Agricultural produce processing

8/10/2019 Agricultural produce processing

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AGRICULTURAL

PRODUCE PROCESSINGMETHODOLOGIES

BY

Fattoria Soluzione Coy

[email protected]

OBJECTIVES OF THE PAPER

1. To expose participants to the modern days technique of agriculture produce processing

2. To expose participants to importance of processing equipment maintenance.

3. To expose participants to the Quality Assurance of Agricultural Processing

4. To inculcate into the participants the importance of ecord !eeping in processing and

mar!eting.

MODULE A

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mailto:[email protected]:[email protected]


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A. AGRICULTURAL PRODUCE PROCESSING / PRODUCTION

1. INTRODUCTION:

"igeria has a population of more than 14# million people $hich pro%ides any in%estor

$ith a ready mar!et.

The ma&ority of "igeria's food is currently imported at a cost of (illions of )* +ollars.

"igeria's fixation on its oil industry has left the agriculture sector largely unde%eloped.

,o$e%er- it is time to thin! strategically and see agriculture as the main dri%er of

future economic gro$th.

The goal is to ensure that "igeria produces enough food for the local population as

$ell as to export to the international mar!ets.Agriculture must (e seen as a (usiness- $ith more commercial farmers and agro

produce processors and mar!eters.

The perisha(ility of most farm produce and ina(ility to store these produce in their

original form (efore consumption has gi%en rise to changing their form.

t is a !no$n fact that most farmers do not ha%e $hat it ta!es to process their farm

produce hence the need for processing agent li!e yours.

The price of most farm produce are not sta(le throughout the year (ecause agriculture

produce are seasonal/ therefore the need to process.

*torage facilities $hich suppose to (e an integral part of farming (usiness are not

adequately pro%ided for the farmers.

2. WHAT IS AGRICULTURE PRODUCE PROCESSING

This is one of the mar!eting stages 0 functions. t in%ol%es changing the original form of the farm commodity to a more accepta(le

form to the consumer

Produce must (e processed into consuma(le form in order to attract the consumer and

at the same time command apprecia(le price.

or example- cassa%a tu(ers are processed into arri- ufu or starch.

3. IMPORTANCE OF PRODUCE PROCESSING

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Processing increase the utility form of the products

Processing increase the %alue and price of farm produce.

Produce processing (rings a(out de%elopment in the community as a result of

esta(lishment of processing industries.

t pro%ides employment opportunities to community mem(ers

t ser%es as a means to reducing $astages especially during the seasonal period of the

farm produce.

t ser%es as another form of storage $here storage facilities are not a%aila(le.

For the sae o! th"s #a#er $e sha%% ha&e a ho%"st"' &"e$ o! #ro'ess"()

*etho+o%o)"es o! the !o%%o$"() 'ro#s (a*e%,: Cassa&a- P%a(ta"( . O"% #a%*

4. CASSAVA PRODUCTS AFTER PROCESSING

*ome processed products of cassa%a include

Cassa&a !%o0r:1 This is an finely ground po$der made from cassa%a. t

can (e used for your pastry- (read- ca!es and can (e used a hundred

percent or mixed $ith little $heat flour.

La!0( This is a fermented edi(le cassa%a flour. t can (e prepared (y

mixing $ith the right proportion of hot $ater to ma!e it into a solid- and

eat $ith soup. F0!0:1This is also an edi(le cassa%a flour (ut $ith a different processing

method from lafun- t can (e prepared the same $ay as lafun for

consumption (ut it definitely tastes different.

Garr":1This is the commonest edi(le product made out of cassa%a in

5est Africa and a staple food in "igeria- there are t$o types- yello$ garri

$hich is mixed $ith palmoil during production process and $hite garri

that has no palmoil. t can (e ta!en for refreshment (y pouring the

desired quantity of it inside cold $ater- add sugar- mil! or $hate%er to

garnish it. t can as $ell (e prepared into solid (y pouring into little

quantity of hot $ater- turn it and ser%e hot $ith soup.

Ta#"o'a:1 ts another cassa%a product that is mostly processed into

granular form. 5hen coo!ed- it s$ells and thic!ens. Tapioca is quite

nutritious and easily digesti(le. t is an excellent food for people $ho are

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sic! or reco%ering from illness. t can also (e garnished $ith mil! and

sugar.

Star'h:1t is in t$o types $hich is edi(le starch and inedi(le starch used

for textiles.

Bett,'a*:1t is made from an edi(le cassa%a flour processed $ith yello$

mai6e. t is prepared into solid- ser%e hot $ith soup.

Eha&"ta:1This is a latest Product made from edi(le cassa%a flour and

guinea corn to (ring a unique taste after prepared into solid. *er%e hot

$ith soup.

7. PROCESSING OF CASSAVA INTO GARRI

Cassa&a #ee%"() Ma'h"(es

8assa%a tu(ers are har%ested from the farm once matured

The har%ested tu(ers are peeled $ith the aid of !nife or peeling machine

The peeled tu(ers are then $ashed $ith sponge in clean $ater

The $ashed tu(ers are mo%ed to the cassa%a grating machine section

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Cassa&a )rat"() Ma'h"(es

After grating- they are pac!ed into (ags for pressing in order to drain the $ater.

The drained and dry grated cassa%as are then sie%e to ha%e a fine coarse texture.

The sie%e granulated coarse texture is then mo%ed into the frying section.

Fr,"() se't"o(

+uring frying- a%oid too much heat as this may (urn the garri and ma!e the

quality (ecome un attracti%e or lo$ heat as this may not ma!e the garri to $ell

coo!ed

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After frying0coo!ing- the garri is exposed for some time to allo$ cooling (efore

(agging for on$ard transfer to the final customers.

9. PROCESSING OF CASSAVA INTO STARCH

At present there are %arious industries engaged in starch processing.

There are t$o !inds of starch namely industrial and edi(le.

*tarch can (e processed manually and industrially.

8assa%a tu(ers are har%ested from the farm once matured

The har%ested tu(ers are peeled $ith the aid of !nife or peeling machine

The peeled tu(ers are then $ashed $ith sponge in clean $ater

The $ashed tu(ers are mo%ed to the cassa%a grating machine section

The grated cassa%as are then mo%ed to the pulpsifter $here they are thoroughlymixed $ith proportionate quantity of $ater.

The grated cassa%as mixed $ith $ater are then allo$ed to settle- the starch

sediment at the (ottom- $hile the chaff float. : this method is for edi(le starch

and usually manual. Though %arious community adopt different methods to

extract starch

;n the other hand for industrial starch production- grated cassa%as mixed $ith

$ater are then mo%ed to the centrifugal machine $here the mixed grated cassa%a

$ith $ater is separated through centrifugal force.

Photo)ra#h o! Star'h #ro'ess"() *a'h"(e


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;nce the har%ested fruits are not processed earlier enough- it leads to a rapid

increase in the amount of ree atty Acid =A> in the fruits.

,igh content of ree fatty Acid =A> leads to deterioration of the oil quality.

The traditional methods of processing do not gi%e good quality oil as $ell as the

fact that lo$ percentage of extraction is achie%ed. The oil mills gi%e the (est result (oth in terms of oil quality and percentage

extraction. After har%esting- (unches should (e sliced into four part and put into drum of

$ater.

The drums of $ater containing the sliced (unches are then heated for some time

from the (ottom.

;n a large farm you can use electric sterili6er pro%ided you can afford it.

The cut heated sliced (unches are the stripped so as to remo%e the fruit and later

(oil the fruits for a period of a(out 3# 47 minutes.

;nce the fruits are coo!ed- =do not allo$ the fruit to (urn $hile coo!ing as this

$ill affect the quality of the oil> the fruit are then (ailed from the drum into the

digester to as to remo%e the mesocarp from the nut.

The digested fruits are mo%ed into the presser $here the oil $ill (e pressed out.

The presser could (e =i> the scre$ hand press- =ii> ,ydraulic press =iii> thecentrifugal press.

The fluid $hich is the oil is then mo%ed to the coo!ing section again $here they

are to (e coo!ed so as to separate $ater and sludge from the oil.

The coo!ed oil is the (ail from the $ater and sludge through clarification

method

?nsure that the A @ of your processed oil is not a(o%e 4@. Any oil $ith o%er

4@ A is not of quality and as such can not meet the international standard. *uchoil can only (e used for soap and candle ma!ing.

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Photo)ra#hs sho$"() Pro'ess"() o! Pa%* O"%

. PROCESSING OF PLANTAIN

8ameroon is one of the ma&or exporters of (ananas and plantains in Africa.

?do *tate is %ery rich in land and human resources in plantain0(anana

production.

ro$ing and processing of plantain is not ela(orate. ;nce plantains are matured- they are har%ested. +o not let them sustain any

in&ury $hile har%esting to a%oid decaying.

The har%ested matured plantain can (e further processed into flour or chips.

THE PLANTAIN FLOUR

The matured (ut not ripe plantain are neatly peeled and $ashed.

They are then sliced using slicer or !nife : manual

The sliced plantains are then sun dry or o%en dry into apprecia(le moisture

content.

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;nce dried- they can (e milled- sie%ed and pac!aged for mar!eting.

Plantain flour does not contain car(ohydrate- rather large amount of iron.

They are good for dia(etic patient- pregnant $omen etc.

THE PLANTAIN CHIPS 2PE3ERE4

The har%ested matured plantain is peeled.

The plantain can (e ripe or not. The peeled plantain is for$arded to the slicer or

can (e manually sliced $ith the use of !nife into equal si6es

The sliced plantains are then mo%ed to the frying section.

The oil to (e used must not (e rancid and must (e odour free so as not to affect

the quality of the plantain chips.

+o not allo$ the chips to soa! too much %egeta(le oil so as not to reduce the

quality of the plantain chips

;nce the oil has drained- you can then pac!age them for mar!eting.

Pro'ess"() o! a(, a)ro1#ro+0't $"%% 5e "('o*#%ete $"tho0t a+here('e to '0rre(t

#ro'ess"()/*a(0!a't0r"() 60a%"t, #ra't"'e.

B. WHAT IS CURRENT AGRO PROCESSING PRACTICE 2CAPP47

t is an aspect of quality assurance $hich aims to ensure that farm products are

consistently processed and controlled to a quality appropriate for their use and

mar!et authori6ation.

t is the use of adequate materials/ facilities equipment and instrument perform and

super%ised (y qualified $ell trained staff in accordance $ith national and $ell

defined $ritten process and procedure to produce (est products.

1#. COMPLIANCE WITH 2CAPP4:All Agro processing industries must comply $ith

current Agro :processing practise for the follo$ing

To ensure that your Agroproduce0products are consistently relia(le

To helps companies achie%e impro%ement in all areas of processing and production

To (uilds confidence amongst customers as $ell as staff.

To supports auditing of the processing firm.

n compliance $ith 8urrent Processing Practice of food products- your

processing )s are expected to adhere strictly to the follo$ing guidelines

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8learly defined manufacturing procession of your cassa%a- plantain and

oil palm

Cou must define all the critical steps0significant changes of your

processing procedure

Pro%ision of the follo$ing minimum facilities Qualified0trained personnel Adequate premises and space *uita(le equipment and ser%ices 8orrect materials containers0la(els Trained operators to carry out their assigned procedures Adequate !eeping of records during processing Proper procedure for the storage and distri(ution of products after

processing

8omplaints a(out mar!eted products shall (e properly examined

and in%estigated- and appropriate measure ta!en to pre%ent future

occurrence.

11. BASIC RE8UIREMENT OF 2 CAPP4:n order to properly process your plantain-

palm fruits and cassa%a- the follo$ing (asic requirements are needed.

a. Fa'tor, La,o0t 2Pre*"ses/E(&"ro(*e(t4: the premises for your processing

factory must include

Pro+0't"o( Areas This must minimi6e ris!s of errors and across

contamination. t must also permit effecti%e cleaning- effecti%e

maintenance- minimi6e (uild up of dirt and dust. ?liminate any ad%erse

effect on quality.

Des")( Pr"('"#%es:o Process lo$

o Daterial flo$

o People flo$

Pa'a)"() Areas: this is an area $here the processed goods are $ell

arranged for on$ard transfer to the (uyer

t in%ol%es the su(di%ision of (ul! finished product into pac!s that

contain sufficient quantity $ither for a course of mar!eting- distri(ution or

for retail use.

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The Pre*"ses as a $ho%e:

Dust (e constructed to allo$ flo$ of the ra$ materials

The Processing0Production areas should not ha%e sharp edges

The (uilding must (e high enough for easy mo%ement of processed

materials- equipments and enough space for %ehicles to load and off loadgoods.

The premises should (e clean and $here applica(le fumigated routinely

The premises should (e carefully maintained- ensuring that repairs and

maintenance operations do not constitute any ha6ards to the quality of

products

80a%"t, Co(tro% Areas:

o Cour ) can ha%e a quality control la(oratories separate from

your processing0production areas

o Cour la(oratory should (e of suita(le design $ith sufficient space to

a%oid mix ups

o The la(oratory should (e pro%ided $ith effecti%e %entilation

A09"%"ar, Areas:

o n order to maintain hygienic $or!ing conditions- there should (e

facilities for changing clothes- $ashing and toilet purposes- as $ellas pro%ision for eating and drin!ing. All these acti%ities should not

(e permitted in the production0processing- la(oratory and storage

areas.

Stora)e Areas:

o t is recommended that there should (e separate recei%ing and

dispatch (ays and that materials and products (e protected from

$eather during loading and off loading.o All laminated materials and selfadhesi%e la(els must (e !ept in

cool room of temperature not greater than 27#8.

5 E60"#*e(t:

The equipment required for the processing of cassa%a into garri-

starch/ include Eister ?ngine to po$er the grating machine- the

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peeler0!ni%es- pulpsifter- dryers- pul%eri6ers and (agging machine.

This is peculiar to 8assa%a processing industry alone.

;n the other hand- equipment required for processing palm fruits

into palm oil include large drum for (oiling the fruit after remo%alfrom the (unches- (uc!ets to (ail out the coo!ed fruit from the

drum- lister engine to po$er the digester- the digester- the presser to

press the digester. The presser can (e manual or automatic

depending on the a%aila(ility of fund.

or the palm !ernel crac!ing industry- the equipment includes- the

sie%e to remo%e the chaff from the !ernel- lister engine- the crac!er-

the (lo$er- a large $ashing areas to the separate the !ernel shell

from the palm !ernel nut.

?quipment must (e designed- constructed- located- adapted and

maintained to suit production0processing

Fessels- scales or (alances and other measuring equipment must (e

cali(rated on a specified schedule.

All equipment and instrument must (e thoroughly cleaned on a

specified schedule

?quipment should (e installed to minimi6e any ris! of error or of

contamination

ixed pipe $or! must (e clearly la(elled to indicate the contents

and $here applica(le the direction of flo$

5ashing and cleaning equipment should (e chosen and used so as

not (e source of contamination to the processed products

+efecti%e equipment should (e remo%ed from processing line and

quality control areas and clearly la(elled as +??8TF?

MAINTENANCE OF PROCESSING E8UIPMENT:

t is important to ensure adequate care and maintenance of processing equipment

for optimum usage. The follo$ing are some $ays to carry out processing

equipment maintenance

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ollo$ the manufacturers hand(oo! instructions on all equipment

purchase for your processing .).

Golts and nuts of processing equipment should (e inspected tightened

regularly.

+amaged and $orn out parts of machines should (e replaced or

repaired $ithout delay.

?ngine oil of your digester must (e chec!ed on daily (asis (efore

usage to pre%ent sei6ure of the engine.

All processing equipment that require grease must not (e compromised

All equipment that are not in use should (e protected from the sun and

rain

"on operators of processing machine should not (e allo$ed to operate

the equipment

' Perso((e%:

There should (e qualified and adequate personnel at all le%els $ith a(ility-

training- experience and s!ill appropriate to the tas!s assigned to them

All personnel of processing H mar!eting ) must (e moti%ated to

support the aim of the ) and maintenance of high quality standards.

Dust (e pro%ided $ith adequate onthe&o( training to enhance

performance

Production0processing line are not to (e hired and fired randomly as these

may affect the quality of processed products.

Personnel are not to (e encouraged $ith the ha(it of la6iness

8ode of conduct for all personnel must (e $ell stated (efore and during

assumption of operations All personnel should (e pro%ided $ith safety measure $ell documented

All personnel should (e pro%ided $ith adequate protecti%e clothing-

including o%eralls- aprons- mas!s- safety glasses goggles- glo%es- etc and

compel them to use these items

irst aid !its should also (e made a%aila(le and strategically located in

operations areas for the personnel

+ I*#orta('e o! Do'0*e(tat"o(/Re'or+ 3ee#"():

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+ocumentation0record !eeping sho$s that $or! or processing procedure

has (een done

t is used for %alidation and internal quality audits

t is a !ey regulatory requirements

t is used for training personnel

t is used for o(taining loans from the (an!

t gi%es a history of $hat has happened in your processing0mar!eting )

t ena(les your ) to determine the strength and $ea!ness of your

acti%ities

t $ill tell your ) if you are gaining or losing in your

mar!eting0processing %entures

t $ill pro%ide enough information necessary for taxation of your ) in

the nearest uture. T,#es o! Do'0*e(tat"o(s/Re'or+ "( #ro'ess"() "(+0str"es:

i. S#e'"!"'at"o(s

8hemical a$ Daterials

Pac!aging Daterials

inished Products

ii. Ma(0!a't0r"()/#ro'ess"() "(str0't"o( re'or+:

The Daterials $e need

The quantities $e must process to arri%e at a particular quantity

The equipment to use

The operating and chec!s to ma!e

Sta(+ar+ O#erat"() Pro'e+0re re'or+:

nstruction and information on ho$ to carry out a $ide range of

operations.

Bat'h Do'0*e(tat"o( Re'or+s:

ecords of recei%ing and issuing out the ra$ materials or finished

products

ecords of testing materials and products.

Other Re'or+s

+istri(ution ecords

*torage ecords

?n%ironmental Donitoring ecords

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*ales ecords

?xpenditure and income records

ecords of minutes from meeting held (y the management or the

management $ith staff or all mem(ers of ).

12. 8UALIT- 8UALIT COST AND CONSE8UENCIES OF POOR

PROCESSING 8UALIT:

What "s 80a%"t,:

t is the conformance to the requirements0expectation of the customers

t is meeting the agreed customer requirement0needs

C0sto*er:

t is anyone $ho is impacted (y our processes

t is anyone $ho use $hat $e produce

There are 2 classes of customer namely internal and external

Cost o! 80a%"t,;

Danufacturing a quality product or pro%iding a quality ser%ice or doing a

quality &o( is &ust not enough

There is a cost of achie%ing these goals and they must (e properly managed n other $ords- the cost of quality are all the cost attri(uted to the

production of quality products that is not 1##@

T,#es o! 80a%"t, Cost

Pre&e(t"o( Cost:this is the cost incurred in other not to process a poor

quality product. This cost includes training- research and de%elopment cost-

supplier %etting- products design etc

A##ra"sa% Cost: this includes testing %endor rating- process inspection-final inspection- incoming inspection and %endor sampling

Fa"%0re Cost: this includes external and internal cost. ?xternal cost

includes the cost of recalling all process products sent out (ac! to the

processing firm. t includes the lia(ility and $arrant claim- loss of good

$ill- repairs and ser%icing and loss of sale. The internal cost includes re

$or! cost- discount cost- re&ect cost- scrap cost- reinspection cost or re

testing cost- do$ntime- do$ngrading- failure analysis cost. etc

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Co(se60e('es o! #oor #ro'ess"() 60a%"t,:

t leads to loss of (usiness

t leads to lia(ility claims on the processing firm

t encourages lo$ producti%ity

t increases the cost incurred (y the organisation


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14. TEAM WOR3 IN PROCESSING/MAR3ETING FUG:

A team is a small num(er of people $ith complementary s!ills $ho are

committed to a common purpose

Cour ) is a group of people $ith the same goal

Cour ) must as a matter of fact (e mutually accounta(le

Tea* A%")(*e(t: As a mem(er of either processing or Dar!eting )-

All must ha%e a sense of (elonging : good of communication $ithin the

group

All must ha%e a sense of identity : emerges from clear a$areness of team

goal

All must ha%e a sense of direction

All must sho$ commitment to the goals and mission of the team

All mem(ers responsi(ilities must (e $ell defined

Cour ) success or failure is on your hand as a mem(er. ?nsure the

success of your mar!eting00processing ).

!"# CONCLUSION

t is clear that %irtually all other )s depend on your )s for processing their

farm produce.

This is (ecause it is expected that you (uy from the farmers- processed and re

sell to the pu(lic.

Cour ) must (e a force in your community.

Any failure of your ) $ill ad%ersely affect other )s $hich loo! unto you

for processing their farm produce.

Cou must see your )s as one of the most important )s in A+ADA

programme (ecause production $ithout processing and mar!eting amounts to

nothing.

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Agricultural produce processing

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