PROCESSING OF BESAN

INTRODUCTION

INDUSTRIAL OVERVIEW

• The edible seeds of plants in the family of legumes are pulses.

• Elven types of pulses are recognized by food and agriculture

organization (FAO): dry beans, dry large beans, dry peas,
chickpeas, cow peas, pigeon peas, lentils, Bambara beans,
vetches, lupines, and pulses.

• Dal is sometimes referred to as' lentils' but simply refers to a

split variant of a variety of lentils, peas, chickpeas, kidney
beans, etc.

• Sustainable agriculture is also supported by growing pulses, as

pulse crops help reduce greenhouse gases, improve soil quality
and use less water than other crops.
 INTRODUCTION

INDUSTRIAL OVERVIEW
TYPES OF PULSES

IMAGE ENGLISH NAME HINDI NAME

Pulses can be : Yellow split pigeon Arhar dal, Toor
 Split & Skinned peas dal, Tuvar dal
lentils Split & skinned green Moong dal, Mung
 Split Lentils gram, yellow lentils dal
 Whole Lentils &
Red lentils Lal masoor dal
Pulses

Split & skinned black

Urad dal
gram

Split Bengal gram lentil Chana dal

Green Gram, Mung Sabot moong, Hari

bean
moong dal
 INTRODUCTION
INDUSTRIAL OVERVIEW
TYPES OF PULSES
IMAGE ENGLISH NAME HINDI NAME

Black Gram Sabut urad dal, maaki dal

Indian Brown Lentils Kali Masoor

Horse Gram Kulthi

Chickpeas, Garbanzo beans Kabuli chana, Chole

Black chickpeas Kale chane

Red Kidney Beans Rajma

Black Eyed Peas Lobia, Chavle, Raungi

Sukhe safed matar,

Dried white peas
 INTRODUCTION

PRODUCT DESCRIPTION

• BESAN is a product obtained by grinding, dried and

decuticled Bengal Gram.

• It is yellowish in colour and possesses characteristic

Bengal gram taste and smell.

• Gram/Besan has a high percentage of carbohydrates, a

higher percentage of fibre than other pulses, no gluten,
and a higher percentage of protein than other pulses.

• Chickpea, chana or gram Besan, is widely used in India

and parts of the Mediterranean as well. It is also fine as a
thickener in various kinds of fries in curries and coatings.
 INTRODUCTION

PRODUCT DESCRIPTION

It is also used as a facial mask mixing with milk or yogurt

and turmeric, and is popular among young women in Asia.

This face mask has been shown to be effective as a skin

cleanser and whitening.

Besan is a very important ingredient, so it enjoys

continuous use throughout the year in Indian kitchens.
 INTRODUCTION

MARKET POTENTIAL

• The global demand for pulses is mainly driven by the growing consumption of different pulses and bakery products
in different regions.

• With an annual production volume of more than 5 million tons, Besan is a high potential market in India; that is, over
50 percent of the approximately 10 million tons of desi Chickpeas produced in India.

• Market demand for Besan is largely dependent on the freshness, consistency and fineness of the grinding process.

• In the Asia Pacific region, the demand for pulses is projected to rise at the highest CAGR in terms of both volume
and value between 2017 and 2022.

• With countries such as India, China, Australia, Japan, Myanmar, Thailand, the Philippines, and Malaysia contributing
to the high consumption of various food products produced using pulse ingredients, the region is the largest user of
pulses
 INTRODUCTION

RAW MATERIAL DESCRIPTION

• Basic raw material required in the proposed Besan unit is “split &
skinned Bengal Gram”.

• It is a product obtained through Bengal Gram grinding, drying and de-

cuticulating.

• Khesaru dal and other products are not supposed to be added in true
besan flour for colouring.

• The pulse proteins are lysine-rich and have low sulphur levels.

• Bengal gram collection and blending of various Bengal gram varieties

is a key factor in the development of the right quality and right price
besan
 INTRODUCTION

TYPES OF RAW MATERIAL

SL. VARIETY NAME YEAR OF RELEASE YIELD Q/HA

1 Pusa 408 1985 22-25

2 Gaurav 1983 20-24
3 GNG 146 1985 22-25
4 RSG 2 1984 16-20
5 Pusa 413 1985 18-80
6 Pusa 240 1985 18-20
7 Pusa 261 1985 20-22
8 Pusa 244 1985 20-22
9 Pusa 417 1985 20-22
10 JG 315 1984 15-18
 INTRODUCTION

TYPES OF RAW MATERIAL

SL. VARIETY NAME YEAR OF RELEASE YIELD Q/HA
12 Pusa 256 1985 20-23
13 Phule G 5 1986 20-22
14 Pusa 267 (Kabuli) 1988 20-25
15 H 82-2 (Haryana chana-1) 1990 20-22
16 GL 83119 (PBG-1) 1988 22-25
17 Pusa 329 1993 22-23
18 KPG 59 (Uday) 1992 20-22
19 PDG 84-10 - 18-20
20 w 39-2 - 20-22
21 ICCV-10 (Bharti) 1992 15-18
22 Pusa 372 1993 20-22
23 Pusa 362 - 23-24
PROCESS & MACHINERY REQUIREMENT

RAW MATERIAL ASPECTS

• There is a large amount of iron, sodium, selenium, and a

small amount of copper and manganese zinc in Bengal gram.

• They are a source of protein , folic acid, fibre, phytochemicals

that can serve as antioxidants, called saponins.

• There are two chickpea varieties: the larger light tan Kabuli
and the multi-colored Desi chickpea.

• When picked early, they are green and range from tan or
beige, speckled, dark brown to black.
 PROCESS & MACHINERY REQUIREMENT

SOURCES OF RAW MATERIAL

• Gram is the most significant pulse crop in India, commonly known as chick pea or Bengal gram.

• Fresh green leaves are used as vegetables, while chickpea straw is an outstanding cattle food.

• The principal gram-growing countries are India, Pakistan, Ethiopia, Burma and Turkey.

• With regard to production and acreage, India ranks first in the world, followed by Pakistan.

• In India, the main gram producing states are Madhya Pradesh, Rajasthan, Uttar Pradesh, Haryana,
Maharashtra and Punjab.

• Gram is classified into two classes on the basis of the size, color and shape of seeds: 1) Desi or
brown gram 2) Kabuli or white gram. Compared to the Desi gram, the yield capacity of kabuli is low.
PROCESS & MACHINERY REQUIREMENT

TECHNOLOGIES

SADDLE STONE

• Besan is made in rural areas and at home scale level in Atta chakki. Capacities of
such machines vary between 50-100 kg per hour.

• this would have been done by dehusking and then grinding the gram seed between
two stones, a lower, stationary stone called the quern stone, and an upper, mobile
stone called the hand stone.

• A saddle stone is a piece of hard stone that is cradle-shaped and carries the grains
or dal or seeds. The sandstone will have been either a cylindrical piece of stone or
a disc held in one hand with a vertical handle on its back (rather like an upside-
down mushroom).

• The dal joins the quern through a hole at the middle of the runner stone and
migrates when it is ground to the edge, emerging as a coarsen ground floor from
between the stones.
 PROCESS & MACHINERY REQUIREMENT

TECHNOLOGIES

MULTIPURPOSE PULSE AND GRAIN MILLS

• On top, the grinding chamber consists of a serrated ratchet liner and a

classification panel at the bottom.

• The feed material is manually passed through a hopper into the grinding
chamber. Depending on the desired fineness, the ground power is collected
in a way fitted below the screen.

• For small-scale industries or beginners, these Multipurpose Pulses and

Grains Mills are ideally suited
PROCESS & MACHINERY REQUIREMENT

TECHNOLOGIES

SCREEN LESS IMPACT PULVERIZER

• An enclosed rotor carrying swing hammers, a whizzer classifier for

fineness regulation and a pressure gradient creator mounted on a solid
shaft are the impact pulverizer.

• Raw material to be pulverized enters through the hopper or the automatic

rotary feeder into the crushing chamber.

• It is reduced to fine powder by the effect of the hammers on the feed

material on the liner plates.

• . In the system, a dust collector is provided to ensure less running of the

dust and no loss of ground powder.
 PROCESS & MACHINERY REQUIREMENT

MANUFACURING PROCESS
• THE PROCESS IS AS FOLLOWS:

 Pre Cleaning: - Eliminate broken grains, dirt, similar sized impurities, leaves and other impurities from Gram.

 De-stoning- Remove the pebbles and another small foreign particle from the Gram seed.

 De-husking- The process of removal of husk or outer layer from the cotyledons is called dehusking it is a necessary
process to improve the quality of the final product. The dehusking machine used for this process.

 Cleaning: After De-husking, the gram is taken to the cleaning section where the other layer is separated from the
seed through the aspirator.

 Grinding: Hulled grams are then fed to a Heavy-duty Pulverizer. this machine simply grinds these grams into a fine
powder.

 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.
 PROCESS & MACHINERY REQUIREMENT

FLOW CHART
STEPS MACHINE NAME DESCRIPTION MACHINE IMAGE.

Gram Delivery Unloading Bins These are large bins designed for unloading
of Grams & similar product; they are
equipped with large rod mess to prevent big
impurities from entering system.

Storage Storage Tank These Equipment are class of storage

Equipment which are specifically designed
for dry Dal or similar products (Raw material)
of small granule composition.

Pre- Cleaning Aspirator It’s a more fine-tuned separator designed to

remove finer impurities like remaining dirt,
 PROCESS & MACHINERY REQUIREMENT

FLOW CHART
STEPS MACHINE NAME DESCRIPTION MACHINE IMAGE.

De-stoning De-stoner Remove the pebbles and another small

foreign particle from the Gram seed.

Grinding Heavy-duty Pulverizer It’s a grinding class Machine, used for

grinding grams to a fine powder.

Sifting Sifter This machine used for screening,

sieving, grading Besan flour.

Packaging Automatic packaging It’s a simple packaging machine,

machine designed to fill the given food grade
plastic material’s continuous pouch with
required product after sealing one end &
after filling sealing the other end also.
 PROCESS & MACHINERY REQUIREMENT

ADDITIONAL MACHINE & EQUIPMENTS

MACHINE DEFINITION IMAGE

Disc Separator It’s a separator class machine,

generally used to remove foreign
grains from required grain
efficiently
Magnetic It’s a type of separator which is
Separator used to magnetic impurities from
given product using powerful
electromagnets, used in wide
range of industries for separation.
Food Grade These are conveyors with food
Conveyor grade belt to maintain food safety
 PROCESS & MACHINERY REQUIREMENT

GENERAL FAILURES & REMEDIES

General Failures Remedies

Ball bearing failure of various machine 1. Proper periodic lubrication of all bearings in various machines.
2. Regular replacement of all bearing to prevent critical failures.

Power Drive Overload 1. Ensure proper weighing & metering specially in case of semi-automatic plant.
2. Install warning sensor in buffer region of loading capacity to ensure efficient
operation.

Mechanical Key Failure 1. Ensure that mechanical keys are replaced as per there pre-defined operational life.
2. Prevent Overloading.

Loss of Interface 1. This problem is dominant in newly established automatic plant, one must learn to
maintain rules in plant & ensure no employee goes near transmission lines, unless
authorised.
2. Provide proper physical shielding for the connections.
Hulling 1. Gram has the whole- hull intact. Extra cleaning required for Gramm flour milling to sift
out the impurities (dirt, chaff, etc.)
 PROCESS & MACHINERY REQUIREMENT

NUTRITIONAL INFORMATION
NUTRITIONAL INFORMATION PER 100G BESAN NUTRITIONAL INFORMATION PER 100G BESAN

Minerals Quantity %DV+

Energy 1,619 kJ (387 kcal)

Carbohydrates 57 g Magnesiu 166 mg 47%

m
Sugars 10 g
Phosphor 318 mg 45%
Dietary Fiber 10 g
us
Potassium 846 mg 18%
Fat 6g
Selenium 8 ug 11%
Protein 22 g

Vitamins Quantity %DV+ Sodium 64 mg 4%

Niacin (B3) 1 mg 7% Zinc 2 mg 21%

Folate (B9) 437 ug 109%
Other Quantity

Minerals Quantity %DV+ Constitue

nts
Calcium 45 mg 5%
Water 10 g
Iron 4mg 31%
 PROCESS & MACHINERY REQUIREMENT

EXPORT POTENTIAL & SALES ASPECT

• India is the world's largest growing country, accounting for 61.65% of the world's
total gram area under Bengal during 2002 and 68.13% of the world's total output.

• It is a complement to cereal-based diets rich in protein, especially for the poor in

developing countries where people are vegetarians or are unable to afford animal
protein

• India has exported about 12,000 tons of besan worth Rs. 7800 lakhs in year 2015-
16 (APEDA) mainly to USA, UK, Australia, Kuwait, Canada, New Zealand, UAE,
Singapore, Saudi Arabia, Oman and other countries.
 OPPORTUNITIES FOR MICRO/UNORGANIZED ENTERPRISES

PM – FME SCHEME

Ministry of Food Processing Industries (MoFPI), in partnership with the States, has launched an all India centrally
sponsored "PM Formalisation of Micro Food Processing Enterprises Scheme (PM FME Scheme)" for providing
financial, technical and business support for up-gradation of existing micro food processing enterprises. The objectives
of the scheme are:

I. Support for capital investment for up-gradation and formalization with registration for GST, FSSAI hygiene standards
and Udyog Aadhar;

II. Capacity building through skill training, imparting technical knowledge on food safety, standards & hygiene and
quality improvement;

III. Hand holding support for preparation of DPR, availing bank loan and up-gradation;

IV. Support to Farmer Producer Organizations (FPOs), Self Help Groups (SHGs), producers cooperatives for capital
investment, common infrastructure and support branding and marketing
 For More details Contact:

National Institute of Food Technology and Entrepreneurship

and Management
Ministry of Food Processing Industries
Plot No. 97, Sector-56, HSIIDC, Industrial Estate, Kundli,
Sonipat, Haryana-131028

Website: http:[Link]

Email: pmfmecell@[Link]
Call: 0130-2281089