Introduction
Food engineering is a multidisciplinary field that combines the principles of engineering,
microbiology, and food science to design, develop, and optimize processes for food
production, preservation, packaging, and quality control.
Pilot plants serve as scaled-down industrial food processing units that allow researchers and
students to understand real-time industrial processes before full-scale production.
CSIR-CFTRI food engineering pilot plant is equipped with a wide range of advanced food
processing instruments, pilot-scale fermenters, dryers, packaging machines, and analytical
devices. These facilities help bridge the gap between laboratory research and commercial
food product development, making them highly beneficial for innovation in functional foods
and nutraceuticals.
The instruments described below are those that would also be required in my Ph.D. research,
which focuses on creating shelf-stable fermented ragi mix through freeze-drying.
1. Digital Weighing Balance
The digital weighing balance is used at the initial stage for accurately measuring the
quantities of ragi grains, starter cultures, water, and additives. It operates on the principle of
strain gauge load cells, which convert the applied weight into an electronic signal that is
displayed on a screen.
Specifications of a typical balance include a weighing capacity of 0 to 15 kg with an
accuracy of ±0.01 grams. It usually comes with an LCD screen and a tare function.
Advantages of using a digital balance include high precision, user-friendliness, and
consistency in batch formulation, which is critical for fermentation reproducibility.
2. Wet Grinder or Colloidal Mill
After cleaning and soaking, the ragi grains are ground into a fine slurry using a wet grinder or
colloidal mill. This equipment uses high-speed rotating blades to reduce the grain size and
produce a homogenous mixture suitable for fermentation.
The grinder typically has a motor power of 750 to 1500 watts and can handle batch sizes
ranging from 2 to 10 liters. The equipment is usually made of food-grade stainless steel to
ensure hygiene.
The advantage of using a grinder is that it helps in maintaining a smooth texture, retains
nutrients, and prepares the substrate for efficient microbial fermentation.
3. Fermenter or Incubator Chamber
Fermentation is carried out in a controlled chamber or bioreactor that maintains optimal
conditions for probiotic growth, such as temperature, pH, and duration. The principle of the
fermenter is to provide a stable, sterile, and controlled environment for microbial activity.
The fermenter typically maintains a temperature range between 30°C and 42°C, and comes
with sensors to monitor parameters like pH and time.
The advantage of using a controlled fermenter is that it enhances probiotic viability,
improves consistency, and promotes the development of health-promoting metabolites in the
ragi.
4. Freeze Dryer (Lyophilizer)
The freeze dryer is the core equipment in the project. It removes water from the fermented
ragi via sublimation by freezing the product and applying vacuum pressure. This process
allows the water to transition directly from solid to vapor, bypassing the liquid state.
A standard pilot-scale freeze dryer operates with shelf temperatures from –40°C to +40°C
and vacuum levels below 0.1 mbar. The chamber is typically made from stainless steel (SS
316) and comes with an integrated control panel.
Advantages include excellent retention of probiotics, minimal loss of bioactive compounds,
and production of lightweight, shelf-stable powder that can be rehydrated without significant
change in texture or flavor.
5. Planetary Mixer or Reconstitution Stirrer
Once the freeze-dried powder is prepared, it can be reconstituted into a beverage by mixing it
with potable or sterile water. This is tested using a planetary mixer or magnetic stirrer that
uniformly dissolves the powder to assess rehydration quality.
Typical equipment specifications include adjustable speeds between 300 and 1500 rpm and
optional heating for solubility studies.
The main advantage is ensuring smooth reconstitution with desirable mouthfeel and no
clumping — critical for consumer acceptance.
Conclusion
The pilot plant facilities at CSIR-CFTRI provide an ideal environment to simulate industrial
food processing on a smaller scale, making it invaluable for research and development. The
instruments described above—from initial weighing and grinding to fermentation, freeze-
drying, reconstitution, and packaging—are critical for my Ph.D. work on developing a
functional, shelf-stable, probiotic-rich, freeze-dried reconstituted ragi mix. The use of such
advanced food engineering equipment ensures not only quality and safety but also enables
innovation and scalability in health-focused food products.
