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Use of dehumidifiers in food processing & packaging
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Monday, 01 September, 2008, 08 : 00 AM [IST]
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Irum Khan, Mumbai
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Chocolates, hard candies, chewing gums and such confectionery products contain a large percentage of sugar or sugar-based ingredients which are hygroscopic. When the humidity is high, these products regain moisture and become sticky and prone to mould formation. This inhibits the natural flow as it sticks to the high speed processing and packaging machinery and also to the wrapping material.
The processing thus slows down and also creates a problem of hygiene, resulting in loss of production as well as loss in the final product quality. Uncontrolled humidity/moisture during the manufacturing and coating process of confectionery causes:
● Change in the structure/dimension of interface
● Grainy and irregular coating
● Increase in residual moisture content adhesion i.e. degradation of coating quality in the presence of moisture
● Sugar bloom and change in flavour.
The solution to the problem lies in maintaining required stringent conditions of temperature and humidity and in surrounding the processing, packaging and storage areas with dry air.
Dehumidifiers lower the moisture content of the surrounding maintaining RH as low as 1% at a constant level regardless of the ambient condition during the production, storage and packaging to help improve the quality and retain the freshness of the chocolates longer.
Bry- Air, is one such leading manufacturer of desiccant dehumidifiers, product dryers & environmental control systems for commercial and industrial applications. Dehumidifiers have been helping to ensure required humidity conditions are maintained in processing, coating and packaging areas.
Bry-Air dehumidifiers have been successfully functioning during the gum coating process at the Wrigley company's facilities in Kenya and India.
Chocolates need to be stored at 35 +/- 5 % RH at 25 degree celcius for safe storage in order to retain its original flavour and aroma. Cadbury installed Bry-Air dehumidifier when it was facing environmental challenges in its food drinks packaging hall factory causing increased machine downtime, poor product quality, etc.
The food industry is incorporating more and more sophisticated technologies to maintain growth fuelled by changing consumer taste and lifestyles. Every processor is endeavouring to ensure that the food product reaches the consumer with the right flavour, perfect shape as well as a long shelf life. Moisture or rather uncontrolled humidity during processing, packaging, storage often plays a party spoiler. Moisture control is essential in every segment of the food industry in the spheres of
● Storage
● Production
● Packaging
● Processing
● Low temperature drying
In processing powdery foods, especially health foods like juice concentrates, protein supplements, soup powders, cocoa as well as gelatines, dehydrated soft drink concentrates, instant coffee powders and milk powders, the presence of moisture in the surrounding air can cause lumping or caking causing the tiny particles to stick or cluster together, thus inhibiting their free flow in the manufacturing or packaging process. Many granular or powdered materials are transferred to packaging via high velocity air streams. This process is commonly referred to as pneumatic conveying or just airveying. For food handling, the efficiency of transporting powdered, granulated or flaked materials by high velocity air streams is significantly improved by drying the air. Highly hygroscopic sugar, flour, starches and beverages and food powders make humidity control crucial element of materials handling system. In addition, the presence of moisture in the air may interfere with the operation of the processing machines and obstruct the free and easy movement of the foodstuff. Obviously, if moisture affects the food and the machinery in this fashion, the solution to the problem lies in surrounding the processing and manufacturing area with dry air. During packaging, in many instances, low RH has to be maintained so as to prevent moisture regain. Desiccant dehumidification systems ensure optimum moisture control as required by the process and are dependable, efficient and versatile.
Dinesh Gupta, president & director of Bry-Air Asia, talks about the growing concern over food wastage and the solutions that dehumidifiers can provide in a tele-con with Irum Khan.
What is the use of a dehumidifier? And where is it installed?
As humidifiers are used to increase the moisture content of air, dehumidifiers reduce the moisture from the air, making it dry. Dehumidifiers are generally installed in process-areas like pharmaceutical companies and drying equipment, where low humidity is required.
Can you estimate the loss occurring due to wastage of food due to fungal growth, moisture or mould formation?
Almost 30-40% of fresh fruits and vegetables produced are wasted due to decaying or fungal growth or decaying. It happens when proper storage facility is not provided. In India, only 2% food is processed from the total food production, the rest 98% is supplied in the market, out of which almost 48% is decayed. Whereas, in developed countries 70% of food produced is processed, which increases the shelf life of the food product.
There were instances when worms were found in a chocolate produced by a well-known company. What role can dehumidifiers play to avoid such happenings?
That instant might have triggered due to a number of reasons. If there is an external force of insects in the food product, they can multiply if proper conditions are not provided. Second, there could be a possibility of the growth of insects from within due to wet surface areas. The vendors must have lowered guards and hence the quality conditions must have been missed.
De-humidifiers play a role in creating hygienic conditions by absorbing water from the air.
India being an agricultural country, what can be the contribution of Bry- Air dehumidifiers to protect food grains from insects?
In India grains are stored at Central Warehousing Cooperation or in the open with a plastic covering. In this process the grains at the bottom get spoilt. Food Corporation of India estimates that loss to be around 3-5%. Worldwide, storage is done in silos. Dehumidifiers are installed on these silos. Silos can prevent losses that occur during drying (moisture loss results in weight loss and the farmers get paid for a lesser quantity), during transit as well as losses that occur when the stocks in the godowns become old.
What is the estimated cost to install a dehumidifier?
Well, that depends on the storage system. In warehouses the cost could be high due to the enormous storage required. If installed in silos the cost would be nominal.
Dehumidifiers installed on a silo of height up to 20-30 metres would cost less than Rs 2 lakh. The government should think of investing in silos by extending the initial costs as the results are far more profitable.
Which companies does Bry -Air dehumidifier cater to?
We cater to companies like Cadbury's Wrigley, Nestle, M&M and Perfetti. We have tie-ups with retail companies. In Assam dehumidifiers are installed in the tea plantation area, and would be soon installed in turmeric plantations. Dehumidifiers are also installed at spice processing centres in south India.
Give a brief on dehumidification process.
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