Component-2 “Production-to-Consumption”

A Value Chain on Composite Dairy Foods with A Value Chain on Composite Dairy Foods with Enhanced Health AttributesEnhanced Health Attributes

Project Sanctioned: 1st, March, 2009

Website: www.compositefoods.org.in

Completion Date: 1st, June, 2012

National Dairy Research Institute, Karnal

Central Institute of Post Harvest Engineering & Technology, Ludhiana

Arpana Research & Charities Trust, Madhuban, Karnal Total Budget Outlay: 283.076 Lakhs

Objectives To harness the nutritional and therapeutic

potential of milk by-products and underutilized plant species (pearl millet and barley) for development of functional foods

To develop technological package for composite dairy foods (complementary foods, fortified convenience foods and probiotic milk-cereal foods) with enhanced health attributes

To validate the consumer acceptability and targeted health benefits of composite dairy foods

To assess the techno-economic feasibility of the newly developed technologies through linkages with industry, marketing personnel and Self-help group

Primary Processing Equipments• Millet Pearler developed by CIPHET, Ludhiana

and the performance evaluation of the machine is completed

• It is quite useful for the manufacture of primary processed products like grits, semolina and flour from Pearl millet

• Problems of low shelf-life, unattractive colour and higher tannin/phenolics could be simply solved by hydrothermal treatment

• Process of germination and roasting could also be applied to enhance the nutritional profile and organoleptic quality of millet crops

PEARLERDESTONER

Some equipments/machines for primary processing of pearl millet and barley.

CLEANER CUM GRADER

Convenience Products• Processing technology for the manufacture of

convenience mixes for Halwa and Upma has been optimized

• These mixes can be utilized at home scale as well for Institutional catering to save time

• Pearl millet pasta enriched with whey protein has been developed. Addition of hydrocolloids improved the quality attributes of the product

• Test marketing of these products indicate that the acceptability of these products could further be improved if they are used in combination with wheat grits or flour

Snack Foods

• Formulation and technology to produce protein-enriched extruded snack has been completed.

• Biscuits of highly acceptable quality is made from a formulation of composite dairy-cereal mix consisting of whey protein concentrate, pearl millet flour and refined wheat flour

• Optimized biscuits will provide 15.6% of calorie, 20% protein, 7.6% iron and 9% of daily calcium requirement of RDA per 100 g of product.

• Whey & Skim milk blend in the ratio of 70:30 or 80:20 can be utilized for complementary food base material

• Germination of Pearl millet grains for 48 hr followed by roasting decrease phytic acid level and also results in higher amylase activity.

• Optimum levels of pearl millet, barley malt extract and maltodextrin in the complementary food is 20 %, 15 % and 5.7% respectively

• The product developed was readily reconstitutable and at 9% level of reconstitution, it was highly acceptable

• The product was nutritionally superior in terms of minerals, protein and digestibility

• Protein, moisture, ash, carbohydrate and microbial quality was according to PFA rules (2008) for milk-cereal based complementary foods.

Pearl Millet-Whey Based Complementary Pearl Millet-Whey Based Complementary FoodFood

Pearl Millet-Whey-Skim Milk Pearl Millet-Whey-Skim Milk Complementary FoodsComplementary Foods

Spray Dried Complementary Food

Tray Dried Complementary Food

Pearl Millet based Beverage (Bajra Lassi)

• Suitable bacterial starter have been identified that can ferment milk as well as millet solids

• Process of fermentation reduced the level of phytate and improved the bioavailability of minerals

Milk-Millet Based Probiotic FoodMilk-Millet Based Probiotic Food

• Millet components perform number of functions in probiotic consortium

Provide fermentable substrates for growth of probiotic microorganisms

As prebiotics due to presence of non-digestible carbohydrates

• Malt and extracts of millet showed significant protective effect on L. plantarum & L. acidophilus strains under acidic conditions

• Presence of certain compounds like fermentable sugar, free amino acid favour the growth of probiotic microbes in millet based substrate

Popularization of Developed Products

• Development of publicity material related to nutritional and therapeutic potential of Pearl millet & whey

• Brochure and Posters of the products developed in the project

• Development of a website www.compositefoods.org.in for disseminating the information through ICT tools

• Participation in more than 20 exhibitions at various places of the country to display our products and distribution of samples

• Test marketing in collaboration with industry and prospective entrepreneurs for the developed products

• Publication of articles on composite foods in print media. Demonstration of technologies and products on electronic media

Market Access to Technology

• Test marketing of instant mixes, pasta from CIPHET, Ludhiana and Bajra lassi & biscuits from NDRI Parlour has been started

• One Integrated processing unit has started the production of composite dairy foods at Amritpur Kalan, near Karnal

• Linkage with Technology Business Incubator (TBI) and ZTM-BPD Units of ICAR for technology transfer and entrepreneurship development

Rural Enterprise on Composite Foods

Unit is involved in Manufacturing & Marketing of dairy products including whey based drinks, Bajra lassi and Biscuits, run by 14 resource poor women

Observation of Beneficiaries/Stakeholders

• 32 entrepreneurs have registered with TBI for training and Technology Business incubation

• Bhartiya Kisaan Union (BKU) of Haryana has indicated their willingness to promote the primary processing of Pearl millet in Jind District of Haryana

• Invited to make special presentation during the 46th All Indian Coordinated Project on Pearl Millet Improvement at Hisar

• Invited to make special presentation at National KVKs Conference held at Udaipur, Rajasthan

• Danone India Pvt. Ltd. is working for the establishment of rural enterprise in similar way as developed in project

• Britannia India Ltd. New Delhi are willing to start certain composite dairy products developed in project.

Cross Consortia Learning

• Strengthening the linkage with stakeholders for promoting the production, consumption and value addition through composite dairy foods

• Assistance in promotion of developed products in Northern states through display of publicity material

• Development of technological packages for milk/sorghum/small millet products like lassi, extruded snacks and complementary foods at NDRI

• Assistance in organization of “Entrepreneurship Development Programme” at NDRI, Karnal for the benefit of interested personnel

Outreach Programmes

• Inclusion of Post Harvest Processing & Value addition as major activity in 12th Plan of All India Coordinated Research Project on Pearl Millet Improvement

• Identification of “Composite Dairy Foods” based on Millets & minor cereals as Major Research Programme for the next 5-year plan of NDRI, Karnal

• Submitted project in “Milk-Millet” based composite probiotic foods under Indo-Finnish Cooperation

Cross Consortia Learning

• Strengthening the linkage with stakeholders for promoting the production, consumption and value addition through composite dairy foods

• Assistance in promotion of developed products in Northern states through display of publicity material

• Development of technological packages for milk/sorghum/small millet products like lassi, extruded snacks and complementary foods at NDRI

• Assistance in organization of “Entrepreneurship Development Programme” at NDRI, Karnal for the benefit of interested personnel

Experience & Lesson Learned •Experience is quite encouraging as there is increasing awareness among stakeholders regarding millets and dairy by-products

• Incorporation of millets with milk/milk by-products not only improve nutritional profile but also enhance consumer acceptability

•Certain products like millet based bakery products, snacks and beverages could attract large consumer base

•Technology transfer mechanisms are quite cumbersome and discourage the industry and entrepreneurs

Antimicrobial Activity

E.ColiE.Coli

SalmonellaSalmonella

B.CereusB.Cereus

Listeria MonocytogensListeria Monocytogens

S.AureusS.Aureus

Antifungal activity

AspergillusAspergillus

Kluveromyces LactisKluveromyces LactisRhizopusRhizopusCandidaCandida

Saccharomyces cerevisiaeSaccharomyces cerevisiaeKluveromyces marxianusKluveromyces marxianus

Procedure

- L.rhamnosus RSI-3 has shown good survivalability at different pH, and different concentration of Bile salts in in-vitro treatment

- L.rhamnosus RSI-3 shown good cell surface hydrophobicity

- L.rhamnosus RSI-3 has exhibited best antifungal activity, antimicrbial activity and antibiotic sensitivity against various antibiotics

- L.rhamnosus RSI-3 produces sufficient β-galactsidase enzymes and has ability to deconjugate bile salts

• Probiotic fed group of Rats significantly increased level of haemoglobin as compared to Normal control and Diabetic control group

• Probiotic fed group of rats significantly increased level of antioxidative enzymes in liver and RBCs such as Catalase, SOD and GPx

• Probiotic fed group of rats slightly improved lipid profiles, including the reduction of Serum/Plasma total cholesterol, LDL-cholesterol, VLDL-Cholesterol and triglycerides or increment of HDL-Cholesterol.

The present investigation has culminated in establishment of potential probiotic attributes of RSI3, a native strain bioprospected from a traditional cereal based fermented milk product.

This strain has shown better in vitro probiotic attributes vis –a- vis LGG.

In animal model, this strain has shown as a good antidiabetic effect in terms of ---------and better in terms of ……….in comparison to LGG.

This study has shown that probiotic therapy is effective in control of diabetes.

This strain is a prolific grower typical of probiotic organism which are invariably slow grower and has the potential to be used as commercial probiotic strain with due validation and has the techno-functional attributes for its use in manufacture OF a functional dairy food.

The present investigation has culminated in establishment of potential probiotic attributes of RSI3, a native strain bioprospected from a traditional cereal based fermented milk product.

This strain has shown better in vitro probiotic attributes vis –a- vis LGG.

In animal model, this strain has shown as a good antidiabetic effect in terms of ---------and better in terms of ……….in comparison to LGG.

This study has shown that probiotic therapy is effective in control of diabetes.

This strain is a prolific grower typical of probiotic organism which are invariably slow grower and has the potential to be used as commercial probiotic strain with due validation and has the techno-functional attributes for its use in manufacture OF a functional dairy food.