Post-Harvesting Processing: Food and Agriculture Organization of The United Nations
Post-Harvesting Processing: Food and Agriculture Organization of The United Nations
Post-Harvesting Processing: Food and Agriculture Organization of The United Nations
General information
Each type of cereal requires a specific post-harvest treatment, however, there are certain
general principles that apply to most of them.
Cereals undergo a number of processing stages between harvest and consumption. This chain
of processes is often referred to as the total post-harvest system. The post-harvest system can
be split into three distinct areas.
The first is the preparation of harvested grain for storage. The second, which is referred to as
primary processing, involves further treatment of the grain to clean it, remove the husk or
reduce the size. The products from primary processing are still not consumable.
The third stage (secondary processing) transforms the grains into edible products.
Primary processing involves several different processes, designed to clean, sort and remove
the inedible fractions from the grains.
Primary processing of cereals includes cleaning, grading, hulling, milling, pounding, grinding,
tempering, parboiling, soaking, drying, sieving.
Secondary processing of cereals (or 'adding value' to cereals) is the utilisation of the primary
products (whole grains, flakes or flour) to make more interesting products and add variety to
the diet. Secondary processing of cereals includes the following processes: fermentation,
baking, puffing, flaking, frying and extrusion.
Puffing. Puffed grains are often used as breakfast cereals or as snack food. During puffing,
grains are exposed to a very high steam pressure which causes the grain to burst open. The
puffed grains can be further processed by toasting, coating or mixing with other ingredients.
Flaking. Flaked cereals are partially cooked and can be used as quick-cooking or ready to eat
foods. The grains are softened by partially cooking in steam. They are then pressed or rolled
into flakes which are dried. The flakes are eaten crisp and should have a moisture content of
below 7%.
Fermentation. Doughs made from cereal flour can be fermented to make a range of products.
Baking. Doughs and batters made from cereal flours are baked to produce a range of goods.
Extrusion. Extrusion involves heating and forcing food (usually a dough) through a small hole
to make strands or other shapes. The extruded shapes then undergo further processing such
as frying, boiling or drying. Extruded products include pastas, noodles, snack foods and
breakfast cereals.
Projects and small businesses may involve only one or several of the activities in the total
chain, from the growing of crops through to the production of edible products. Some small
businesses are set up to clean and package wholegrains. These businesses can be successful
as there is very little need for equipment. However, as with all businesses, there must be a
clear demand for the product.
A.1-Harvesting
There is an optimum time for harvesting cereals, depending on the maturity of the crop and
the climatic conditions. This has a significant effect on the quality of the grain during storage.
Harvesting often begins before the grain is ripe and continues until mould and insect damage
are prevalent. Grain not fully ripened contains a higher proportion of moisture and will
deteriorate more quickly than mature grains because the enzyme systems are still active.
If the grain remains in the field after maturing, it may spoil through wetting caused by
morning dew and rain showers. There is also an increased risk of insect damage.
Cereals are traditionally harvested manually.There are three main types of harvesting
equipment for the small scale producer: manual, animal powered and engine powered.
A range of mechanised harvesting equipment suitable for the small-scale farmer has been
developed. Some of it is more efficient and cost effective than others.
Harvested crops are left in the field for a few days to dry before further processing.
A.2.-Threshing
Threshing is the removal of grains from the rest of the plant. It involves three different
operations: Separating the grain from the panicle; sorting the grain from the straw; winnowing
the chaff from the grain.
Separation of the grain from the panicle is the most energy-demanding of the three processes.
It is the first process to have been mechanised. Sorting the grain from the straw is relatively
easy, but is difficult to mechanise. Winnowing is relatively easy, both by hand and by machine.
Most manual threshing methods use an implement to separate the grain from the ears and
straw. The simplest method is a stick or hinged flail that is used to beat the crop while it is
spread on the floor.
A.3.-Winnowing
Winnowing is the separation of the grains from the chaff or straw. It is traditionally carried out
by lifting and tossing the threshed material so that the lighter chaff and straw get blown to one
side while the heavier seeds fall down vertically.
Hand-held winnowing baskets are used to shake the seeds to separate out the dirt and chaff.
They are very effective, but slow.
There is a range of winnowing machines that use a fan to create artificial wind. This speeds up
the winnowing process.
Some of these contains sieves and screens that grade the grains as well.
A.4.-Drying
Prior to storage or further processing, cereal grains need to be dried. The most cost-effective
method is to spread out in the sun to dry. In humid climates it may be necessary to use an
artificial dryer.
Simple grain dryers can be made from a large rectangular box or tray with a perforated base.
The grain is spread over the base of the box and hot air is blown up through a lower chamber
by a fan.
The fan can be powered by diesel or electricity and the heat supplied by kerosene, electricity,
gas or burning biomass.
The grains should be inspected regularly for signs of spoilage and the moisture content tested.
If the grain has picked up moisture it should be re-dried. Grains are often protected with
insecticides and must be stored in rodent-proof containers.
Before further processing, grains are cleaned and graded according to size.
Winnowing machines can be used to separate out the chaff, soil and dirt.
Some machines have integral sieves that combine cleaning with grading.
B.2.-Hulling
Several grains have an unpalatable husk or shell that needs to be removed by a decorticator. A
range of specialised machines are available for this task. A range of small rice hullers (both
manual and powered) is available.
Less rice is broken during hulling if the rice is parboiled first. Rice polishers are available for
removing the rice bran after hulling.
B.3.-Pounding/Milling
Three main types of grain mill are available: Plate mill; Hammer mill; Roller mill.
The choice of mill depends on the raw material and the scale of production. Hammer mills are
almost universally used throughout the developing world. Plate mills are widely available in
West Africa.
Roller mills are not used at the small scale because of their high cost and maintenance
requirements.
The plate mill is usually limited to about 7kW and is derived from the stone mill or quern.
Two chilled iron plates are mounted on a horizontal axis so that one of the plates rotates and
the grain is ground between them.
The pressure between the two plates governs the fineness of the product and is adjusted by a
hand screw.
There are manual versions of the plate mill available, though they are arduous and hard work
to use.
Small-scale hammer mills range in size from 2kW to 20kW. They consist of a circular chamber
in which beaters whirl at a high speed.
The milled grain is filtered out through a perforated plate that runs around the edge of the mill
chamber.
The size of the holes in the perforated plate determines the fineness of grinding of the
particles.
Grain for human food is ground to a 1mm particle size while animal food is ground to a 3mm
particle size.
Hammer mills cannot be used for wet milling. Roller mills crush the grains rather than milling
them into smaller particles. Roller mills are usually used for animal food. It is important to
ensure that the grains have the optimum moisture content before milling. If the grain is too
dry and hard, it is difficult to break down and requires more energy to convert it into flour. If
the grain is too moist, the material sticks to the mill. The optimum moisture content varies
between cereal types and with the particular mill being used. Dry grain can be conditioned by
soaking in water. Moist grain can be dried before grinding. Different cereal grains have
different milling and grinding requirements. See the individual grains for more details.
B.4.-Paraboiling
Parboiling rice is an optional step, but one that improves the quality of hulling as it results in
fewer broken grains. About 50% of all rice grown is parboiled.
Parboiling involves soaking and heating the rice which pre-cooks the grains, loosens the hull,
sterilises and preserves the rice.At the village level, parboiling is carried out in large pans over
an open fire. Rice parboilers, that improve the efficiency of cooking, are available.
B.5.-Drying
Prior to storage or further processing, cereal grains need to be dried. The most cost-effective
method is to spread out in the sun to dry. In humid climates it may be necessary to use an
artificial dryer.
Simple grain dryers can be made from a large rectangular box or tray with a perforated base.
The grain is spread over the base of the box and hot air is blown up through a lower chamber
by a fan.
The fan can be powered by diesel or electricity and the heat supplied by kerosene, electricity,
gas or burning biomass.
The grains should be inspected regularly for signs of spoilage and the moisture content tested.
If the grain has picked up moisture it should be re-dried. Grains are often protected with
insecticides and must be stored in rodent-proof containers.
The quality of raw materials has an influence over the quality of the products. High quality raw materials
should be used.
Small-scale bakers do not normally have facilities for flour analysis and rely on information supplied by
the miller or wholesaler. There are a few simple tests that they can carry out which give useful
information about the flour quality.
3.1.-Flour
Flour can be milled from a variety of cereals. The type available in each country or region may
depend upon the types of cereal grown, although wheat flour tends to be available in most
places.
Wheat flour
Wheat flour contains proteins known as glutens. These are capable of forming a strong elastic
network within the dough, which is very useful when making leavened bread.
The protein network traps the gas that is given off by the yeast during fermentation. This
causes the dough to increase in volume and produces a bread with a light texture.
If flours that are low in gluten are used to make leavened bread, the gas escapes and the
bread is flat and heavy.
Wheat flour is available in different grades according to the degree it is extracted from the
whole wheat grain. Flours of different extraction rates include the following:
Non-wheat flours
There are a variety of non-wheat flours available that can be mixed with wheat flour to make
bread.
Cassava flour is a fine white powdery flour that has a shelf life of up to one year. It is widely
used as a staple food and for the production of a range of fried and baked goods including
bread, cakes and biscuits.
Cereal flours, especially from maize and sorghum, which are both staple crops, are used to
make breads and snackfoods. Sorghum is mainly used to make bread or porridge. Maize is
used to make tortillas, snacks and for the production of cornflour and thickeners.
Soy/composite flour is a fine creamy flour that is combined with maize flour or other cereal
flours to increase the protein content and balance the amino acid composition of the composite
flours. In this form it is used as a breakfast porridge and as a weaning food.
Different types of wheat flour are available in each country. Wholemeal flour is used for the
production of brown bread, rolls and other high fibre products.
Atta is a wheat flour that is suitable for making chappatis. It is also available as a wheatmeal
flour.
Special bakers flour (bread making flour) is a strong flour that is used for bread, rolls and
pastry. Bakers flour should contain a good quality gluten so that it can produce a light bread.
Biscuit flour. This is a special blend of flour that is made for mechanical biscuit plants.
Self raising flour. This flour is a soft flour that is fortified with a chemical aerating additive
similar to baking powder. It is used for making chemically aerated breads such as soda bread.
Soft flour is used for cake making.
Maize (Zea mays ssp. mays) is a cereal grain that was domesticated in Mesoamerica. It is
called corn in the United States, Canada, and Australia, but in other countries that term may
refer to other cereal grains. It is called mealies in southern Africa. Hybrid maize is preferred by
farmers over conventional varieties for its high grain yield, due to heterosis ("hybrid vigour").
Maize is one of the first crops for which genetically modified varieties make up a significant
proportion of the total harvesting.
Because it is cold-intolerant, in the temperate zones maize must be planted in the spring. Its
root system is generally shallow, so the plant is dependent on soil moisture. As a C4 plant (a
plant that uses C4 photosynthesis), maize is considered a substantially water-efficient crop,
but it can be sensitive to drought, mainly at the time of silk emergence, when the flowers are
ready for pollination. In the United States, a good harvest was traditionally predicted if the
corn was "knee-high by the Fourth of July", although modern hybrids generally exceed this
growth rate.
Maize used for silage is harvested while the plant is green and the fruit immature. Sweet corn
is harvested in the "milk stage", after pollination but before starch had formed. Field corn is
left in the field very late, in order to thoroughly dry the grain. The importance of sufficient soil
moisture is shown in many parts of Africa, where periodic drought regularly causes famine by
causing maize crop failure.
Cultivars of maize
Scientific classification
Kingdom: Plantae
Division: Magnoliophyta
Class: Liliopsida
Order: Poales
Family: Poaceae
Genus: Zea
Species: Z. mays
Binomial name
Zea mays
4.- Proximate composition of cereal grains (FAO, 1999)
5.- Maize
Maize can either be wet or dry milled. In dry milling, maize is ground between stones or by
using a hand-powered plate mill or at a larger scale, using a hammer mill or powered plate
mill.
In wet milling, the grain is soaked and allowed to ferment slightly to improve the flavour
before milling with a hand or pwered plate mill.
Maize is sometimes soaked in alkaline water to facilitate removal of the bran before it is milled.
If the maize meal is not used whole, it is transferred to a flat basket and shaken so that the
bran is separated from the floury endosperm.
The flour is sometimes ground again to make a finer product. The bran is often used to feed
chickens.
Maize has a relatively high fat content and tends to go rancid quickly. Ground maize meal
therefore has a short shelf life.
6.-Paddy rice
In some countries paddy is parboiled before the husk is removed. Parboiling is the partial
cooking of the rice to gelatinise the starch, which makes the grain tougher. There is also a
slight change in flavour which some people prefer.
The toughening process makes the seed more resistant to insect attack and to shattering
during husking. It also helps to prevent absorption of moisture from the air during storage.
The parboiling process involves three stages:
- soaking or steeping of the paddy in cold or hot water to increase its moisture content
- drying.
The rice should be dried carefully after parboiling to minimise losses. Husking paddy, which is
sometimes referred to as de-husking or milling is the process of removing the outer husk.
Husked paddy is referred to as brown rice, whereas de-husked (or polished) rice is white rice.
Brown rice is nutritionally superior to white rice as it contains some of the bran which contains
protein and vitamin B1 (thiamine).
7.- Millet
The outer layers of some varieties of sorghum seed (usually the red seed varieties) contain
tannins that are slightly toxic, have a bitter taste and inhibit the digestion of proteins. For this
reason, sorghum is generally hulled before grinding into a flour.
Traditionally sorghum and millet is ground by hand using querns or hand plate mills.
The seed is winnowed to remove foreign matter, then put into a large mortar and wetted. It is
then pounded to strip the bran or shell from the grain, followed by winnowing to get rid of the
bran, Pounding and winnowing are repeated several times to get a good quaity milled seed.
The milled seed is washed to remove any small pieces of bran and soaked in water for 24
hours to condition or temper it. The grain is dried to the correct moisture content then re-
ground using a pestle and mortar.
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