UNIT - III
HEALTHY PASTRY: “SAMOSA”
Defining Product
And
Process Specification
TEAM - C
Alzahrani Ibtisam
Bande Ajinkya
Chen Lu
Psylou Marilena
Yang Yushan
Zhai Lili
Summary
The main purpose of Unit III is to develop and optimize the product with respect to process and ingredients and to have a brief idea about the required process equipments and packaging eligible according to legislation to fit the product in European market.The industrial process was designed and monitored in such a way that it assures the safety and quality of the final products. The selection of the equipments is based on the quantity of samosa production per day. For a production of 10,000 units per day, where each unit equals to 6 samosas for ready-to-eat production and 15 samosas for frozen production, the factory will produce 150,000 samosas per day. Taking into account that the base of each samosa weighs 13gr and the filling 10gr, the weight of raw materials for producing 150,000 samosas per day is 1500kg and the weight of base is 1950kg per day. The aim of consumer acceptability and preference test was to provide an indication of whether the formulated product is acceptable to the consumers, so that the preferred formulated product will be found out and process can be optimized. Two replicated experiments were carried out among 36 untrained assessors to assess in which three top attributes related to base and overall acceptability of product were examined. The results concluded that there is a significant difference only between crispiness and oiliness of samples. No significant interaction between factor X1 (frying time) and factor X2 (base combination) is identified, and X1 is considered as an important factor that affects sensory attributes when optimizing processing conditions. The group decided to chose sample I which is 25% of whole meal flour and 75% of plain flour in base and half fried for 30 seconds. The final product will be manufactured according to the process specification with use of specified quality ingredients to give a uniform product at the end of the process. The raw material could be sourced from local market or directly from the manufacturers according to amount needed. According to the calculations done the final product will be weighing average of 23gm and about 75cal energy (per samosa) and product will be sold as ready to eat (RTE) samosas and as frozen samosas. The packaging used in both cases will be transparent as far as possible to give a view of product and as far as shelf life is concerned RTE samosa have short shelf life than frozen which will be determined in further units. Food standard is a very important aspect in the food industry, given that it is directly associated with human health. It is therefore important to examine whether the industrial production of samosa conforms to the safety and quality criteria that have been set up in existing industrial standards and legislation. There are several of them that have been enforced globally, aimed at regulating the industrial production of food products. The Food Standards Agency is mandated with carrying out policies that are aimed at ensuring that food substances are safe for human consumption. This includes research funding on microbiological, radiological, and chemical safety, as well as allergy and food hygiene. It has been noted that the samosa production process was adequate and conformed to the legislation and standards of food production. However, the training process of the staff is not well developed despite its significance in the production process.In the next stage, we will continue to optimize our product in terms of the filling. We will also develop the product commercialisation, which include conducting a commercial product test, determine the factors affecting shelf-life, find proper packaging and legislation for our product, propose GMP,GHP, HACCP and quality control plans.
I. Develop process and equipment flowcharts with description of the whole production process
# Optimal Laboratory Process Flowchart
Filling Base
sweet potato soya chunks
ready-to-eat
half fried and frozen
# Industrial Process Flow Chart
Filling Base
READY-TO-EAT FROZEN
Description of the industrial process flow chart:
1. Washing of the vegetables:
The first step of the industrial process for samosa production is the washing of the vegetables stage. In this stage, the onions and the sweet potatoes are put in the vegetable washing machine in order to remove soil remains, stones and any other physical hazard derived from the field.
2. Dicing of the vegetables:
The vegetables used in the samosa filling should have equal size, thickness and shape in order to achieve equal heat transfer uniformity during cooking procedures. Size reduction leads to an increase in surface-to-volume ratio and a more efficient rate of heating and cooling. Size reduction also aids to the proper mixing of the ingredients in the filling. The knife blades in the dicing machine must be kept sharp so as to reduce the force required to cut the material and to minimize cell destruction. Cell destruction enables the mixing of enzymes and substrates and that leads to loss of flavor, aroma and color. Furthermore, cell destruction can be a cause for microbiological growth and off-flavor and aroma development. Vegetables are first sliced and cut into strips by rotating blades and then are cut into cubes. (Fellows 2000)
3. Cooking of soya chunks:
In this step of the process, the soya chunks which are already bought in a dehydrated form are put in a cooking kettle with boiling water in order to rehydrate and retake their previous texture and form.
4. Straining out water from soya chunks:
After the completion of soya chunks dehydration, the remnant water is poured in a colander.
5. Cooking of the filling (50% soya chunks + 50% sweet potato):
In this step of the process onions, sweet potatoes and soya chunks are cooked all together in a cooking kettle for the preparation of the filling with the addition of spices. Sweet potatoes are not already cooked before entering the cooking kettle because the team decided that there was no difference in the texture of precooked sweet potatoes and raw sweet potatoes. It is very important that all ingredients are properly mixed in order to ensure homogeneity of the filling and improve the characteristics of the final product. (Fellows 2000)
6. Dough preparation:
Dough preparation takes place at the same time with the preparation of the filling. Dough is prepared in a mixing machine, where 25% of whole meal flour and 75% of plain flour are mixed with sunflower oil, water and grounded cumin. Dough is a high-viscosity material and mixing is achieving with the aid of three main actions: kneading, folding and shearing. In that way, folding and shearing forces extend protein molecules and gluten network is developed, which promotes the desirable texture of dough. Due to the nature of the dough (viscoelastic material), it is important that the mixer blades are moved throughout the vessel in order to achieve an efficient mixing. When the dough is ready is left to rest for a while in a tray. Furthermore, when the filling is cooked is also left to cool in a tray. (Fellows 2000)
7. Forming/shaping of samosas:
When the dough has rested and the filling has cooled, both materials are put in the samosa making machine, which forms the samosa. The device opens the dough in large sheets, which length and thickness can be adjusted, and then it cuts the dough in small pieces. After that, the stuffing depositor places the filling in each small sheet and as the conveyor belt transports the samosas, workers in both sides of the conveyor belt wrap the samosas.
8. Frying the samosas till crispy and golden brown surface:
Frying is used not only for altering the eating quality and texture of a food material, but also for increasing the shelf life by deactivating the enzymes, destroying the microorganisms and reducing the water activity at the food surface. In an industrial level is important to maintain high temperatures during frying in order to reduce processing time and increase production rates. However, such high temperatures cause oil deterioration and free fatty acids formation. The formation of free fatty acids can alter the organoleptic characteristics of the oil (flavor, aroma, viscosity). Samosa production requires frying in high temperature in order to achieve the desirable crispiness level. It is important that the crust is rapidly formed so as to seal moisture into the food and to reduce the rate of heat transfer to the interior. The method which is industrially used for frying samosas is shallow frying, because samosas have a large surface-area-to-volume ratio. The heat is transferred from the hot surface of the equipment, through a thin layer of oil, to the food by conduction. Shallow fried samosas present an irregular browning on their surface because the thickness of the oil layer is not constant but it depends on the surface of the food. Furthermore, steam bubbles raise the food from the hot surface of the equipment and that causes temperature variations during frying. Those temperature variations contribute to the irregular browning of shallow fried samosas. Finally, despite the fact that shallow frying has a high surface heat transfer coefficient, the heat is not uniformly transferred to the food surface. (Fellows 2000)
9. Cooling:
After shallow-frying the samosas, those batches that are destined for ready-to-eat consumption should be put in the cooling machine in order to rapidly decrease their temperature before packaging.
10. Individual quick freezing:
After shallow-frying, the batches which are destined for freezing are put in the air-blast freezing machine for 1hr. Its principle is based on quick freezing. It is important that the freezing process is fast in order to avoid thawing of the material. In the blast freezer the air is recirculated at a very high velocity. The high air velocity contributes to the reduction of the thickness of the boundary film around the food and also increases the heat transfer coefficient. Samosas are transported through an insulated tunnel on -conveyor belts. Furthermore, blast freezing is a very economical way of freezing and it can be used for different shapes and sizes of food. (Fellows 2000).
11. Primary packaging of ready-to-eat samosas:
After cooling down the ready-to-eat samosas are packaged in plastic bags which are closed with a vacuum packaging machine.
12. Primary packaging of frozen samosas:
The frozen samosas are put in the packaging machine which produces three sealing pack in order to assure a safe product.
13. Metal detector:
After the primary packaging, all batches, ready-to-eat and frozen ones pass through the metal detector in order to check if all products are free of metal remnants from the equipment surfaces. Furthermore, at the same time the weight of each package is checked.
14. Storage of ready-to-eat samosas:
The ready-to-eat samosas are stored at storing rooms under controlled conditions of temperature (2-6°C), lighting and humidity in order to maintain the quality and safety of the products. (Fellows 2000).
15. Storage of frozen samosas:
The frozen samosas are stored at storing rooms at below -18°C.
16. Dispatch of ready-to-eat samosas in secondary pack:
The primary packages of ready-to-eat samosas are put in plastic transparent boxes and then are ready for distribution.
17. Dispatch of frozen samosas in secondary pack:
The primary packages of frozen samosas are put in cardboard boxes and then are ready for distribution.
II. HEALTHY SAMOSA FACTORY LAYOUT
III. Selecting process and ancillary equipment required to meet the define production requirement
# Equipment Flow Chart
Filling Base
READY-TO-EAT FROZEN
# Description of the equipment flow chart
As far as the equipments which are used for the industrial production of samosas, they should be shelf-draining and to have a minimum number of ‘dead spaces’ where microorganisms can grow. In order to have a continuous process, belt conveyors are used, which transport the solid materials between the steps of production.
The choice of equipments will be based on the process flow chart and the quantity of the products which will be produced per day. The factory will produce 10,000 units per day. For the ready-to-eat samosas, each unit is equivalent to 6 samosas, because 6 ready-to-eat samosas will be contained in the package. For the frozen samosas, each unit is equivalent to 15 samosas, because 15 samosas will be contained in the package. The selection of the equipments was based on their capacity, after taking into consideration that the medium weight of each samosa is 23g from which 10g is the filling and 13g is the base. So, the weight of raw material needed for producing at least 150,000 samosas per day is 1500kg. And the weight of the base needed for producing at least 150,000 samosas per day is 1950kg.
At first stage, two processes take place simultaneously, the preparation of the filling and the preparation of the base.
Washing of the vegetables:
As far as the filling is concerned, the first step is the washing of the vegetables (potatoes and onions). The vegetable washer model which is used in the factory is the Spiral vegetable washing machine (product of the Kasmac Industries Co., Ltd.) which has a capacity of 800-1500kg/hr, a power of 3.3kw and its water consumption is 500-1000kg/hr . The washing of the vegetables is a very important step because in that way, the physical hazards (soil remnants, stones, etc) are minimized. [3]
Dicing of vegetables:
In this step, the sweet potatoes are put in the dicing machine, Multifunctional Vegetable/Meat Dicing Machine (product of the Weishi Huifa Machinery Plant) with capacity of 1,500kg/hr, the cutting size of the machine is 5mm and the cubic size is 8mm. [2]
Cooking of soya chunks:
Soya chunks are put in a cooking kettle with boiling water. For that purpose a cooking kettle is used (Hammilton Style “SB”) with a capacity of 57-1330ltrs. [10]
Straining out water from soya chunks:
After the rehydration of soya chunks, the content of the kettle is poured in a colander (Carlisle 10628 Colander, Clear, 18" x 26" x 5"). [9]
Cooking of the filling (50% soya chunks + 50% sweet potato):
The diced sweet potatoes and the boiled soya chunks are put in a kettle in order to be cooked with the addition of spices. For that purpose, a cooking kettle is used (Hammilton Style “SB”) with a capacity of 57-1330ltrs. [10]