PAPAD MAKING

Food & Agro

Details of the Product

The iconic and delectable food item papad has long been a staple of the Indian diet. According to regional tastes, different combinations of pulses, cereals, fruits, roots, and tubers are used to make papad in different parts of the world. In India, a variety of papads made with various flours and flavours are sold. Any meal is made more wholesome by having crunchy, tasty papad on the side, whether you are eating a bowl of comforting moong dal khichadi or a spicy plate of biryani. It goes by the name Papadum in southern India. India's preferred namkeen for traditional meals is papad or pappadam.

It is a traditional food item produced from black gram or various flours from other sources, such as lentils, chickpeas, rice, or potatoes, that can utilise. It has the thin, crisp disc-shaped texture of a wafer. It is formed from fried dough comprising cereal flour, either by itself or combined with various pulse flours, salt, Khar, and spices, such as ragi, rice, maize, sorghum, wheat flour, or sago. It is deep-fat fried to produce a tasty, crispy wafer-like product that is frequently served as a side dish with a complete dinner.

Raw Material Sources

Black gram dhal flour, salt, Sodium bicarbonate, Water potable, crushed cumin seed, black pepper, asafoetida, Ca-propionate.

Ragi flour, salt, Bicarbonate, Water-potable, cumin seed and ajwan seed, Oil, Ca-propionate.

Technology and Process

IMPORTANCE OF PAPAD

A healthy appetizer and aid in digestion is papad. Papad that has been roasted or grilled aids in absorbing the fatty substances from the mouth and throat. Papad should be consumed in moderation otherwise it may become the cause of acidity. Papad has a lot of sodium. therefore, not recommended for those with hypertension. Lentils are used to make papad, which makes it gluten-free and high in protein and nutritional fiber.

Types of Papads

Black Gram (Urud Dal) Papad

A staple addition to rice, sambhar, and pickle in South Indian households, this dish is a savoury delicacy. Black gram is used to make the urud dal papad, along with salt and other components.

Ragi Papad

The ragi or nachani papad is a common Maharashtrian side dish. It is prepared with nutritious ragi flour. It distinguishes itself from other papad varieties with its deep brown hue and coarse texture.

MANUFACTURING PROCESS FOR PAPAD

Black gram dhal (urad dhal)/ Ragi Millet is initially cleaned by going through the stone-removal designer. To get rid of the fibre and coarse material, it is finely processed in the hammer mill and put through a screen. After being collected and weighed, the material that has passed through the sieve is sent to the kneading machine in the appropriate amounts. The necessary amount of salt, spices, and sodium bicarbonate are added, and everything is properly mixed. Slowly incorporating water causes the dough to develop. Strong kneading is required. To put the dough in the flattening machine, it is rolled into lengths and cut into even pieces. By depressing the foot-operated pedal, the dough is flattened to the appropriate thickness, shape, and size. The extra dough is taken out and reused once more.

PROCESS FLOW CHART FOR PAPAD MAKING

Cleaning of Black Gram / Ragi Millet

To produce high-quality flour with a better recovery rate, the black gram/Ragi millet that is received at the mill needs to be cleaned. Reciprocating air-screen cleaners and reel-screen cleaners are the two types of cleaners most frequently utilised. In reciprocating air screen cleaners, lighter material like dust, stalk, dried leaves, husk, etc. are separated by blowing air through two screens (sieves). For final cleaning, the second screen has fewer perforations while the upper screen has larger perforations. There are two to four cylindrical compartments in the reel screen cleaners. The machine's structure is constructed from sheets of mild steel or wood. On a 5-7.5 mm diameter shaft, various size perforation screens are mounted in these compartments. At a speed of 5-35 rpm, the screen drum is cylindrical.

De-hulling for Black gram

Removal of the seed coat is beneficial for the following reasons:

Reduces anti-nutritional factors, such as tannins and insoluble fibre (non-nutrients that can bind protein and other nutrients), improving nutritional quality, protein digestibility, texture, and palatability.
Removes astringent taste caused by tannins.
Allows the production of higher quality flours without browning/speckling (also increases leavening ability).

Grinding

Grinding whole or dehulled seeds, dhal, or millet into minute particles is the process used to make flour. In order to create flour with more consistent particle sizes, ground particles are sent through one or more screens.

Kneading of the dough

Papad is made by the act of kneading. It is a crucial step in the process of combining flour and water. It is used to combine the ingredients and give the finished product more strength. Machines for shaping and kneading can be used for kneading.

Shaping

The papad press is a mechanical device. Pulse flour, ideally urad dal, slat, carbonates, farinaceous material, and water are the ingredients used to make papad dough. The dough is formed into sheets by the machine pressing it to a 1-mm thickness and then cutting it into a circle. Using a dryer machine, the pressed circular papad is dried to a moisture content of 14–15% at room temperature.

Urud Dal (black gram)

One of the significant pulse crops growing all over India is black gram. It is eaten either sprouted or as "dal" (whole or split, husked or un-husked). It serves as a nutritious feed, particularly for dairy cows. It is also a crop grown as green manure. Urban is a great addition to rice in terms of balanced human nutrition due to its high lysine content.

Process

Dehulling
Grinding of black gram
Kneading of the dough
Shaping
Drying at room temperature

Mixing of ingredients

Black gram flour is combined with other components to make papad, such as salt, sodium bicarbonate, water, black pepper, asafoetida, calcium propionate, and crushed cumin seeds. in the right amount.

Health benefits of Black Gram

Improves Digestion
Boosts Energy
Improves Bone Mineral Density
Manage Diabetes
Skin Care
Reduces Pain & Inflammation
Protects Heart Health

RAGI PAPAD

Ragi is made from finger millet, which is millet that is stronger in minerals and protein than all other grains combined. It is ideal for vegans and is a source of protein as well. Isoleucine, leucine, methionine, and phenylalanine, four necessary amino acids found only in finger millets, are absent from other starchy foods.

Health Benefits of Ragi

High Protein
Natural Weight Loss Agent
Prevents your Skin from Ageing
Ragi is Good for your Hair
Ragi has loads of Calcium
Increases Production of Mothers Milk
Prevents Diabetes
Good Digestion

Process

Grinding of ragi
Cooking
Kneading of the dough
Shaping
Drying at room temperature

Preparation method

Boiling water on the stove requires a large container of water. Incorporate salt and ajwain. Stir the ragi powder thoroughly once the water has begun to boil. Cut the stove off. Put cooked ragi dough parts on a platter. Ragi dough is steamed for 7-8 minutes on a high flame after being placed on a plate covered with hot water and ragi dough. After that, extinguish the flame, lay out some plastic, pour the batter on it, and smooth it out with a ladle. These need to dry in the sun for two days.

Tip: Prepare big-sized thin papad if you want to roast it or small-sized thin papad if you want to fry it.

SETTING UP UNIT

Investment is the first. Basic tools like a griddle, rolling pins, and drying trays will need to be purchased. If you sell your papads on the open market, you might also want to consider purchasing a food dehydrator.

The next step is to register your business. You can accomplish this by submitting documentation to the Secretary of State, another state regulatory agency, or your local government.

Do your homework on the registration procedures and make sure you adhere to all legal regulations.

Availability of Raw Material

The amount of raw materials necessary to make the desired number of papads is the next factor to consider when starting a papad-making business.

Depending on the recipe you employ, this will change, but it's a good idea to start modest and increase production as necessary.

Flour, water, oil, salt, and spices are all used as row ingredients. These ingredients can be obtained locally or through a provider. To make high-quality papads, it's crucial to use high-quality ingredients.

Space & Manpower

To start this business, at least 200–300 square feet will be needed. In addition, there will be a need for one supervisor, two skilled workers, and three unskilled workers.

Plants and Machinery

Plate grinder, Sieve shaker, Low-pressure boiler, steam-jacketed kettle with a stirrer, motorised mixing, shaping, and kneading machine, leg-operated papad press, and sealing apparatus are the main pieces of equipment.

Auxiliary equipment includes a stove that runs on electricity, general lighting and heating, an electronic balance, and workstations.

Equipment Involved

Plate grinder: This device is used to mill pulses (black gramme) into extremely fine powder. It includes a flour purifier, screening equipment, and grinding equipment.

Sieve shaker

Sieve shakers are used to separate and measure the size of the flour made from pulses. A standard sieve shaker separates particle by agitating the sample as it moves through a series of chambers with mesh filters to achieve a thorough separation.

Low-pressure boiler

Low-pressure boilers are most frequently utilised for applications involving process heating, humidification, and lower temperatures. The technology of steam boilers is employed in many different fields. The maximum design pressure for low-pressure steam boilers is 15 PSIG, and they are frequently employed in heating applications.

Steam jacketed kettle with stirrer

A well-designed machine that facilitates various commercial and domestic food preparation tasks is the steam jacketed kettle with stirrer. Typically, raw materials are processed in a steam-jacketed kettle with a stirrer without compromising their quality.

Motorized mixing

It automates the monotonous processes of beating, whisking, and stirring. A mixer kneads the flour when a dough hook takes the place of the beaters

Papad-making machine

This device is used to roll out the dough into a sheet and cut it into a papad form.

Hand impulse sealer

A motorised equipment called an impulse sealer is used to seal various kinds of plastic packaging, most frequently poly bags containing collections of parts or components. It heats a metal wire with an electrical impulse, melting one layer of plastic into the next.

PROJECT PROPOSAL

Project Plan
Land & Building
Plant & Machinery
Pre-Operative Expanses
Working Capital
Miscellaneous

PRODUCTION CAPACITY – (Estimate)

A year's worth of 300 days can be worked with the installed capacity of 100 kg of completed product per shift.

TECHNOLOGY / MANUFACTURING PROCESS – Availability

The technique and general procedures for processing papads made from ragi have been standardised by CFTRI. The institute also offers information on the equipment in addition to this process for quality control, packing, and packaging material specifications.

The FSSAI standards of Papad

According to the FSSAI standards, Papad means Pulses based Products made by grounded Pulses flour.

"foreign matter" means any extraneous matter other than food grains comprising of-

inorganic matter consisting of metallic pieces, sand, gravel, dirt, pebbles, stones, lumps of earth, clay and mud, animal filth, and in the case of rice, kernels or pieces of kernels, if any, having mud sticking on the surface of the rice, and

Organic matter consisting of husk, straws, weed seeds, and other inedible grains and also paddy in the case of rice;
Poisonous, toxic, and/or harmful seeds - means that any seeds, such as dhatura (D. fastur and D. stramonium linn), corn cokle (Agrostemma githago L, Machai Lallium remulenum linn), and akra, that are present in amounts that are greater than the permissible limit may be harmful or dangerous to health, organoleptic properties, or technological performance (Vicia species).
"Damaged grains" means kernels or pieces of kernels that are sprouted or internally damaged as a result of heat, microbe, moisture, or whether, viz., ergot affected grain and kernel bunt grains;
"Weevilled grains" means kernels that are partially or wholly bored by insects injurious to grains but do not include germ-eaten grains and egg-spotted grains;
"Other edible grains" means any edible grains (including oil seeds) other than the one which is under consideration.

Food Additives for Use for Cereals and Pulses Based Papads

Sorbic acid and its sodium, potassium and calcium salts (calculated) as sorbic acid should not be more than 0.1%

Packaging of Papad

Deteriorating factors: Knowing the elements that influence papad quality is crucial for choosing an appropriate packing material or style of packaging for papad.
Moisture Content: Since papad is hygroscopic by nature, it absorbs moisture from the air, resulting in a high moisture content. The reduction of the Papad's shelf life is another effect of moisture absorption.
Loss of Aroma / Flavour: Papad has a certain scent that gives it its distinctive flavour and perfume. Some aromatic substances lose their scent and flavour when they oxidise.
Discolouration: The quality of the papad may be impacted by light, which may cause colour fading or loss and other papad degeneration.
Insect Infestation: Papad is prone to spoilage due to insect infestation, which can further accelerate due to high humidity, heat, and oxygen.
Microbial Contamination: Moisture absorption occurs at 65% and above high humidity. Beyond a certain level of moisture content, spoilage due to microbial growth sets in.

Packaging Requirements

The packing material to be used must be carefully chosen, considering the functional and marketing needs, in order to preserve the quality of the papad during handling, transit, storage, and distribution.

The following is a list of the general packaging requirements for Papad:

to prevent spills and deterioration of the goods.

Protect atmospheric elements including heat, humidity, light, and oxygen. High water vapor and oxygen barriers should be present in the packing materials chosen.

To stop aroma/flavor losses and the entry of outside odour, the packing material should have a strong barrier property.

Due to the spices in papad, the volatile oil in it reacts with the inner/contact layer of the packaging material, which can occasionally result in a greasy and dirty box with smudged printed text. Therefore, the packaging material needs to be suitable with the product and resistant to grease and oil.

In addition to the aforementioned functional specifications, the packaging material should be readily available, disposable, and have good printability and machinability.

Packaging Materials

The papad, which has a label indicating a moisture content of 14–15%, is packaged in polythene sheets using a hand-sealing machine and then distributed to markets in 200 g plastic bags, which cost between Rs. 150 and Rs. 170 each bag.

GOVERNMENT SCHEMES AND POLICIES

Finally, researching government support programs is a terrific approach to get started on a tight budget. Find out if there are any grants or loans available to help new enterprises get off the ground. Depending on where you reside, you may be eligible for a variety of different forms of loans.

Mudra Loan Scheme

Additionally, you can receive government assistance for creating your own papad company. The Indian government's Mudra loan programme provides loans for enterprises of up to Rs. 50 Lakhs. This is a fantastic method to get going with little financial outlay.

You can apply for a Mudra Loan from the government through the Pradhan Mantri Mudra Loan Scheme at any nationalised or private sector bank. can return the loan in full over a five-year period.

Sales & Profit

You might attempt to sell the papad in the wholesale market after it has been prepared. Additionally, grocery stores, retail stores, and supermarkets might be contacted to improve their sales of the product. Your potential monthly income is between Rs 25,000 and 30,000. By putting a small amount of money into raw materials, equipment, machinery, and other resources, you can launch a papad production business from home.

SANITARY AND HYGIENIC REQUIREMENTS FOR FOOD MANUFACTURER/ PROCESSOR/HANDLER

The place where food is manufactured, processed, or handled shall comply with the following requirements:

The location of the premises, the absence of unclean surroundings, and the maintenance of an overall hygienic atmosphere are all requirements. shall locate all new units away from locations that are environmentally polluted.

In order to maintain a generally hygienic atmosphere, the location where food manufacture will take place should have enough room for manufacturing and storage.

The location must be tidy, well-ventilated, and lit, and it must have enough room for people to move around.

Must maintain Floors, Ceilings, and walls in a sound condition. They should be smooth and easy to clean with no flaking paint or plaster.

The area must be kept free of any insects by regularly cleaning the floor and skirting walls with an efficient disinfectant. Spraying is prohibited while conducting business; instead, spray flies entering the premises should be killed with fly swatters or flaps. To keep insects out of the premises, windows, doors, and other openings must be fitted with a net or screen, as necessary. The water used in production must be potable, and if necessary, it must undergo routine chemical and bacteriological testing at any reputable laboratory.

Shall guarantee a steady supply of drinkable water on the property. Make sufficient storage measures for water required for cooking or washing when the water supply is intermittent.

When used, machinery and equipment must be built in a way that makes cleaning simple. Provide provisions for cleaning the functioning portions of the machinery, tables, containers, etc.

When preparing, packing, or storing food, no vessel, container, or other equipment that could lead to metallic contamination that is harmful to health should be used. (Vessels made of copper or brass must have the suitable lining.)

At the conclusion of operations, all equipment must be maintained clean, washed, dried, and packed to prevent the growth of mould, fungi, and infestations.

Shall place all equipment away from the walls to allow proper inspection.

There should be an efficient drainage system and adequate provisions for refuse disposal.

The workers working in processing and preparation shall wear clean aprons, hand gloves, and head wears.

Those who have contagious illnesses are not allowed to work. Any cuts or wounds must always be covered, and the person shouldn't be permitted to touch food directly.

All people who handle food must keep their fingernails neatly trimmed, wash their hands with soap and water before starting work, and again after using the restroom. During the food handling processes, one must avoid scratching any body parts or hair.

All those who handle food should refrain from touching their faces or their hair, from wearing false nails, and from wearing other jewellery that could fall into food.

It is forbidden to eat, chew, smoke, spit, or blow your nose while handling food in any way.

All items that are being stored or are destined for sale must be fit for consumption and have the appropriate cover to prevent contamination.

Must maintain a clean vehicle for transporting food.

Foods must keep the necessary temperature while in containers or packed form during transportation.

Disinfectants and insecticides must be kept and stored separately, away from places used to manufacture, store, or handle food.

Scope of Market

At the moment, papad production and sales are primarily conducted in the unorganised sector at the household level or as a small-scale industry. Even huge manufacturers of well-known papad brands like "Lijjat" or "Amani" are really home businesses. Currently, the majority of them are manually operated, low-cost machines. Daily sales of late papad producers targeting export markets, which require semi- or fully-automatic plants and are on the hunt for such innovations, are used to cover working capital demands. The demand for papad varies with the seasons. It reaches its height around holidays and throughout the wedding season, when a lot of players emerge. The daily market volume is approximately four tones.

It's time to start promoting your goods after you've registered your business and calculated how much raw material you need. This can be accomplished both offline and online. You can advertise your papads in a variety of ways, such as through social media, word-of-mouth, and other conventional methods. While offline marketing can be more successful for focusing on local clients, online marketing is a terrific approach to reach a wider audience (online, supermarkets, provision stores, hotels export)