DESIGN AND DEVELOPMENT OF VACUUM PAN EVAPORATOR FOR SOLID AND GRANULAR JAGGERY
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Date
2021
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Indira Gandhi Krishi Vishwavidyalaya, Raipur
Abstract
Jaggery is an unprocessed sugar made from sugar cane juice that is utilised in all countries throughout the world under many names. It's not simply a sweetener; it's also a flavour and colour enhancer. More minerals and vitamins are found in jaggery than in pure sugar.Juiceboiling is the second most important unit operation in the preparation of jaggery. The mainobjective of boiling is to concentrate the juice to make thick syrup to form solid or powder formof jaggery. There are various types of boiling systems they are open pan with with bagasse/firehood,open pan steam boiling, and 3 pan furnaceboiling.
Traditionally open pan boiling is being practiced by jaggery producers with pan made ofmild steel (or) galvanised iron (or) aluminium sheets and boils with bagasse/fire hood. Thisprocess consumes more time, energy and labour and there is no control overboiling process.Also the entire process is unhygienic as boiling of juice is carried out with direct burning of largeamount of bagasse in open grate furnace. As a result, the quality of juice is highly effecte
colour and bitter in taste due to overheating of syrup, which leads to lower price of jaggery inmarket. To overcome these problems and for commercial adoption of upgraded technology onlarge scale unit an investigation was carried out to design, fabricate and testing of vacuum panevaporator for solid and granular jaggery to decrease the boiling time and increase the quality ofjaggery.
Vacuum vanishing is that the technique for causing the weight in a fluid stuffed instrument to be decreased beneath the fume weight of the fluid, exacting the fluid to dissipate at a lower temperature than customary. Whentheprocessisappliedtojaggerythewaterisevaporated and removed thus jaggery can be stored for long period of time without spoilage. Thevacuum pan evaporation is the most advanced and automated method in terms of saving ofboiling time, fuel and labour. It also retains the quality parameters of jaggery. The principal partsvacuumpanevaporatoraremainbody,calendria,catchall,topcone,bottomconewithdischarge, top tube plate, vapor inlet and outlet, feed tube, inspection glasses, condensate piping,nozzles,flangesandsamplecollector.Thesystemisoperatedwithvacuumpumphavingultimatepressureof 33mbar-900m bar with liquid flowrate of 5Liters/min.
Afterdesignandfabricationof800kgboilingcapacityvacuumpanevaporator,performance evaluation was carried out with a view to optimize operating process variables atvarious Pressure, Time and Temperatures ranges. Response surface methodology (RSM) withBox Behnken design of 3 variables and 3 levels each was used to investigate the impact of different levels of process variables on various quality indicators of jaggery products, such as (Brix, Moisture,Water activity, Color, Texture, Sucrose and Reducing sugars). The independent process variablesconsideredforexperimentwerePressure(550-700mmofHg),time(60-100min)andTemperature(100-120⁰C).UsingtheDesignExpertStatisticalSoftwarepackage(Version11.06.2, Stat-Ease) The process parameters were adjusted by establishing targets in order to achieve the required product quality. The dependent variables (Y) were expressed as a function of the independent variables using a 2nd order polynomial equation. The developed technology saves time of 60minutescompared to conventional methodof 150 min to raisebrix from 61.8º to 80º.
Among the 17 combinations the best combinations sample suited was R 12 at 110⁰C for 80min at 700 mm of Hg sample which reported having good percentage of moisture content, wateractivity,colorandhardness.Whereasforsucrose,andreducingsugarstheoptimalqualityjaggerysuitedat100⁰Cfor80minat700mmofHg.Theexperimentaldatarevealedthatthe
TSS of jaggery samples ranges varied from 60º to 83º brix with increase in time and temperature,showedincreasedtrend.TheTSSconcentrationwasmaximum83ºbrixat1080Ctemperatureand there was major change in TSS also with increase in pressure. The moisture content ofjaggery in different samples ranged from 4% to 11.5%. In result of numerical optimization, theoptimal water activity (aw) is obtained at 0.44 at R1 run sample of temperature 120ºC, time 80min and vacuum pressure of 700 mm of Hg. It was revealed that hardness of the jaggery samplesincreases from 12.6 to 17.5 with increase in temperature. There was no change in color value ofL* and a* (lightness-darkness) up to a temperature of 100ºC and time 90 min. Upon increaseintemperaturefrom60100ºCincreasesinsucrosecontentupto84.72%from81.88%.Therewasno significant change with increase in vacuum pressure in vessel.The reducing sugars increasedas vacuumpressureandtimeisincreased.There wassignificant increase inreducing sugars from 9.12 to 12.88% with increase in vacuum level from 550 to 700 mm of Hg and time from 60 to 90minutes.
Thequalityjaggerydevelopedfromvacuumpanevaporatoratoptimizedprocessparameters was evaluated by sensory evaluation using fuzzy logic method and the order ofpreferencescoreswassweetness>color>texturalappearance>flavor.Amongtheoptimizedsix samples of S1, S2, S3, S4, S5 and S6 the highest sensory evaluation score revealed by panelmembers was for sweetness followed by color for sample S1 (Rank-1) obtained at optimizedvalue of (Vp: 700 t: 80 T: 100) and S2 (Rank 2) optimized at (Vp: 700 t: 80 T: 110) and forsampleS5 & S6 followed by S3 and S4respectively.
At the end, the experiment is concluded with analysis of techno-economic feasibility.Variable cost of product was Rs. 1,26,000 and fixed cost was1,18,249. If the produced jaggeryof 1800 kg is sold at @Rs. 70/- per kg the net profit is Rs. 7751/-. The break even period can beachievedinabout 3 months withB/C ratio is 1.06.
The developed technology opens new avenues for jaggery manufactures on large scaleproduction to develop good quality jaggery. This technology has been developed indigenouslyandthe componentshavebeenlocally manufacturedoffering greatvaluetomoney andtime.