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Module I
Plantation Crops
E .P. Banuu PriyaAssistant Professor
Kongu Engineering College
Importance of plantation crops
• Plantation crops are high value commercial crops
• Economic importance
• Export potential
• Employment generation (app. 0.5 million people)
• Poverty alleviation (rural sector)
• Ministry of Agriculture - Coconut, cashewnut, cocoa, arecanut, oil
palm and palmyrah
• Ministry of commerce - Tea, coffee and rubber
Cashew nut
• Cashew is brought from Brazil to India by the Portuguese • Initially cultivated to arrest soil erosion and sea winds
• India was the first country to enter the global cashew trade.
• The country processes about 1.18 million tonnes of cashew
• 1959 – 150 mills; 2008 – 3500 mills
• Organized - 46 % ; Unorganized – 54 %
• Annual demand - 1.5 million tonnes, only a half of which is met by the
existing production.
Cashew (Anacardium occidentale L.)
• India is the largest Producer, Processor and Exporter in the world ?
1960 1970 1980 1990 2000 until 20120
200000
400000
600000
800000
1000000
1200000
Top production - cashew nut
Mozambique Nigeria Vietnam India
Cash
ew P
rodu
ction
(MT)
Contd..
• India imports - raw in-shell cashew from Congo, Tanzania, Indonesia and
Thailand (Zheng, 2012)
• India exports processed nuts to USA, UK, Japan, Netherlands, Australia,
Canada and Germany (Directorate-General of Commercial Intelligence and
Statistics, 2011).
• “zero cholesterol nut”
Nutrition Composition
Protein - 21.2
Carbohydrates - 22.0
Fat - 47.0
Rest is total Minerals (Calcium, Phosphorus, Iron), Moisture and total Fiber
(in 100 g of cashew nut)
Parts of cashew fruit
Ripening stages of cashew
Processing of cashew• Raw material
• Cleaning• Grading• Drying • Storage
• Conditioning• Roasting or steam cooking• Decortication (wooden mallets or cutting)• Separation of kernel• Kernel drying• Peeling• Grading and packaging
Over view of processing
Raw cashew nutsFreshly harvested cashew
nuts (initial m.c. 25%)
Cleaning (Rotary screen)
Grading
Sun drying
(2-3 days till 8-9% m.c)
Storage (gunny bags – 8-9 %)
Methods of processing
Cleaning
• Manual cleaning – sand, stones, dried cashew etc., are removed• Hand sieves (0.95 cm mesh)
Conditioning• Washed by dipping the nuts in cold water in a tank
• Heaped on the floor are covered with moist gunny bags
• Water is sprinkled over the heaps periodically to keep the nuts in wet condition and
allowed to absorb moisture gradually
• Conditioning with moisture ensures quality of the final product
• Over humidification – desert grades
• Under humidification – scorched grades
• Steam cooking/roasting
• Oil recovery will be less and breakage of kernels would be more if the nut has not
absorbed sufficient amount of water
Roasting
Purpose - carefully separate the kernel without CNSL contamination - less breakage
• Open pan• Drum drying (unconditioned)• Oil bath roasting
Open pan roasting
• Used by traditional cashew processors in India.
• This technique is very simple with minimal equipment requirements.
• Requires skill and judgement in order to prevent the nuts from burning.
• The roasting pan is an open circular mild steel dish, measuring 2 to 2.5 feet in
diameter, supported over an open fire.
• Between 1 and 1.5 kg of raw nuts are placed on to the heated pan at a time.
• The nuts are heated on the pan, with constant stirring, in order to prevent burning
• As the nuts heat up, the CNSL is exuded onto the pan
Open pan roasting
Drum roasting• An improvement on the open pan roaster was the development of a drum
roaster, within which the cashew nuts are roasted.
• Nuts without any conditioning are fed into a rotating drum, heated initially to red hot to allow the shell of the nut to ignite and burn
• Drum is tilted at an angle (15-20°) over the fire and rotated during heating to prevent the nuts from burning
• During rotation, nuts pass through the cylinder and out of the opposite end of the drum.
• Duration of the roasting process can be regulated by changing the speed of rotation of the drum.
• Takes about 3-5 minutes and the drum is rotated by hand
• Rate of shelling and out turn of whole kernel is higher
• Cylinder is covered in a hood connected to a chimney which draws the black smoke upward into the atmosphere and makes it less unpleasant for the operator
Drum roaster fired from a furnace below
Oil bath roasting• Consists of a rectangular vessel and embedded in brick work and
heated by a furnace – shell is used as fuel• Conditioned nuts are passed through a bath of heated cashew nut
shell liquid (CNSL) maintained at a temperature of 175-220°C (190°C) for about 1-2 minutes
• Small (18 – 22 cm) -90 sec• Medium (23 – 25 mm) – 100 sec• Large (26 – 35 mm) – 110 sec
• Screw or belt conveyor is operating inside the bath of liquid• Roasting time is adjusted by the speed of the conveyor• During the passage, the shell gets heated , rupturing the cell walls
and releasing the shell liquid• Nuts are conveyed through a suitable outlet to a centrifuge – residual
oil is removed • Oil recovered from the roaster and centrifuge is filled into drums.
Mild roasting• Conditioned grains are mild roasted for 20-25 min to remove
surface water• Loosens the kernel from the shell • After roasting, the nuts are spread on the floor as a thin layer for
cooling and later sent for shelling
Shelling
• Roasted nuts are placed on a flat surface and cracked with a wooden mallet
• Efficiency - 10 nuts/min• 8 h shift - approximately 30 kg of raw nuts – 7.5 kg kernel• Cooling – 2-4 h
Kernel drying – “BORMA”
• Purpose – to peel the testa from the kernel• Temperature – 60-70°C• Time – 6-7 h• Final m.c – 3.5 – 4%• Borma ovens are fired – shell or CNSL removed cake • Natural draft stack – 13-15 cm • Cooling
Borma or Tray dryer
Peeling
• The peeling process involved removal of testa from the kernel with the help of sharp knife (made of bamboo).
Rehumidification
• Exposed to humid air• m.c – 5 %
Grading• Grading operation is important since it is the last opportunity for
quality control of the kernels.
• Grading system is known as the American Standard, which is also incorporated in the Indian Government export criteria.
• Kernels are categorized on the basis of colour and condition.
• Peeled cashew nuts can be classified into between 11 and 24 grades. These are roughly divided into three groups: white whole, white pieces and scorched grades.
GradingS.NO GROUPS SPECIFICATION
1 White wholesW180 (super large)W210 (large)W240W280W320W450
Between 120 and 180 kernels per lb (266-395 per kg) 200 and 210 kernels per lb (395-465 per kg) 230 and 240 kernels per lb (485-530 per kg) 270 and 280 kernels per lb (575-620 per kg) 300 and 320 kernels per lb (660-706 per kg) 400 and 450 kernels per lb (880-990 per kg)
2 White piecesButtsSplits
Pieces
Small piecesBaby bits
A kernel broken cleanly across the section of the nut.Kernel which has broken down the natural line of cleavage to form a cotyledon.
A kernel which has broken across the section but does not qualify for a butt and is above a specific size.
As above but smaller.Very small pieces of kernel which are white in colour.
3 Scorched gradesWholes
Butts
Whole kernels that have been slightly scorched during the process but are otherwise sound. These are not graded according to size.Butts that have been scorched.
Packaging
• Graded kernels are packed in square tins of 25lb capacity• After filling and weighing - 65 cm vacuum and filled with CO2
• Tins are carefully tested for leaks after a day’s storage. • Then they are packed in cartons• Flexible packages - polyethyene and polypropylene • filled with 33.3% vacuum and 66.7% CO2 (1:2 ratio of CO2:N2)
Semi - mechanical• Grading of raw nuts (before roasting)• steam roasting (instead of open pan or drum or sun or oil-bath
roasting) • cutting (instead of shelling)
Grading
• 3 groups – small, medium, large.• Depending on size, nuts may require different timings for roasting• Vibratory screens / calibrator
Steam roasting process
• The steam roasting process, commonly known as “cooking process” • Baby boiler followed by a steam cooker where the cashew nuts are
cooked with steam• Adopted widely in India
Baby boiler
• Hand stoked fire tube boiler, which produces steam at 4.5-5 kg cm−2
• 2-3 kg fuel once in 15-20 min• Cashew shell or de-oiled cake• Discharge – stack height – 13-15 cm
Cashew nut cooker
• Maximum – 360 kg cashew can be processed• Steam pressure – 4.5 – 5 kg cm−2
• process time - 10-20 min • total batch time is about 40- 45 min• cooking operation - 2-4 h in a day• 5-10 batches of nuts (depending on capacity)• Cooling
Cutting
• nut-shaped knives• nuts placed between the knifes and pushed towards kernel to cut the
shell leaving the kernel intact• 40 to 50 kg raw nut/person/8 hr• 90 % whole kernel• Nuts smaller than 18 mm cannot be cut using cutting machines
FULLY AUTOMATIC METHOD OF PROCESSING• OLTERMARE
1. Cleaning and calibration2. Washing and conditioning3. Roasting, centrifugation and cooling4. Drying5. Shelling and pneumatic separation of the shells6. Peeling, grading / sorting7. Packing
Cleaning and calibration
• size grading and pre-cleaning• dried raw cashew nut (RCN) – dust, debris etc.,• calibrator/grader machine is used, the machine will have cylinder
shaped sieves having whole of various dimensions/size • RCN passed through different wholes will be segregated and collected
separately• 3-5 grades (India only 3)
Roasting and centrifuging
• CNSL roasting followed by centrifuging to remove the remaining oil• conveyed through the cooling tunnel• next section (shelling)
Shelling
• shelling machines - shell is split into two halves• kernels and shells - vibrating screen• Aspirator – suck out empty shells• If not separated – centrifugal separator • super calibrator - whole, broken and rotten kernels are separated.
Peeling
• Mechanical and pneumatic actions – remove testa• Rocket peeler• Air peeling (pneumatic) machine
Raw nuts
Conditioning
Drum roasting
Hand shelling
Borma drying
Hand Peeling
Grading
Packing
Shells
Testa
Cashew Processing – Quilon (Kerala)
Raw nuts
Conditioning
Mild roasting
Shelling in leg & Hand operated machine Shells
Borma drying
Hand peeling
Grading
Rehumidification
Packaging
Expeller
CNSL Residue Testa
Cashew processing - Mangalore
Cashew processing - Panruti
Raw nuts
Sun Drying
Hand Shelling Shells
Borma drying
Hand peeling
Grading
Packaging
Kilns
CNSL ResidueTesta
Raw nuts
Conditioning
Single action cutting m/c
Improved Through Flow Drier
Abrasive peeler
Hand Peeling
Grading
Rehumidification
Packaging
Expeller
CNSL Residue
Shells
Peels
Extraction
Residue
Improved Cashew Nut Processing
Tannin
Storage
• Resistant to insects
• Do not suffer from infection or deterioration in quality up to six months after harvesting
• Optimum moisture contents is 8.9% for good keeping quality and for yielding good quality kernels
Mechanical sheller• Designed by Post Harvest Technology Centre, Indian Institute of
Technology,Kharagpur.
• Sheller uses principles of compression and shear, taking into account the physical and mechanical properties of cashew nuts.
• Consists of four compartments power supply transmission, feeding, shelling and discharging
• Feeding section consists of a hopper and horizontal screw conveyor for positive feed of the roasted nuts to the shelling section.
• Design criteria for the hopper and screw conveyor use size, bulk density, coefficient of friction and angle of repose of roasted cashew nuts.
• A flat plate sliding gate is used to control the feed rate of cashews into the sheller.
Contd..• Shelling of roasted nuts takes place between two wooden discs, one of which is
stationary (fixed to the machine casing) while the other is mounted on to a shaft.
• The rotating disc is spring loaded in order to compress and shear the roasted cashew nut against the stationary disc.
• Sufficient pressure is exerted by the spring in order to compress the nuts between the two discs.
• The compression and differential speed of the discs causes the shells to be broken and removed.
• At the bottom is a square opening for discharging the kernels and shells.
• A conduit is provided to prevent the kernels from being damaged by falling on to the collecting tray.
• Performance of the Sheller is optimal at 320 rpm. • Capacity :18 kg/h• Shelling efficiency :70 %• Whole kernel yield :50 %• Half split yield :22 %• Broken yield :28 %
Cashew shelling machine
Cashew products
• Three main cashew products are traded on the international market: raw nuts, cashew kernels and cashew nut shell liquid (CNSL)
• A fourth product, the cashew apple is generally processed and consumed locally.
• The raw cashew nut is the main commercial product of the cashew tree, though yields of the cashew apple are eight to ten times the weight of the raw nuts.
• Raw nuts are either exported or processed prior to export.
• Processing of the raw nuts releases the by-product CNSL that has industrial and medicinal applications.
• The skin of the nut is high in tannins and can be recovered and used in the tanning of hides.
Cashew nut shell liquid• Cashew nut processing allows for the development of an important by-product,
which can increase its added value.
• The liquid inside the shell (CNSL) represents 15 percent of the gross weight and has some attractive possible medicinal and industrial uses.
• CNSL is one of the few natural resins that is highly heat resistant and is used in braking systems and in paint manufacture.
• It contains a compound known as anacardium, which is used to treat dermatological disorders.
• The main markets for CNSL are the United States, the European Union (mainly the United Kingdom), Japan and the Republic of Korea.
• Together these account for over ninety percent of world trade, most of which is supplied by India and Brazil.
Cashew apple
Plucking and removing nuts
Washing and weighing
Fruit mill
Juice extractor
Sulphitation
Inoculation
Fermentation
Distillation
Adjusting strength to 60%
Aging in Wooden vats
Dilution to 43%
Bottling
Preparation of Feni
Cashew kernels• 60 percent of cashew kernels are consumed in the form of snacks
while the remaining 40 percent are included in confectionery.
• Cashew competes in the same market as other edible nuts including almonds, hazels, walnuts, pecans, macadamias, pistachios and peanuts.
• There has recently been a considerable rise in demand for edible nuts by consumers interested in quality and health aspects of food.
• The breakfast cereal, health food, salads and baked goods markets are all expanding markets for cashew nuts.