When the traditional manual spice preparation is mechanized, the technology will be handed to the next generation. Installing a Drying Facility consists of the following steps: The company desires to install close loop type air conditioning model dryers that are fitted with an ozone treatment, as opposed to the usual drying methods. The technology contained within the dryer ensures that spices retain their original flavor, aroma, and consistency in chemical composition while being completely free of contamination.
It is anticipated that a commercial processing system will be established as an extension to the present business in order to meet the ever-increasing demand. The method that will be developed will ensure that spices and herbs retain their original flavor, aroma, and consistency in chemical composition while being free of contamination and microbiological concerns such as E.coli and salmonella. The proposed machinery list and their intended use are detailed in the table below.
The company desires to install close loop type air conditioning model dryers that are fitted with an ozone treatment, as opposed to the usual drying methods. The technology contained within the dryer ensures that spices retain their original flavor, aroma, and consistency in chemical composition while being completely free of contamination.
1. Pepper Thresher
This is used to remove green pepper seed from pepper corn. With this machine, contamination of removing seed from pepper corn can be reduced.
A decorticator is a machine for stripping the skin, bark, or rind off nuts, wood, plant stalks, grain, etc., in preparation for further processing. The outer layer of pepper fruit is rubbed off as pepper fruit moves through the circular cylinder, water is sprayed inside the circular sieve in small quantity for lubrication and thus green/black layer is discharged out from the flat holes of the circular screen, white/polished pepper comes out of the point without any physical damage. With proposed machine 250-300kg/hr can be processed. With this machine, processor can keep consistence quality of seed and will improve the volume that can be processed.
3. Ginger|Turmeric Washing Machine
The surface of ginger/turmeric is rough with deep wrinkles, small holes, and slits. General washing machine is not easy to wash ginger. Proposed fresh ginger/turmeric washing machine has a new technology of high-pressure spraying, which can effectively remove surface contaminants (such as pesticides, insects, soil, dirt, etc.) without compromising the quality of the material. The ginger/turmeric washing machine uses a high-pressure spray method. The upper part of the washing machine is equipped with a nozzle with a high-pressure spray head, which performs high-pressure water cleaning under the action of the pump. High-pressure water flow and air bubbles will bind and clean the ginger surface to complete the final washing work.
Turmeric/Ginger boiling system based on convectional boiling technique had been developed to retain curcumin content up to highest possible level and reduce the cooking time. The whole system consists of steam generation unit and blanching vessel. The blanching vessel was modified to mobile boiling vessel which consists of a steam inlet, turmeric holding body (100 kg), safety valve, pressure release valve, pressure and temperature gauge, condenser, steam distribution unit having center-mounted perforated pipe with blinded end to distribute the steam uniformly throughout the vessel and vessel holding stand with wheels. The blanching time, drying rate, drying time and heat utilization factor were quantified. The cooking time under the developed vessel for turmeric was found to be 10 min compared to 15 min under parboiling drum and 25 min under open steaming used by the processor.
5.Ginger |Turmeric Cutting Machine
Proposed machinery, process parameters were optimized for better slicing efficiency. Cutting cum slicing machine was developed to meet the requirement of small-scale entrepreneurs and also the farmers who are interested to set up their own rural level low-capacity processing plant with low initial investment for preparation of processed products. Slicing machine have centrifugal action and consists of hollow drum with beaters, stationary blade, and a rotor plate. Capacity of machine, breakage percentage and slicing efficiency were studied for ginger. The performance of the developed turmeric slicer was found to satisfactory, and the machine was found to be techno-economically feasible for the entrepreneur. Slicing of these products will reduce the drying time as well.
6. Bubble Washer
The bubble washing machine is designed for material with high shape requirements. It is suitable for cleaning and soaking of granular, leafy and rhizome products such as ginger & turmeric. This equipment has the characteristics of high cleanliness, energy saving and water saving. And stable and reliable equipment under the combined work of air bubbles, surfing, lifting, spraying, and brushing. The rinsed water is filtered and recycled, it is self-contained and easy to connect. It can produce 250-450 kg/hr.
Heat pump tray- cabinet dryer designs are well suited to spice, herbs, vegetables and fruit processing and have special features such as open cycle – compact design, very high energy efficiency, control unit with LED touch screen and drying cycle can be programmed into multiple period/steps with specified temperature and humidity for improved product quality. Total tray area is 600sqft & capacity is 400-700 kg/day.
8. SS Grinder
This food grade grinder made out with SS material can be make fine powder and pieces by changing blades. Both spice powder and TBC will make by using this grinder. Per hour 25-30 Kg can be produced.
9. Winnowing Machine
This machine is used to grade pepper according to the weight. Average 500kg/hr can be produced. Food grade material has been used to make this machine.
10. Vibrating Shifter
This machine is used after the grinding machine to make TBC. All pieces segregate according to different sizes as per the customers requirement can be made by using this. Food grade material has been used to make this machine. Per hour 200-400kg can be made from this machine.
11. Weighing & Filling
After finished products are made, this machine has to be used to weigh the product as per the pack size and fill the finished products as per the pack size. This also made with food grade materials, and this will increase the efficiency of production of the firm. 15-35 packs can be packed per minutes.
12. Bottle Sterilizer
This is to sterilize all the bottle before fill the finished product. To keep the food safety standard and hygienic condition and avoid any contamination this must be fixed in the production process. Per batch 40Lt can be loaded to this machine.
13. Vacuum Sealer
Once the finished product is produced, vacuum packing machine will be used to suck all air in the packs, and this will avoid any chemical reaction and contamination such as developing fungi. This is most recommended by EU & USA buyers.1-4 pack can be packed per minutes by using this machine.
14. Bottle Sealer
All bottle products will be packed with this machine. After filling products to sterilized bottle a lid of the bottle will be fixed by using this machine. 60-80 bottle can be seal with this machine.
15. RO Plant
Ro plant is used to enhance water purity to wash raw material before drying. With purified water (TDS level below 5) microbes such as E.coli& salmonella can be removed from the products. Capacity of this plant is 250Lt /hr.
16. Water Tank
This is to store water to wash raw material before drying. Capacity of the tank is 2000 Lt.
17. SS Table
This is an accessory to be used during the production for cutting and packing purposes and made out with SS material (8×4).
The Process in Pictures
This graphic depicts the method of fixing/process flow chat of the planned production facility, which is depicted below. This cutting-edge and revolutionary technique is the key to successfully entering the EU and USA markets without contaminating them or introducing microbiological difficulties like as E.coli and Salmonella, which are unavoidable in the majority of processing plants. This can be accomplished by utilizing a RO plant and purchasing all spices and herbs in their raw form, allowing the company to maintain complete control over the process. The water purity (TDS Level) should be less than 5 percent, which is the secret to be revealed. TDS (total dissolved solids) is the concentration of dissolved particles or solids in water that is intended for usage. The higher the total dissolved solids (TDS) content, the more difficult it is to consume water without treatment. These dissolved substances may be harmful to your health and must be removed from the water before it can be consumed.
Water purity (TDS Level) should be less than 5 percent, which is the secret to be revealed. This can be accomplished by utilizing a RO plant and purchasing all spices and herbs in their raw form. These dissolved substances may be harmful to your health and must be removed.
The following table contains a list of the machinery that is required. There are numerous suppliers all over the world, the majority of whom are involved in the production of large-scale machinery. If you want to purchase small-scale machinery, you should consult with providers.
|Name of M & E||Suppliers||Capacity|Kg||Day Production|Kg||Purpose of Use|
|Decorticator||udayaindustries.lk||250-350/hr||2000-2500kg||To remove pepper seed from corn|
|Pepper Seed Remover||udayaindustries.lk||250-300/Kg||2000Kg||To remove outer layer of green pepper|
|Ginger/Turmeric Washing Plant||udayaindustries.lk||500Kg/Hr||3000-3500Kg||To sand and soil from raizome|
|Steamer||Discussed with manufacturer.India having many suppliers.||50-70Kg/Hr||500-700Kg||To steam ginger & turmeric|
|Ginger& Turmeric Cutting Machine||udayaindustries.lk||100-200/Kg||500-700Kg||To slice ginger & turmeric for drying|
|RO Plant||dir.indiamart.com||250lt/hr||2000Lt||To purify water/make TDS water|
|Water Tanks||Any hardware store.||To use for washing|
|Bubble Washing||dir.indiamart.com||250-450hr||1500-2000kg||To wash with TDS water|
|Dryer||dir.indiamart.com||400-700/3-8 hr||400-700kg||To dry all products|
|Industrial Grinder||dir.indiamart.com||50-70Kg/Hr||500-700Kg||To make powder & TBC|
|Vibrating Shifter||dir.indiamart.com||400Kg/Hr||1000-1200Kg||To make TBC|
|Powder Packing/Weighing & Filling||dir.indiamart.com||5-10 packs/Min||750-1200packs||To weigh & fill to packs|
|Winnowing Machine||dir.indiamart.com||500Kg/Hr||1500-2000Kg||To grade spices & Herbs|
|Vacuum Pack||dir.indiamart.com||1-4 per min||750-1200Packs||To vacuum pack final products|
|Bottle Sterilizer||dir.indiamart.com||Accessory||Accessory||To sterilize bottles before filling|
|Bottle Sealer||dir.indiamart.com||Accessory||Accessory||To seal bottles after filling|
|Packing & Cutting Table||dir.indiamart.com||Accessory||Accessory||To use for packing|
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