National Institute of Food Technology Entrepreneurship and Management - NIFTEM
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National Institute of Food Technology Entrepreneurship and Management
Introduction
Pulses are the edible seeds of plants in the legume family.
Pulses are one of the most cost-effective proteins around, enjoyed by
people around the world as a food staple.
India is the largest producer and consumer of Pulses in the world.
Besan is a product obtained by grinding of dried and decuticled Bengal
Gram.
Besan is a bengal gram widely consumed in India.
It is yellowish in colour and possesses characteristic bengal gram taste and
smell.
Pulse splits and broken obtained in dal milling could be further processed
Cont…
to produce (Besan) by grinding. 2
Introduction
Besan is a staple ingredient in the cuisine of the Indian subcontinent,
including in Indian, Bangladeshi, Burmese, Nepali, and Sri Lankan cuisines.
Indians by nature are fond of sweet as well as spicy food and Gram is an
important ingredient in such preparations.
It is a versatile product used in many preparations round the year.
Apart from individual households, there are some institutional bulk
consumers like restaurants, other eateries hostels and canteens, clubs,
caterers, etc.
It is a very commonly used item in the Indian kitchens and thus enjoys
continuous market throughout the year.
3
Major components of Besan
Nutritional value per 100 g (3.5 oz)
Energy 1,619 kJ (387 kcal)
Carbohydrates 57 g
Sugars 10 g
Dietary Fiber 10 g
Fat 6g
Protein 22 g
Vitamins Quantity %DV+
Niacin (B3) 1 mg 7%
Folate (B9) 437 ug 109%
Minerals Quantity %DV+
Calcium 45 mg 5%
Iron 4 mg 31%
Magnesium 166 mg 47%
Phosphorus 318 mg 45%
Potassium 846 mg 18%
Selenium 8 ug 11%
Sodium 64 mg 4%
Zinc 2 mg 21%
Other Constituents Quantity
4
Water 10 g
Market Potential
The global pulse market is primarily propelled by the rising consumption
of various pulse s and bakery products in various regions.
Besan is a high potential market in India with annual production volume
of over 5 million tonnes; i.e. over 50% of the approximately 10 million
tonnes of desi Chickpeas produced in India (which goes for grinding into
Besan).
it is estimated that that over two thousand besan mills process the
produce.
The market for pulse s in the Asia Pacific region is projected to grow at
the highest CAGR in terms of both volume and value, from 2017 to 2022.
5
General Machines
De-stoner
It’s a machine used to remove stones from given food
grain.
It is used for separating dry granular material according
to specific weight of object.
The goal is the elimination of heavy impurities, such as
stones, metallic particles and other objects from pulses.
6
General Machines
Hammer Mill
A hammer mill is a mill whose purpose is to
shred or crush aggregate material into smaller
pieces by the repeated blows of little hammers.
It’s a Grain Milling Machine, used for grinding
grains to fine powder. This mill utilizes rotating
hammer to perform actual grinding.
7
General Machines
Packaging Machine
It’s a packing class machine, used to pack given
efficiently.
It’s especially designed to handle with minimum
wastage
8
General Equipment
Bucket Elevator with Gear Motor
It consists of:
Buckets to contain the material;
A belt to carry the buckets and transmit the pull;
Means to drive the belt;
Accessories for loading the buckets or picking up the material,
for receiving the discharged material, for maintaining the belt
tension, and for enclosing and protecting the elevator.
Bucket elevators are designed to move flowing powders or bulk
solids vertically.
9
General Equipment
Conversion cum Drying Bins
Cleaned material is conveyed into soaking cum-
drying bins where it is conditioned with little water.
Storage Tank For Dal 300kg:
It is used for storing of besan.
10Processing Technology
The fumigated and processed chana dal/split & skinned Bengal
gram/cheakpea is procured from the vendor and then processed to make
besan in the plant. The process is as follows:
Cleaning
Eliminate pebbles, broken grains and other impurities from Gram.
Conditioning:
Based on physical properties of gram dal, remove other coloured
gram halves.
Water content, if any, should be removed by drying to maintain
minimum 12 to 14% moisture.
The spilt dal is again moisturized and conditioned for four hours.
11Processing Technology
Grading/Grinding:
Spilt lentils are then graded if they are to be sold else fed to
Hammer Mill.
Hammer Mill simply grinds these lentils into fine powder. This is
fed to holding tank of packaging machine.
12Processing Technology
Packaging
Finally, besan is packed directly in gunny bags, poly-line gunny bags for
bulk selling and in laminated pouches or poly-bags for retail selling.
13Flow chart
14Project components
Raw materials
Basic raw material for the proposed unit
is “split & skinned Bengal Gram”
Packaging material
15Project Components
Land- The approximate total area required for a complete small scale factory setup is 1200-1500 Sq. ft.
approximately smooth production.
Civil work-
Workshop Area- This area includes the machinery setup and foundation space for all tools and
equipment etc. The total workshop area is approx. 800 Sqft.
Inventory Area- This area includes the storage space for all the raw materials, finished Product
area. Total inventory area is approx. 400 Sqft.
Office Area – This space includes staff working region, their accommodation space, canteen area,
medical facility, etc. The total workshop area is approx. 200Sqft. This may be considered above the
ground floor.
Parking Space, Electricity Utensils Mounting Space, and Others. This could be approx. 100Sqft.
Land and building requirements may vary depending on the size of project.
16Project Components
Miscellaneous Assets-
Water Supply Arrangements
Furniture
Power requirement
The manufacturing unit requires 10-12 KW.
Man power requirement
For a small unit to begin with around 8-10
people is required including skilled, non- skilled
worker and a supervisor.
17Packaging of Besan
Besan for retail sale is generally packaged packed
in plastic packages.
Also for wholesale market besan can be
packaged in huge pillow or hand bags
Shelf Life of Besan
Besan can stay fresh for up to 6 months and
longer if refrigerated.
Besan from Indian stores sometimes is already a
few months old and has been stored in hot
conditions should be refrigerated.
18Quality considerations during packing
Quality control of packed products is the last time the product is checked before
reaching the customer.
Documented checking of the packages entails:
Weight of the package
Weight of the Flour
Arrangement of the flour
Defects; and Moisture content.
The surrounding area is also checked:
Cleanliness of the handling equipment during processing
Calibration of the scales (automatic or manual);
Writing on the packages;
Satisfactory working of the metal detector (installed on every retail
packing line);
Repackaging installations and marking; and
Qualification for international standards such as ISO and HACCP
19Selection of Packaging Material
Factors to consider include product damage, fines,
stickiness, bag opening size, re-closure among other things.
In selection of packaging materials for sweet packaging the
following need to be considered:
Tensile Strength & Elongation
Tear Strength
Heat Seal Strength
Performance Properties
20Selection of Packaging Material
Types of Packages for Besan
Hanging Bags- Hanging bags are frequently seen in grocery stores
and other retail locations. They are a type of plastic bag that is sealed
on both ends and sometimes with a back-middle seam as well.
Hanging bags have a pre-cut hole that allows them to hang easily from
hooks, so they can be displayed in an attractive way.
Pillow Bags - Another common type of packaging is a pillow bag. The
bags get their name from their shape, which resembles a pillow. They
are found lying flat on grocery store shelves and have been known to
hold the product.
21Selection of Packaging Material
Types of Packages for Besan
Gusseted Poly Bags- Gusseted bags are often called flat-bottom bags
because they feature a tucked in pleat that’s been pressed flat. It allows
the bag to expand for greater carrying capacity and to keep the shape of a
box if necessary. These types of poly bags can be heat sealed, tied, stapled,
or taped shut.
Flexible Pouches- Flexible pouches are a great option for holding any
processed products. They can be manufactured with zipper-seal closures,
which help keep the interior contents fresh for use. Flexible pouches offer
amazing printing capabilities, so you can add your attractive product
branding to the pouch itself.
22FSSAI REGULATIONS AND STANDARDS OF BESAN
Besan means the product obtained by grinding dehusked
Bengal gram (Cicer arietinum) and shall not contain any
added coloring matter or any other foreign ingredient.
Besan shall conform to the following standards:—
• Total ash – Not more than 5.0%.
• Ash insoluble in dilute hydrochloric acid – Not
more than 0.5%.
23FOOD SAFETY AND STANDARDS (FOOD PRODUCTS STANDARDS AND FOOD ADDITIVES)
REGULATIONS, 2011
2.4.6 food grains: 2.4.6.13: Dal Chana
(i) Moisture Not more than 14 per cent by weight (obtained by heating the
pulverized grains at 130oC-133oC for two hours).
(ii) Foreign matter - (Extraneous matter) Not more than 1 per cent. by weight of which not more than
0.25 per cent. by weight shall be mineral matter and not more
than 0.10 per cent. by weight shall be impurities of animal
origin.
Other edible grains - Not more than 2 per cent by weight.
Damaged grains- Not more than 5 per cent by weight
Weevilled grains- Not more than 3 per cent by count.
(vi) Uric acid- Not more than 100 mg. per kg
Aflatoxin Not more than 30 micrograms per kilogram.
Provided that the total of foreign matter, other edible grains and damaged grains shall not exceed 7 per cent by weight.25
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