Lecture Two

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FOOD PROCESSING

TECHNOLOGY
Lecture Two

By: Shewarega Habtamu (PhD candidate)


Chapter 2
Cereals processing technology

2
Learning Objectives
• At the end of this Lecture, students should be able to:-
A.Differentiate between major and minor grains
B.Understand the chemical composition of major cereal
grains and important terminologies.

C.Explain the post-harvest treatment for storage and the


steps involved in wheat flour production.

3
1.Introduction
• Cereals are staple foods, and are important sources of
nutrients in both developed and developing countries
• Wheat, rice, and corn are the major important grains in the
human diet.
• The minor grains include oats, barley, rye, triticale, sorghum
and millets
• Teff is a minor cereal crop worldwide, whereas in Ethiopia, it
is a major food grain, mainly used to make injera, a
traditional fermented Ethiopian pancake.
Cont’d
• Consequently, studies on the nutritional composition of
teff and its processing qualities have grown, and the
development of new teff-based products has accelerated.
2. Nutritional (proximate) composition of some cereals
Starch protein moisture fat Fibre ash
maize 65-84 9-10 12-15 3-5 2-3 3
sorghum 68-80 10-15 11-12 3 2 2
rice 80 6-8 11 2 0.2 0.5
Wheat 65-75 8-10 10-14 1-2 1.5-2.5 0.4-1.0
Teff 73 8-11 10-11 2.5 3 2.8

• rich sources of fiber, vitamins, minerals, and Phytochemicals


• main source of energy, contributing 70-80% of the requirement.
• The fiber constituents are cellulose, hemicellulose and pentosans.
• Of the soluble carbohydrate, starch is the most important carbohydrate in
all cereals.
• Incomplete protein-Generally deficient in lysine.
• More lipids are present in bran than in other parts of the grain.
Glycemic index (GI)
• The rate of carbohydrate digestion
of a food can be characterized by
its glycemic index .
• GI is a measure of how
carbohydrate-containing foods
raise blood glucose.
• Foods are ranked based on how
they compare to a reference food,
either glucose or white bread,
which has a GI of 100.
Cont’d
• The consumption of high GI foods leads to
a rapid and large release of glucose into the
blood.
• The predicted glycemic index of teff (54)
was significantly lower than that of white
wheat (100) but comparable to that of
sorghum (52) and oats (51)
• Low GI foods can reduce the risk of type 2
diabetes
Celiac Disease
• a serious autoimmune disease that occurs in genetically
predisposed people where the ingestion of gluten leads to
damage in the small intestine.
• due to intolerance to gluten, a protein found in wheat, barley, and rye.
• The disease affects about 1% of the world population.

• The gluten has unique elasticity and flow


properties which are used for baking bread
and other products.
Cont’d
• The only effective and safe treatment available for those
affected by celiac disease so far is a strict and lifelong
gluten-free diet.
• Teff, as nutrient-rich gluten-free grain, is being frequently
used as the best choice for celiac disease patients
Mineral content of teff grain compared to other cereals, mg/100g
2. Post-harvest treatment for storage

• optimum time for harvesting cereals,


depending on the maturity of the crop and
the climatic conditions.
• Manual and mechanised harvesting
Cont’d
• 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 - 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
Handling and storage
• Most food grains harvested lost because of inadequate
methods of handling and storage.
• To prevent losses, the following methods are used
• Fumigation –to control insect infestation
• phosphine, chloropicrin, and methyl bromide
• Storage facilities (silos) must be proof against vector.
• Grains of good quality, free from foreign matter and dried to a
moisture content not higher than 15% be stored
• Cleaning of storage facilities
• Ventilation
Cereals storage structures
(Traditional and modern )
Moisture migration

• As outside air warms up/colds down, moisture migration cycles in the bin can
concentrate warm moist air, creating a potential start point for spoilage.
3. Wheat
• Today, thousands of different wheat varieties are grown
throughout the world.
• Wheat is the most popular cereal grain for use in baking
industry.
• Gluten provides: Extensibility
Elasticity
Gas retention.
3.1 Whole Grains vs. Refined Grains
• Wheat kernels have three main parts: the endosperm,
the germ, and the bran.
Cont’d
• Whole grain- Grains are naturally “whole” when they
grow in the field because they have all three parts of the
kernel.
• Refined grain- When the bran and the germ are removed
from the grain to make white or enriched grains.
Whole Vs refined cont…
Three parts of Nutrients in Whole grain Refined grain
grain each part

Bran Fiber, B-
Vitamins

Endosperm Starch,
protein,
vitamins, and
minerals

Germ B vitamins,
protein,
minerals and
healthy oils
3.2 Unit operations of wheat flour
1. Cleaning
2. Conditioning/ tempering
3. Milling
4. Sifting
5. Purifying
1) Cleaning

The selection parameters of wheat:


• protein content and starch content,
• moisture content,
• amount of impurities,
• gluten qualities of wheat,
• Hard wheat-has a higher gluten content
• Soft wheat- has more starch and less gluten than hard wheat
• Durum wheat-pasta wheat or macaroni wheat
Main objectives of grain cleaning:
• to separate the grain from
organic and mineral impurities
• to remove parts of bran from
grain endosperm
• reduction of adhesion between
bran and endosperm
• to standardize of grain
moisture before milling
Cont’d
a. Magnetic Separator
• The wheat first passes through magnet that removes
iron and metal particles.
Cont’d
b. Separator
• Vibrating screens remove bits of wood and straw and almost
anything bigger or smaller than wheat.
Cont’d
c. Aspiration
• Air currents act as a kind of vacuum to remove dust and
lighter impurities from wheat.
Cont’d
d. De-Stoner
• A means of separation stones using combined (vibration,
air currents) system to create swirriling action and
separate the stones out of wheat.
Cont’d
e. Scourer
• The scourer removes outer husks, crease dirt and polish
the outer surface with an intense scouring action.
2. Conditioning/Tempering

• It is the addition of water into the wheat and allowing


resting for sufficient time in order to tougher the bran.
Objectives of conditioning

• separation of bran from endosperm during milling,


• Bran is toughened,
• reducing bran powdering,
• lessening bran contamination in flour,
• Endosperm hardness is also reduced facilitating
reduction into flour.
Effect of moisture level
• High moisture- endosperm becomes wet and difficult in
grinding process.
• Low moisture- the bran would be friable and separation
become difficult which contaminates flour.

Controlling parameters
• amount of water,
• resting time
• temperature is less than 450c. If temp. exceeds gluten quality is affected.
Cont’d
• The amount of water added at this stage will be dependant on
several factors:
• The variety of grain to be milled
• The natural moisture content
• The type of the mill
• The prevailing climate
• Specification of the finished flour
• Normal moisture levels in wheat vary from around 9% upto
14% dependant on variety, and these will normally need to be
"conditioned" to between 15-17% prior to milling.
3. Grinding (Milling)
• Milling process is a gradual reduction of the wheat kernels to
produce particles of endosperm which are then graded &
separated from the bran by sieves & purifiers.
Two main objectives of wheat milling:
• to separate endosperm of the grain from bran and germ.
• to reduce dimensions of endosperm particles for fine flour
particles.
Cont’d
Main stages of milling are breaking stage and reduction stage.
a. Breaking rolls
• The conditioned wheat is passed between large steel rollers
provided with corrugation.
• The rollers are operated in opposite direction at the
differential speed of 1:2.5.
• Semolina obtained from the break rolls is passed through ten
or more reduction rolls.
Sifting

• The broken particles of wheat are


introduced into huge, rotating,
box-like sifters where they are
shaken.
• Plan sifters may have four, six, or
eight sections. Each section has a
stack of 14-30 layers of sieves.
• Up to 6 different sizes of particles
may come from a single sifter.
Cont’d
Purifiers
• controlled flow of air lifts off bran particles while at the
same time a bolting cloth separates and grades coarser
fractions by size and quality.
• Thesloped oscillating sieve promotes downward
movement of stock in a layer.
Cont’d
b. Reduction rolls
• Reduction of particle size of
semolina into fine flour by passing
it through a pair of smooth rolls.
• The process is repeated over and
over again, sifters to purifiers to
reducing rolls, until the maximum
amount of flour is separated.
Application of wheat flour

bread

Noodles Wheat Macaroni


product
flour

Biscuit
, cake,
cookies

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