heat desiccation. Standardized milk is boiled in a steam-jacketed stainless steel scraped surface heat exchanger to obtain sweetened khoa with a smooth body. The mixture was transferred into a stainless steel tray and allowed to set for 12 h at room temperature. The resulting pat is cut into cubes and dehydrated osmotically to a moisture content of less than 10 percent. The dried cubes were ground into a fine powder.

Fig. 30.1 Preparation of rasmalai syrup using

Dehydrated patty is prepared with cow milk (standardized to fat: SNF ratio of 0.35) chhana. The chhana balls flattened to patty shape were cooked in the syrup and subsequently partially dehydrated by a standardized dehydration technology till the moisture content was less than 10.0 per cent. The dehydrated patties were vacuum packed in co-extruded multilayer plastic pouches.

Fig 30.2 Preparation of rasmalai patty using

30.8 Ready-to-Reconstitute Basundi Mix

Ready-to-use Basundi mix is produced using the concept of osmo-air drying and spray drying. The product mix is formulated by dry blending of ingredients like whole milk powder (WMP), sweetened milk solids, particulated whey proteins (PWP) and sugar.

The spray dried WMP is prepared from mixed milk standardized to a fat: SNF ratio of 0.27. The sweetened milk solids (SMS) powder is prepared from standardized buffalo milk (fat: SNF ratio of 0.35) by heat desiccation. Particulated whey protein (PWP) is made by coagulating heated whey and cow milk mixture with a food grade coagulating agent and subsequently admixing with partially desiccated sweetened milk solids in predetermined proportion. The entire mixture is transferred to a stainless steel tray and allowed to set for 12 h at room temperature. The resulting pat is shredded and air dried to get desired flakes. Dried shreds were packaged separately in co-extruded multilayer plastic pouches.

30.9 Conclusion

A wide variety of traditional dairy delicacies, drawn from different regions of the country, are produced in India using processes such as heat and/or acid coagulation, desiccation and fermentation. Traditional milk sweets and dairy desserts form the large bulk of such products. However, tremendous economic potential of this sector has remained untapped because of the fact that the manufacture of traditional dairy products has remained confined to small level operations, which is manual and energy intensive. Therefore what is needed is adoption of existing unit operations and machines to upgrade and mechanize manufacturing processes of traditional dairy products. The products developed at NDRI, are an attempt in this direction. It is expected that such ready mixes would add convenience to the existing array of customary dishes. Value addition to this effect will not only help in exploiting domestic market-reach of our dairy products but also open new vistas for export to neighbouring countries.

References

Ghosh, J. 1991 Process development for the manufacture of instant kulfi milk powder. Ph.D. Thesis Kurukshetra University, Kurukshetra.
Jha A . 2000 Developments in the manufacture of cereal-baesd convenience foods. Lecture compendium on “Advances in Formulated Foods” in short course conducted by CAS-DT during June 19th –July 10, 2000, pp.108-111.
Pal D., Rajorhia, G.S., Garg, F.C. and Verma, B.B. 1993. Development of technology for dried rasogolla mix. NDRI Annual Report 1992-93, pp 90.
Sharma Prateek, Singh, R.R.B., Patel, A.A. and Patil, G.R. 2004. Development of ready-to-reconstitute Basundi mix. Paper presented at the XXXIII Dairy Industry Conference held at Hotel Ashoka, New Delhi, September 26-28, 2004 (Souvenir: Poster Abstracts, DP-35, p.108).