Projet on food plant design design of a dried basil leaves plant with the productivity of 2 tons:day

VIETNAM NATIONAL UNIVERSITY OF HO CHI MINH CITY HO CHI MINH CITY UNIVERSITY OF TECHNOLOGY OFFICE FOR INTERNATIONAL STUDY PROGRAMS FACULTY OF CHEMICAL ENGINEERING TP.HCM BK - OISP PROJET

VIETNAM NATIONAL UNIVERSITY OF HO CHI MINH CITY

HO CHI MINH CITY UNIVERSITY OF TECHNOLOGY

OFFICE FOR INTERNATIONAL STUDY PROGRAMS

FACULTY OF CHEMICAL ENGINEERING

TP.HCM

BK - OISP

PROJET ON FOOD PLANT DESIGN

DESIGN OF A DRIED BASIL LEAVES PLANT WITH THE PRODUCTIVITY OF 2 TONS/DAY

Student: Tran Hoang Khanh Linh - 1913960 Instructor: M.Sc Chau Tran Diem Ai

Ho Chi Minh City, 31" December 2022

Ho Chi Minh City,

Ho Chi Minh City,

From the bottom of my heart, I would like to extend my sincere gratitude to my supervisor, M Sc Chau Tran Diem Ai, for allowing me the chance to work under her guidance, as well as for the ongoing support and encouragement she has provided throughout this project on food plant design M Sc Ai gave me unrestricted support and enthusiastically offered me advice whenever I needed it

Additionally, I would like to express my gratitude to all of the professors at Ho Chi Minh City University of Technology, particularly those in the department of Food Technology, from whom I have benefited greatly throughout my studies

I am also appreciative of each and everyone of my project group mates and classmates from CC19HTP for their friendship, support, and the time we spent together Without the help of my family, I would not have been able to complete this project

I would like to thank them for their support I want to thank my parents for being there for

me through this project’s challenges and for their unwavering support

Without everyone’s assistance and encouragement, I doubt I could have accomplished these goals, I want to express my sincere gratitude and best wishes once more

HCMC, 31*t December 2022

Student Tran Hoang Khanh Linh

CHAPTER 1 TECHNICAL AND ECONOMIC FEASIBILITY STUDY seed

1.1 Analysis of feasibility of the food plant project a 1

1.2.9 Storage, transport and shelf life 10

CHAPTER 2 MATERIAL SELECTION 12

CHAPTER 3 PROCESS DESIGN 16

3.1 Process diagram of dried basil leaves production

CHAPTER 4 MASS BALANCE 27

CHAPTER 5 ESTIMA TION AND EQUIPMENT SELECTION 31

6.1.2 Selection of water tank and elevated wafer tanf -.-c«c sec

6.1.3 Selection of water pump

7.3 Inter diat storage

7.8 Finishing and packaging area

7.9 Locker rooms, clean rooms and technical room +0sssscssssssssssesesssessseoes CHAPTER 8 SAFETY REGULATIONS

8.1 Potential causes of accidents

8.2 Safety regulations

8.2.1 Working safety and hygiene

Figure 1.1 Annual production and area of vegetables (2015-2020) -~- 1 Figure 1.2 Illustration image of dried basil leaves primary packaging - - 9 tigure 1.3 Iilustration image of dried basil leaves secondary packaging 9 Figure 3.1 Dried basil leaves production diagram 16 Figure 3.2 Variation in moisture content of basil leaves with drying time for vacuum

Figure 5.2 Air bubble water spraying vegetable washing machine GGXQ3000 34 Figure 5.3 The steam blanching machine HLPT-003 0.0 ceeeeeeeeeeeeeeeeeeeeeeeeeeeeeeees 35

tigure 5.7 Vibrating herb sieving machine SY J-700 sàn re 40

Figure 5.9 Rotary bottle unscrambler JS-1-650 43 Figure 5.10 Automatic filling machine ZS-FAL 180P9 0.0 ceeeeeeecreeeeeeeeeeeeeees 44

tigure 5.14 Floor digital scale VX32XW2500Ì Á Ăn SH HH re 49 Figure 5.15 Belt conveyor Sanhok-Food Belt Conveyor l7 - «<cc<eceeeees 50

Figure 5.20 Automatic carton packaging machine FX]J-AT5050 54

Figure 7.3 Intermediate storage 1 design

Figure 7.5 Packaging materials storage design

Table 1.1 Nutrition facts of 100 grams of dried basil leaves

Table 1.2 The content of antioxidants in 100 grams of dried basil leaves 4 Table 1.3 Maximum contaminant levels in dried basil leaves -+5 4 Table 1.4 Some pesticides and maximum residue levels in dried basil leaves 5 Table 1.5 Microbiological quality of dried basil leaVes «s«cc+xs sex 5 Table 1.6 Toxicological quality of dried basil leaVes - «c«c<csecekseeeeeeeeees 6 Table 1.7 Chemical characteristic of dried basil leaves - c5 <+c+c+cecceeeee 6 Table 1.8 Physical characteristic of dried basil leaVes c-cĂ cà nie 6 Table 1.9 Analysis of My Tho Industrial Park 11 Table 2.1 Nutrition facts of 100 grams of fresh basil -ó «5c se eieeeirt 12 Table 2.2 Maximum limit of contaminants in fresh basil leaves 13 Table 2.3 Required standards for water using in dried basil leaves production 14

Table 3.2 Comparison between popular herb drying methods

Table 5.2 Air bubble water spraying vegetable washing machine GGXQ3000

Table 5.3 Stềam blanching machine HLPT-003 specifications <<<« 35 Table 5.4 Air cooling tunnel 2MP60 specificatiOns - -« cư, 37 Table 5.5 Vacuum dryer LG75 specifications 38 Table 5.6 Herb cutting machine specifications 40 Table 5.7 Vibrating herb sieving machine specIficatiOns -cc<cc+c<xeeeeeeee 41 Table 5.8 Separating cyclone EFLQ-001 specificatlons cc«cceceeeeerieet 42 Table 5.9 Rotary bottle unscrambler specifCatÍOTS s5 -ĂĂ+ se eeeieeee 43 Table 5.10 Automatic filling machine specIfÍCatONS -.- Ặ «Set 44

Table 5.12 Labelling machine specifications 46

Table 5.14 Digital scale specifications 49

Table 5.15 Belt conveyor Sanhok-Food Belt Conveyor 17 specifications 50

Table 5.L7 Screw conveyor ZS-FM2A šDecIfiCatiOIS -ccSĂSeseeeeret 52

Table 5.19 Date printer ZS-DC127 specificatiOIAS săn 33 Table 5.20 Automatic carton packaging machine FXJ-AT5050 specifications 54 Table 6.1 Summary of volume of cleaning water in each equipment in one day 56

Table 6.3 Water centrifugal pump 2005-95 specIfications « c se ceeeecee 59 Table 6.4 Water centrifugal pump 160WQ150-10-7.5 specifications 59

Table 6.8 Compressor 6HE — 28 specificatiONS -cc cành, 66 Table 6.9 Compressor 4EES — 4Y specifications 66 Table 6.10 Compressor 4CES — 6Y speciflCatiOIS -cSĂ cư 67

67

Table 6.11 Compressor 6FE — 44Y specifications

Table 6.12 Summary of electricity for operating equipmeIIL - 5<<<<<<<<<<+ 68

Table 6.14 Transformer S11-M-§00 specifications «cài, 72 Table 7.1 Summary of area needed for equipment and number of workers in preliminary

1.1 Analysis of feasibility of the food plant project

Inrecent years, Vietnam's vegetable production and area tend to increase steadily

over the years due to the high demand for a healthy lifestyle (shown in Figure 1.1)

With the advantages of favorable weather conditions, the Red River Delta becomes the

greatest vegetable production area (accounting for 29% of the country’s vegetable

production), while the Mekong Delta is the primary vegetable production area in

Vietnam (accounting for 23% of the country’s vegetable production) Along with the

expansion of the planting area, vegetable production in Vietnam increased from 15

million tons in 2015 to approximately 18 million tons in 2018 with an average growth

rate of 5% per year [1]

Annual production and area of vegetables (20 15-2020)

Figure 1.1 Annual production and area of vegetables (2015-2020)

Source: VietnamCredit During the COVID-19 pandemic when some people have to implement the social

distance policy or being locked down, they tend to purchase processed food including

processed vegetables especially herbs for a longer storage period Because of this,

consumers may have gradually changed their buying habits into buying processed

foodstuffs although the pandemic has been controlled On the other hand, due to busy

lifestyles, consumers consider processed fruit and vegetable products as a time-saving

solution that still has an additional source of energy for the body [2] According to

Global Market Insights (https://www.gminsights.com/), the global processed fruit and

2020 - 2027

However, Vietnam's total vegetable production quantity has been overproducing

recently leading to an overabundance of veggies that cannot be consumed in the

country According to the Vietnam Ministry of Agriculture and Rural Development,

Vietnam produces an average of 18 million tons of vegetables of all kinds per year, of

which domestic demand is only about 14 million tons, with 4 million tons remaining

for export (processed and fresh vegetable), or subtracting post-harvest losses and other

costs, other needs [3] Until now, Vietnam has total 31 million tons of vegetables, that

means the excess vegetable also increases

In May 2022, the Vice president of Vietnam Chamber of Commerce and

Industry (VCCI) said that Vietnam is the country with plenty of benefits in diversified

agricultural development Vietnam has made efforts in recent years to broaden export

markets for the fruit and vegetable sector The structure of fruit and vegetable exports

to the continents changes considerably in 2022, with a greater portion of fruit and

vegetable exports to Europe and America The value of vegetables and fruits exported

to the European market is predicted to reach 303 million USD in 2021, a growth of

17.4% over 2020 According to the General Department of Vietnam Customs, fruit and

vegetable exports to the United States climbed by nearly 70%; Australia increased by

45.7%, and the Netherlands increased by 51.5% in the first two months of 2022 This

is expected to create a shift in export markets, aiding the growth of Vietnam's fruit and

vegetable exports in the near future [4]

In particular, the Vice President of VCCI stated that after the period of lockdown

and social distance due to the COVID-19 pandemic, the demand for food products,

especially fruit and vegetable products in the countries of The European Union (EU) is

on the rise As a result, the EU's market potential and consumer demand for tropical

fruits and vegetables are growing, with fresh fruit and vegetable goods expanding by

15-20% every year and processed products increasing by more than 30% Nevertheless,

despite the fact that Vietnam's fruit and vegetable products are thought to have

numerous outstanding advantages, they have not taken advantage of the opportunities,

resulting in a relatively small market share in the EU, accounting for less than 1% of

vegetable processing factories; more than 76% of exported vegetables are fresh, while

the remaining is processed or post-harvest losses [6]

Conclusion: From all of the above, the project “Design a dried basil leaves plant

with a productivity of 2 tons/day” is feasible, with the aim is to handle the excess

vegetable and minimize the domestic post-harvest losses while improving the value of

exporting veggie commodities

1.2 Product design

1.2.1 Nutrition

As a spice, customers demand relatively small amounts of basil in their cooking,

this herb contributes few vitamins and minerals in typical diets Table 1.1 shows the

most notable nutrient content in 100 grams of dried basil leaves

Table 1.1 Nutrition facts of 100 grams of dried basil leaves

inflammatory and other health properties In addition, these compounds give basil its

“essence” — or distinct aroma and flavor Table 1.2 shows the content of some notable

antioxidants in 100 grams of dried basil leaves

Table 1.2 The content of antioxidants in 100 grams of dried basil leaves

The project aims to design the plant focusing on export to the EU market so the

food safety should follow the EU or Global Standards and Maximum Levels

Maximum levels for certain contaminant in dried basil leaves

This follows The Commission Regulation (EC) No 1881/2006 and The

Commission Regulation (EU) 2015/1933

Table 1.3 Maximum contaminant levels in dried basil leaves

Benzo(a)pyrene pg/kg wet weight 10.0

Pesticide residues and maximum residue levels

This follows The Commission Regulation (EC) No 149/2008, The

Commission Regulation (EC) No 839/2008 and The Commission Regulation

(Eu) No 2015/868

The most notable pesticide residues that Vietnam must be aware of is

Ethylene Oxide with the maximum residue level is 0.02mg/kg

Microbiological and toxicological quality

This follows The Commission Recommendation 2004/24/EC

Table 1.5 Microbiological quality of dried basil leaves

Standard characteristic of dried basil leaves

Physical and chemical characteristics of dried basil leaves follow CODEX

Jowlw

max Crushed/Rubbed

/Flaked Table 1.8 Physical characteristic of dried basil leaves

Dead Visible Foreign whole

Common matter? insects,

Style matter! damage

max /100g

max max

Insect Other Live Mammalian

Basil Crushed/Rubbed/Flaked excreta

leaves, % mg/kg | count/100 mg/kg max

w/w, max max g (max)

accepted as part of the final product

? Any visible objectionable foreign detectable matter or material not usually associated with

the natural components of the spice plant; such as sticks, stones, burlap bagging, metal etc

3 Excreta from other animals such as reptiles and birds

N/A: Not applicable, means that this form of the above product has not been evaluated for

this provision, and currently we do not have values N/A does not refer to zero

1.2.3 Sensory properties

1.2.5

Appearance: small pieces of dried basil leaves, <Šmm long and wide

Taste: sweet and savory taste profile with peppery and minty undertones

Aroma: slightly sweet aroma of a mixed scent of pepper and mint

Flavor: more intense flavor than the fresh one

Texture: stronger than fresh one, rough texture

Color: nearly the same color as fresh one, a little darker green

Moisture content: 12%

Level of technology

Intermediate technology

Combining automatic and manual operation

Production line is performed under the supervision and control of labor force in

the factory

An automated technology called automated storage and retrieval system

(AS/RS) combined with warehouse execution system (WES) or warehouse

management system (WMS) can be applied for distributing raw materials and

product and planning for future supply chain strategies more efficiently

Convenience for using

People around the world, especially the European people, are working away from

their home more and more and have busy social lives Moreover, the number of single

households increases Less time is left for the preparation of a full meal and, as a result,

demand for products requiring extensive preparation has declined, while the

opportunities for easy-to-prepare, semi-prepared, catered and processed products are

More specifically for spices and herbs, this development had led to an increasing need

to supply a wide range of ready-to-use spice mixes and herb mixes, as well as

seasonings Promotion of spice mixtures and ready-to-use sauce mixes by the food

industry has made meal preparation simple and quick New varieties of sauces, aromatic

tablets, bottled marinades, and spiced mustards have grown in popularity

1.2.6 Productivity

As previously stated, Vietnam may have around 6 million tons of excess

vegetables Assume that 6 million tons are exported, with processed products

accounting for 24% of the total Every year, around 1.44 million tons of processed

vegetable products are exported and 12% of it is dried herbs [6] That means nearly 173

thousand tons of dried herbs is produced We should enhance productivity to satisfy the

needs of Vietnam's most promising export market, the EU market The dried basil

leaves plant is designed to have a productivity of 2 tons/day and contributes around

0.35% to total exported dried herb products

1.2.7 Packaging

Since dried basil leaves are usually used for seasoning, it is recommended that

at most 2-3 teaspoons of them should be used in a recipe (approximately 8 grams for

one recipe) As a result, the plant only produces the 100g-bottle with the daily product

quantity is 20.000 bottles/day or 400 boxes/day

Primary packaging: cylindrical PET bottle with Scm-diameter and 15cm-

height (included lid)

Secondary packaging: carton box with 25cm-length, 25cm-width and 30cm-

height

Figure 1.3 Ilustration image of dried basil leaves secondary packaging

1.2.8 Labelling

Designing a label is a blend of detail and creativity Think about all of the

components needed on the label before you start designing the label Also, consider

packaging layout and size This will be important for determining what goes where and

how much space you have for the design Then get creative on how you want to make

your package stand out on the grocery store shelves

Requirements for a Food Label:

e Statement of Identity or standard product name

e Net Quantity of Contents statement

e Nutrition Facts Panel

1.2.9 Storage, transport and shelf life

e Storage condition: kept in a cool and dry place, avoid direct sunlight, store at

room temperature

Transport: Factory > Other businesses/Wholesale store/ Supermarket/ Market/

Grocery store/ Convenient store/ Mini-mart > Customers

e Shelf life: 1-2 years

1.2.10 Site and location

My Tho Industrial Park in Tien Giang Province is considered to be the most

suitable place for constructing dried basil leaves plant in the next 10 years After

determining the most important factors (Table 9), we choose the South region of

Vietnam as the main market and we figure that this area is potential market for high

consumption of our product Moreover, the wide range of material sources is quite near

the plant, which is also from Tien Giang The infrastructure is also one of the most

important factors and we recognize that the energy cost is relatively high, so it could be

a challenging point for us to consider if we want to launch our factory there Based on

the short distance from the material sources to our plant and the market, this place is

above all for transport system In addition, our plant is right in the rural area of Ho Chi

Minh city, which labor resource is plentiful supply of cheap labor

Priority industries to receive investment: Food Processing, Sea Food Processing,

Cattle Food Production

Infrastructure:

©

Transportation system:

Internal traffic system: 16m-wide road, 3m middle tree line, 15m

sidewalk tree line on both sides, 4 lanes

Electric supplying system: Currently using 110/220V electricity networks

Water supplying system: Supplied by Tien Giang Water Supply and

Sewerage Company

Wastewater treatment system:

Factory standard: Microbiological treatment reaches column A TCVN 40:

2011/BTNMT with maximum treatment capacity: 3500 m3/day

Telecommunications system:

Internet: VNPT and Viettel

Fire protection system: Fire hydrants are installed along the roads in the

industrial park, each pole is 150m away

2.1 Fresh basil

In Vietnam, basil is one of the fresh green herb cultivated throughout the country

all year round In the South, basil is mainly grown in the Mekong Delta due to favorable

weather and highly-skilled farmers Their harvest time is considered to be fast, around

3-4 weeks to have a bunch of fresh basils Basil is easy to plant and has its own

characteristic aroma, which is suitable for seasoning for stir-fries, steaming foods,

sauces or served with familiar dishes of Vietnamese people like pho, noodles

Basil leaves are collected from the farmers in Tien Giang province since their

cultivation area and production quantity accounts for the largest proportion in Mekong

Delta, also the farmers have high intermediate farming techniques The following

properties is the sensory properties and also the input material requirements

e Appearance: glossy green and 2-4 inches long No sign of decay

e Taste: sweet and savory taste profile with peppery and minty undertones

e Aroma: slightly sweet aroma of a mixed scent of pepper and mint

e¢ Moisture content: around 90%

e Storage condition:

© Keep in cool storage with the temperature 10-12°C [7]

o Storage relative humidity: 90-92% [8] (controlled by automatic mist

nozzle system to avoid water loss in basil)

o Must have the air circulation system to reduce the CO2 concentration [9]

o Avoid the direct sunlight

o Contained in perforated rectangular plastic basket (45-50kg/basket)

Basil not only adds flavor to meals, but its nutrients may also provide health

benefits Along with antioxidant phenols, basil is also a good source of antioxidant

vitamins A, C and E and mineral such as iron

Table 2.1 Nutrition facts of 100 grams of fresh basil

Before entering the factory, food safety standards are required in order to meet

the best quality of the final product According to National Standard TCVN

9006:2011, the sample will be taken right at the time of harvest Moreover, The

QA/QC personnel must receive, preserve and treat the sample for the safety tests

within 24 hours after harvested including contaminants detection such as heavy

metals, pesticide residues, mycotoxins, plant growth stimulant

During the testing, the materials are being delivered to the factory and then stored

in 2-3 days to wait for the testing results If the results are satisfied, the material are

allowed to be received by the factory and being processed On the contrary, they

will be discharged and handled by a third party

The quality standard for fresh basil follows Vietnam Decision No 46/2007 / QD-

BYT, which is shown in Table 2.2

Table 2.2 Maximum limit of contaminants in fresh basil leaves

Total aerobic microorganisms

Cl perfringens Limited by G.A.P

Maximum limit of mycotoxins in fresh basil leaves

2.2 Water

Water is used for basil washing to get rid of impurities, dirt and other inorganic

compounds, steam generation and cooling Standard water is used for washing basil,

generating steam, heat exchanger in the plant The standard is followed by QCVN

Gross B activity pCi/liter 30

3.1 Process diagram of dried basil leaves production

Jnsieve

L nsieved

4 mesh basil

Figure 3.1 Dried basil leaves production diagram

3.2.1 Sorting

& Technological purpose: Preparation

To remove the disqualified basil such as damaged, decay brown or yellow basil

in order to reduce the risk of final product spoilage and prolong the shelf life

“+ Methods: manual, using the belt conveyor

Reason: Human senses work better than any sorting machines with low errors

and high accuracy, but the speed is limited

“+ Technological requirements: Belt conveyor speed: Im/s

“+ Requirements:

The fresh basil must meet the following sensory characteristics:

e Appearance: fresh, glossy green and 2-4 inches long No sign of decay or

damaged

e Taste: sweet and savory taste profile with peppery and minty undertones

e Aroma: slightly sweet aroma of a mixed scent of pepper and mint

3.2.2 Washing

“+ Technological purpose: Preparation

To remove impurities from the ingredients, these ingredients can be inorganic

substances got in the harvesting, e.g sand, metal, glass or post-harvest

pesticides residue These impurities are especially harmful to human health as it

can cause a variety of diseases, moreover, it can also impede the quality of the

ingredients in the following process

+ Methods: using fruit and vegetable washer, washing by clean water, no chemical

tweatment

[Reason Although there are other washing methods such as saltwater washing, _ Commented [LT1]: Nguyên lý máy rửa

chlorine water washing , clean water is preferred due to its relative high safety

and do not leave chemical residues which can affect human health or the final

products quality such as flavor However, using clean water may not get rid of

all the contaminants

oe

%

the water meets the water quality requirements for food processing Spray

pressure is from 1.5 - 2atm

Technological requirement:

e Raw materials after washing should not be damaged and right amount of

rinsing water is used (ratio of raw material and water: 3:1)

e Washing water must meet the requirements of hygiene and hardness

degree (no more than 2mg equivalent/liter) and the amount of chlorine

remaining in the rinse water is from 3 — 5 mg/l

e Soaking time should not be extended too long

oe

% Technological purpose: Preservation, Improvement

Preservation: To inactivate the enzymes in basil with the major enzyme is

polyphenol oxidase (PPO) [10] and some other enzymes (pectinase, oxidase,

chlorophyllase .) [11, 12] which can affect the sensory qualities including color _Commented [LT2]: Inactivation temperature: 75, 65, 85

(chlorophyl degradation, oxidation, [browning effects, ), texture and structure,

and the shelf life of the materials (kill some microorganism) in the following

processes This step can help to prolong the shelf life of the final product

Improvement: Due to the inactivation of enzymes, the color of the material can

be improved In this case, blanched basil remains greener than unblanched one

by the deaeration, enzymatic inactivation and immediately stop the blanching

process by chilled air (or shocking process) to preserve the flavor, the food color

and the texture

Methods: using blancher-cooler machine (steam blanching — air cooling)

Reason: According to the results of P.J.Fellows, Table 13 shows the percentage

loss of ascorbic acid in peas and broccoli in four different blanching-cooling

Commented [LT3]: Browning in fruits and vegetables

is caused mainly by the enzyme PPO, which in the presence of oxygen catalyzes the oxidation of o- diphenols to o-quinones Brown pigments are produced _ by the polymerization of o-quinones

Steam blanch — water cool 24.2 22.2

From the above results, we can clearly see that the treatment “Steam

blanch — Air cool” has the lowest percentage loss of ascorbic acid in both peas

and broccoli compared to the remaining For that reason, steam blanching — air

cooling is chosen to be operated

“+ Technological parameter: The blanching process is at 100°C, total blanching

time: 20s (preheating: 15s, blanching: 5s) ; and the air cooling process is at 2°C,

total cooling time: 20s (precool: 10s, cooling: 10s)

e The volume of the material reduces due to the steam penetration

e© The material becomes softer and more fluid

o This is due to the fact that the cell membrane inside lose their shape This happens when the fatty acid tails of the phospholipids become less rigid and allow more movement of other molecules in and through the membrane

e Loss in nutritional value

o Since the methods is steam blanching, at high temperature, the cell membranes become loose and spaces begin to appear between the phospholipids, some water-soluble components such as vitamins and minerals can be lost because of the steam penetration, water condensation and diffusion

e Minor diffusion of some volatile compounds which can minimally Commented [LT4]: Trong thai gian chan 20s, hiện tượng

khuếch tần tỉnh dâu trong lá vẫn có thê xảy ra nhưng không reduce the product aroma dang ke, giữ được hương của nguyên liệu

Đa số đọc các ref, aroma bị mất đáng kể khi chan trên 3p

Chemical: Thanh phan tinh dau chính có trong basil 14 eugenol, linalool

: : và eucalyptol, các thành phân đó có nhiệt độ bay hơi cao hơn

e Some thermolabile compounds are broken down at high temperature: 1000C

oxidized at high temperature resulting the loss in nutritional value

o The pigments such as chlorophyll can be degraded if the temperature is not high enough to inactivate the chlorophyllase, and carotenoids can also be broken down but it is just minor in short time

Physico-chemical:

e There could be some other transformation such as protein denaturation,

starch gelatinization but they are minor and do not affect the quality of

the product

Biological:

e The microorganism is inactivated or killed due to high temperature, c d [LTB]: Flavobacterium, Sphi

Ancinetobacter, Pseudomonas, Citrobacter

which cause the DNA denaturation and some enzymes in their cells

Ref:

https://w ww.researchgate.net/publication/28 1207228 _Charac

terization_of_the_Bacterial_Community_Naturally_Present_ on_Commercially_Grown_Basil_Leaves_Evaluation_of_Sa

| Techniques

e Some common bacteria: Flavobacterium, Sphingobacterium,

Biochemical:

e The material enzymes are inactivated during the blanching process

(polyphenol oxidase, pectinase, peroxidase )

«* Material transformation in cooling: JAI the reactions and transformation will

be stopped due the temperature shock _ Commented [LT6]: 1 lớp lá, tốc độ bang tải là Im/s

“+ Materials are shrunk when suddenly cooled

“+ Technological purpose: Exploitation, Processing, Preservation

‘The vacuum drying process removes a part of water in the basil Commented [LT7]: Thành phần tỉnh dầu chính có trong

_ basil 1 eugencl, methy] eugenol, linalool và eucalyptol

Exploitation:

Therefore, the content of nutrients contained in a unit weight of the dried product

will increase

such as in physical (volume, shape, texture, density) and physico-chemical

properties (phase changing)

Preservation: The vacuum drying process decreases the water activity inside

the raw material, therefore help to inactivate enzymes and microorganism to

prolong the shelf life

Improvement: The vacuum drying process at low temperature eliminates

oxygens during the operation and provide less heat so it can prevent the|oxidation

of the pigments and volatile components jin the raw materials providing better

product sensory quality (color and aroma)

Reason: There are plenty of drying methods for basil, but only some of them are

chosen to be compared and evaluated which is shown in Table 3.2

Table 3.2 Comparison between popular herb drying methods

{ Commented [LT8]: Oxi cé thể thúc day quá trình oxi hóa

các hợp chất tỉnh dầu có trong basil (eugenol, methyl eugenol, linalool, eucalyptol) nhưng vi sây chân không nên

chúng không bị oxi hóa mà chỉ có thé bị khuéch tán theo hơi

nước và thất thoát ra ngoài

Do say ở nhiệt độ thập (45oC) sẽ khó gây ra phản ứng phân hủy ở các hợp chất sắc c tố như chlorophyl va carotenoids, cũng như các vitamins khác như vitamin C, A, E, K, giữ được màu Cũng như là khó có thể xảy ra oxidation vì ở mt chân không nói trên

Ci d [LT9]: Reading most of the scientific papers,

Drying methods Advantages Disadvantages References

e Noenergy e Long drying time consumption (>24h)

e Low operation e High oxidation and

e Huge loss in volatile compounds and vitamins

e Discoloration occurs

e Moderate energy |e High chance of Oven-drying consumption oxidation and 1141 [15]

(high temperature) |e Low operation components

f Commented [LT10]: Ko ding say bth boi vi can limit the

oxygen content, to reduce the oxidation and degradation of the nutrients and pigments To obtain a better product quality

Static drying in vacuum dryer is commen and efficient The suitable parameters are also researched and concluded in many scientific papers

Hot water: reduce the power consumption instead of using

resistor, and water can be circulated and reuse for other

Purposes, therefore save energy

Low chance of consumption

oxidation and Huge loss in [15], [16],

degradation volatile compounds [17]

Can keep the (for blanched green color of the material) material

Moderate Moderate drying operation cost time (2-5h) Moderate energy

Vacuum drying consumption [14], [17]

Low chance of

degradation

¢ Moderate volatile compounds content

e Can keep the green color of the material

e Based on Table 3.2, we can conclude that vacuum drying is the most suitable

and economical methods for basil leaves

“+ Technological parameter: 45°C, 700mmHg of vacuum, Im/s vacuum rate,

4h10 drying time

Explanation:

The initial moisture content of fresh basil is 80,68% (wet basis), then after

blanching, the moisture of blanched basil is 82,35% (wet basis) or 466,67% (dry

Figure 3.2 Variation in moisture content of basil leaves with drying time

for vacuum drying at 45°C [14]

to 13,64% (dry basis), the drying time is around 250 minutes or 4 hour

and 10 minutes

The water content that needs to evaporate for 13496,6kg blanched basil:

10789,6kg (Chapter 4) > we need to evaporate 1598,9kg water for

2000kg blanched basil in one vacuum dryer

The evaporation speed: = 6,4kg water/min

The evaporation speed per drying area (75m7/vacuum dryer): sa =

During the drying process, a thermal gradient will appear in the material

The temperature will increase at the surface of the material and will

decrease at the center

Moisture diffusion will occur due to moisture difference in different areas

within the material During the isothermal drying phase, the water

molecules in the core of the material will move to the boundary

The volume of the material decreases, density increases

The material texture becomes shrunk and more brittle

Because of the some thermolabile vitamins, the nutritional value of the

material may slightly decrease at the temperature 45°C

Physico-chemical:

The water inside the material changes from liquid phase to vapor phase

Some volatile compounds may be lost during vacuum drying process

which can change and lose the characteristic aroma of the product

Ci d [L711]: Maillard reaction is minor since it

occurs at low temperature

Hydrolysis of triglycerides into glycerol and fatty acids But _ it cannot have the oxidation since vacuum

e When the moisture content reduces, the water activity inside the materials

becomes low This can cause the inactivation of the microorganism and

its metabolism on the material which helps prolong the product shelf life

3.2.5 Cutting

“+ Technological purpose: Preparation

To reduce the size of the products and prepare for the sieving step

** Methods: using Herb Cutting Machine

** Technological requirement: the cutting size of the basil should range from 0.4-

10mm

+ Material transformatfion:

Physical: the cut material reduces in size

3.2.6 Sieving

“+ Technological purpose: Improvement

The materials is being homogenized in size so that consumer can have the best

product experience

+ Methods: using Vibrating Screen Machine

“+ Technological requirement: the final product should be smaller than 5mm

“+ Material transformation: No major transformation is occurred during this

process

3.2.7 Separating

“+ Technological purpose: Improvement

The material is being separated by cyclone based on the density difference and

centrifugal force in order to obtain only dried basil leaves while the dried basil

stems are discharged and being handled or consumed by a third party

“+ Technological purpose: Improvement

“+ Technological requirement: the final product should be properly dried and

tested for heavy metal contamination before packaging to prolong the shelf life

“+ Material transformation: No major transformation is occurred during this

process

4.1 Mass balance summary for process

0,1 0,5

Moss = 1% Mpresh basil

Mraw basil = Myresh basil + Moss Maw basit = 13419,2 kg

Mfreshbasit = 13285 kg 4.3 Washing

Fresh basil Washed basil

Loss of

product: 0,5%

Calculation: