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Advantages of Puffing Technology

Jul 25, 2022

The demand for ready-to-eat foods is increasing day by day and some of the casual foods like popcorn, puffed rice, puffed beaten rice and puffed rice are gaining popularity in different parts of the world. Popcorn produced by thermal expansion of corn (popcorn variety) is gaining popularity not only in India but also in many other countries as the most popular snack/breakfast cereal. Powdered salt and other spices are added, mixed and cooled before packaging.


The popping/puffing process results in aeration, porosity, texture and volume increase with the added benefit of dehydration. The main parameters affecting puffing are the starch content and initial moisture content of the ingredients, the duration of puffing and the temperature. Currently, these operations are performed in sand and electric blasting/puffing machines involving heat transfer conduction modes.


Continuous Hot Air Puffing System

The blasting material obtained from these conventional techniques contains contaminants such as sand, sawdust ash, and the blasting operation is performed under unsanitary conditions. Different raw materials require different types of poppers, each with its own drawbacks. Reports on the design and development of a popcorn/puffing machine that is flexible enough to handle a variety of raw materials (corn, rice, rices, sorghum, etc.) in a continuous and sanitary manner as required by the small-scale/lodge industry. Scarcity. Therefore, in the present work attempts are made to solve these problems by applying fluidization.


Conventional conduction-based machines (static beds) lead to particle-to-particle contact. On the other hand, in fluidization, upward flowing fluid streams pass through contact with solid particles transforming them into a fluid-like state. The average surface area of the dispersed particles increases during particle fluidization, which in turn increases the degree of heat and mass transfer. The main advantages of fluidization are low maintenance costs, ease of scale-up, simplicity of design, uniform exposure of the particles without mechanical agitation and close contact of the particles with the gas.


Although the basic kitchen methods (know-how/operational methods) for the production of traditional casual foods (e.g., puffed rice, puffed rice, puffed rice) are known, a lot of R&D research is still needed to translate them into technological production for mass production. For this, major inputs from food engineers and technicians are required.


Oil Free RTE Foods

Although the provision of the required heat is an important aspect in achieving the desired sensory properties of the food (color, crunchiness and flavor), the mode of heat transfer from the heating medium to the food is known to have a greater impact. Therefore, it is necessary to perform a theoretical analysis of the heat and mass transfer in different grain bursting/puffing processes and to compare them with experimental values.


Certain pretreatments are essential for the preparation of puffed grains. For puffing, 500 g of rice with a moisture content (10%) was subjected to hydrothermal treatment (soaking the grains in hot water at 60 to 70 °C and maintaining pressure) before puffing. After preheating the rice to 150 °C, 10% (w/v) water containing 15% (w/v) rock salt was added and left to stand for 10 minutes. The sample is puffed at 260 °C and the expansion rate of the final product is calculated.


If the grains burst, no treatment is required. The required moisture content of a grain will only cause bursting. Popcorn varieties of corn, jowar and rice were purchased from local markets and analyzed for moisture content and popped using dry grains (no additional moisture added).