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Trainers Manual
Trainers Manual Drying in a Biomass Dryer, TIDE, Bangalore, India, May 2008
CONTENTS
Module 0:
Welcome
Module 1:
Introduction to drying
Module 2:
10
Module 3:
Biomass Dryer
15
Module 4:
17
Module 5:
21
Module 6:
26
Module 7:
30
Module 8:
39
Module 9:
Maintaining Data
44
Module 10:
48
Module 11:
54
Module 12:
57
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Trainers Manual Drying in a Biomass Dryer, TIDE, Bangalore, India, May 2008
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Trainers Manual Drying in a Biomass Dryer, TIDE, Bangalore, India, May 2008
Handouts
These are materials that provide details or explanations of the contents of each module
and will be distributed to the participants of the training. This means that the content
should be adapted to the educational level of the participants. Worksheets are also
provided that can be used in the practical exercises. The trainer should have sufficient
number of copies of the handouts, so that every participant gets a copy.
Global set-up of the training day
Each day of the training course (except the first day) begins with a recap session. The
recap includes checking the extent of dryness of product that the participants would have
put out to dry in the open, a short warming up activity (like a song/game) and a recap of
the content of the previous days sessions.
The recap can be in the form of simple presentations by the participants or in the form of
simple games. E.g. Memory game- Participants should stand in a circle. One of them
begins by saying one thing that she learnt the previous day. The participant standing next
to her repeats what the first participant said and adds one thing that she learnt. The next
participant repeats what the first two said and adds one thing that she learnt. In this way
all the participants would repeat what was learnt the previous day and enjoy themselves
at the same time.
Then the new topics will be treated, both theoretically and practically.
At the end of the day an evaluation of the day is carried out: what went well, what went
wrong, what could be improved, what was not well understood. A method to do this is
appointing every day a person, who is the ears and another one who is the eyes for
that day. These two people start with their comments, others might add. This is important
for the trainer: He/she can adjust the training program for the following day/days
accordingly.
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Trainers Manual Drying in a Biomass Dryer, TIDE, Bangalore, India, May 2008
Module 0
Welcome
Purpose: This module is designed to set the tone of the training programme. The programme
should be interactive and highly participatory. Therefore this session plays an important role in
making the participants feel comfortable with the trainer(s) and with each other.
Objectives:
Duration: 50 minutes
Materials:
Trainers Preparation:
Ensure that the training hall has adequate number of chairs and tables, has enough open
space for group activities, has free wall space to stick charts, posters. Ensure that all
required equipment, like computer, LCD projector, etc are available in working
condition. These preparations have to done the previous day itself.
Keep adequate number of cards and coloured pens ready for making identity cards. Also
prepare enough copies of the training schedule for all the participants. Notebooks and
pens for each participant should be bought.
Contents:
1. Welcome
10 minutes
Welcoming is not new for you, as you do it almost everyday when guests come to your
home. You should start the training session in the same way. Give a genuine welcoming
smile; greet the participants with a Namaskar (or the appropriate local word) and
gesture. Introduce yourself and the programme. While introducing the programme,
mention the duration and session timings. Please emphasise that the programme must be
participatory.
You could mention that it would not be necessary to put down rules for the programme,
(like being on time etc) as, being adults, they would have the sense of responsibility to
maintain all forms of discipline and decorum required in a training programme.
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Trainers Manual Drying in a Biomass Dryer, TIDE, Bangalore, India, May 2008
If the training is a residential course, the name and contact details of the person in case
of any problems/ emergencies should be mentioned. This can even be written down on
the board, for the participants to note down.
2. Expectations
20 minutes
Ask the participants what they expect from the programme. As each participant answers,
write the points down on a flip chart. Try to use the same words as the participants. If
you feel you have to rephrase what has been said, take the permission of the participants
and then write it down. E.g. If a participant says, We will learn about the drying, you
could ask, Can I write it as we will learn how to use the dryer?
Please note to write the points in clear, legible handwriting.
Use capital letters to write, if using English.
Explain the content of the training programme and compare it with the flip chart contents.
If you will not deal with some of the things the participants expect, explain this. See if
you can add training sections that do deal with the expectations. But you dont have to
deal with everything the participants ask.
Emphasise once more that the expectations would be successfully met only if there is
good participation and interaction from all he participants.
3. Name Game
10 minutes
It is very important that a feeling of community is established, and that there is some
laughing in the early phases of the training. A name game will be fun and nice for
warming-up. The trainees, likewise, will get a feel for the tone of the atmosphere that the
trainer wants to set. There are different 'warming up' activities/ ice breakers with which
one could start. An example is:
Ask the participants to organise themselves into pairs. Each person introduces herself to her
partner and tells her any one good thing about herself. Give the pairs about 5 minutes to do
this. Each person then introduces her partner and mentions the good thing to the others.
4. Identity cards
10 minutes
Give each person a card and ask her to write down her name on it. Ask her to make the
identity card as interesting as possible, but ensure that the name is clearly visible. The
identity card should then be pinned on by all the participants.
The hand out giving the programme content is distributed and explained briefly to the
participants, to make the duration of training each day, the timings of sessions and
breaks clear. The importance of being present and on time for every session should be
emphasised.
The session ends with a round of applause for a good session.
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Trainers Manual Drying in a Biomass Dryer, TIDE, Bangalore, India, May 2008
10-10.50
10.50
11-12
-11
Introduction to
Day 1 Welcome
T
drying
E
A
10-10.30
10.3011.30
Venue:
12-1
Spread
product to
dry in the
sun
11.45
L
U
N
C
H
11.30
11.45
T
11.45-1
Exercise:
identifying parts
of dryer and
their functions
11.45
Day 2 Recap of
previous
day
Parts of
biomass
dryer,
functions
Day 3 Recap of
previous
day
Steps for
drying in
a biomass
dryer
Selecting and
preparing fresh
products for
drying
Storing and
packing
Products
E
A
Quiz on dryer
operation, data.
-6-
1.45-2.45
Drying
options
for microenterprise
1.45-2.45
2.453
T
E
A
2.45
-3
3-4
Record sun
drying
procedure,
data
3-4
Blank
operation of
dryer with
different
fuels
Drying
process
How the
biomass
dryer works
Maintenance
and trouble
shooting
In a
Blank
operation of
dryer:
Spreading on
trays,
interchanging
trays.
Cleanliness
and hygiene
Dryer
Feedback
Trainers Manual Drying in a Biomass Dryer, TIDE, Bangalore, India, May 2008
Module 1
Introduction to drying
Purpose: This module explains the what and why of drying foods and the advantages of
drying.
Objectives:
Participants explain why food products are preserved and methods of food
preservation
Understanding how drying is a method of food preservation
The advantages of drying foods
Foods that can be dried
How drying is different from cooking
Duration: 60 minutes
Materials:
Markers
Board
Duster
Flip chart
Samples of fresh and dried products to compare their mass, colour, texture and to
demonstrate their shelf lives.
Notebooks
Pens
Handout 1.1: About drying
Trainers Preparation:
Arrange the flipchart in the training hall. Procure 2-3 food products in their fresh and
dried forms and display them on a table. Get enough copies of the handout for
distribution to each participant.
Contents:
10 minutes
Most women would know about preserving food, since it is a part of housekeeping.
Guide a discussion on why food is preserved, what preservation means, different
methods of preservation. Explain that in a large country like India where horticulture is
prevalent in remote locations, and where cold storage facilities are inadequate and
transport infrastructure deficient, a lot of horticultural produce is lost at the farm level.
Therefore when conditions are not suitable for storage or immediate marketing of fresh
produce, many horticultural crops and other food can be processed at the farm level
using simple technologies. Drying must be mentioned as a method of preservation
among others like pickling, salting, making jams, jellies and sauces, canning, freezing,
juicing etc.
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Trainers Manual Drying in a Biomass Dryer, TIDE, Bangalore, India, May 2008
30 minutes
Explain why dried foods keep well. Ask the participants to give you the reasons, and
explain them as they are mentioned. From this you can go on to explain what drying is
and what are the main requirements for drying. Show them samples of fresh and dried
foods and ask them to enumerate the differences between them. This way they would
understand the advantages of drying products. You could add some facts about drying
like nutritive value if you feel the participants would be interested to know it.
Please read the Reference guide for information on the above aspects.
Drying = Removal of moisture from the food + removal of moisture filled air from
near the food.
Advantages of drying:
Moisture is low; hence do not get spoilt by growth of microorganisms.
Foods can be preserved for long time
Take up less storage space than fresh foods
Dried foods add taste and variety to meals
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Trainers Manual Drying in a Biomass Dryer, TIDE, Bangalore, India, May 2008
Drying = Removal of moisture from the food + removal of moisture filled air from
near the food.
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Trainers Manual Drying in a Biomass Dryer, TIDE, Bangalore, India, May 2008
Advantages of drying:
Moisture is low, hence products do not get spoilt by growth of micro-organisms.
Foods can be preserved for long time
Take up less storage space than fresh foods
Dried foods add taste and variety to meals
Are convenient to use
What you should know about drying:
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Trainers Manual Drying in a Biomass Dryer, TIDE, Bangalore, India, May 2008
Module 2
Drying options for a Micro-enterprise
Purpose:
This module introduces the participants to the features of various methods of drying so
that they can compare the methods and understand why biomass fired dryers are best
suited for them to run a micro-enterprise. Practical exercise in sun drying would be
effective in understanding the advantages of using a dryer.
Objectives:
_ To know the various ways in which foods can be dried
_ Understanding how drying in a dryer is better than drying in the open
_ To understand why biomass dryers are preferable to other dryers for a
Micro-enterprise
Trainers preparation:
Collect and keep ready all the materials required for drying a product in the sun. Have pictures of
various dryers as a slide show for projection. Get sufficient copies of the handouts made for
distribution.
Contents:
1. Spreading product to dry in open
60 minutes
In order that the participants have hands on demonstration to compare open drying with drying in
a dryer, an exercise has to be conducted, where the participants spread a fresh product out to dry
in the sun. The activity must be organised before it is taken up. Keep all the materials required
fresh product, mat, vessel, water, colander, salt, soap, towels, white cloth, gloves- in the room
during the break. Discuss the method to be followed for open sun drying. Most participants will
be familiar with sun drying. Hence, you can ask the participants to collect the materials that they
require. Then, get all the participants to work as a team to spread it out to dry. Also, allot the
- -
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Trainers Manual Drying in a Biomass Dryer, TIDE, Bangalore, India, May 2008
responsibilities to the participants in turns to monitor the drying, storing it at the end of the day
and putting it out the next morning.
2. Methods of drying
30 minutes
Ask the participants why food is preserved, what methods of food preservation they know.
You can add methods if they do not cover all the methods. After explaining about food
preservation you can come to drying and ask about the drying methods they know. There is no
need to explain each method in great detail, as most of it is meant only as information.
Pictures of various methods are on slides, which can be shown. Each picture can be explained
briefly. You can discuss with the participants about the open sun drying that they have started,
and ask them to estimate the time that it will take for the product to get dried.
3. Advantages of drying in a dryer
15 minutes
Since most of the participants will be familiar with drying in the open sun, you can ask them what
drying in the sun involves, whether they face any problems while drying, quality of the dried
product. After all the points are covered, you should be able to conclude that open sun drying is
not suitable for a micro-enterprise. You can then introduce the alternate to open sun drying as
drying in dryers, and get the participants to enumerate the advantages of using a dryer.
4. Biomass dryers vs other dryers for micro-enterprises
15 minutes
After establishing that it is preferable to use dryers if a micro-enterprise has to be developed in
dried products, a suitable dryer has to be chosen. The three commonly used dryers- electric, solar
and biomass dryers can be compared using a chart. Each point can be discussed and explained. At
the end of this session, it should be clear why a biomass dryer would be best suited for the
participants.
5. Recording the sun drying process
60 minutes
As a part of the drying, the participants should record the process they followed to dry the product
in the sun. This is not only required to compare sun drying with drying in a dryer, but also to
introduce data maintenance to the participants. However, this aspect need not be mentioned at this
point, but can be cited in the relevant module. The information can be recorded in a chart that can
be displayed in the training room and filled up every day.
Give the format to the participants as a handout, so that they can fill it up. (Handout 2.2)
- -
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Trainers Manual Drying in a Biomass Dryer, TIDE, Bangalore, India, May 2008
Solar dryers
Electric dryers- uses electricity to heat the air to dry the food
- -
13
Trainers Manual Drying in a Biomass Dryer, TIDE, Bangalore, India, May 2008
Biomass dryers- uses biomass like twigs, dried agricultural waste (like coconut shells, areca husk,
coconut waste) to heat the air in the dryer to dry the food.
4
5
Characteristic
Energy to heat
air
Energy cost
Solar dryer
Suns heat
Electric dryer
Electricity
Availability of
energy
Usage
Temperature in
the dryer
Capacities of
dryers
Depends on weather
and intensity of sun
Usually designed
for 5 kg per batch,
but can be deigned
for higher capacity
per batch.
Control normally
not required since
does not reach very
high temperatures
Highest
Electricity is
expensive
For a few hours
each day
Only when
electricity is
supplied at 220 V
Can go upto 120o C
Control of
temperature
Cost of dryer
for a microenterprise
Emissions
Only on cloudless,
sunny days
No emissions
Biomass dryer
Biomass like twigs/
agricultural residues
Cost of biomass is low.
Available in plenty
Can be used on all days,
including during
monsoon
Can be raised upto
100oC
Range from 25 kg- 1
tonne per batch
Can be controlled
by thermostat.
Can be controlled by
controlling the quantity
of biomass burnt.
Same as biomass
dryer
No emissions
Combustion gases
released into
atmosphere
The biomass dryer is ideal as the fuel for it is available, is cheaper than electricity, it can
be used on all days, including rainy days.
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14
Trainers Manual Drying in a Biomass Dryer, TIDE, Bangalore, India, May 2008
Handout 2.2
Worksheet- Record of open sun drying
A. Name of product spread to dry:
B. Date when spread out to dry:
C. Time left in the open sun:
Day 1
Day 2
Time of
spreading (a)
Time of taking
it indoors (b)
Difference (c)
(hours) (a-b)
Day 3
Day 4
Day 5
Day 6
hours
- -
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Trainers Manual, Drying in a Biomass Dryer, TIDE, Bangalore, India, May 2008
Module 3
Biomass Dryer
Purpose:
The purpose of this module is to show the participants each part of the dryer and explain
their function. It is important for the participants to know this so that they will understand
the working of the dryer, its maintenance and how to troubleshoot minor problems.
Objectives:
Markers
Board
Duster
Flip chart with table on dryer parts and their functions
Pictures of dryer parts and functions
A Biomass Dryer
Notebooks
Pens
Handout 3.1: Parts of a dryer
Handout 3.2: Worksheet to identify dryer parts
Trainers preparation:
Ensure that the dryer is installed and is in working condition. Keep the pictures of the
dryer parts ready, so that they can be shown on the screen during the exercise. The
computer and LCD projector should be available. Sufficient copies of handouts should
be got so that they can be distributed to al he participants.
Contents:
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18
Trainers Manual, Drying in a Biomass Dryer, TIDE, Bangalore, India, May 2008
Handout 3.1
PARTS OF A DRYER
1. Combustion chamber: This is a box-like structure
where the fuel is burnt. It is usually present at the
bottom at the left side of the dryer. It consists of a
grate on which the fuel is placed and burnt. The
combustion chamber has a door that should be
kept closed when the dryer is in operation. The
grate inside the combustion chamber allows air to
circulate in the chamber, so that the fuel burns
well.
- -
19
Trainers Manual, Drying in a Biomass Dryer, TIDE, Bangalore, India, May 2008
runners, on which trays are arranged. The ducting, gravel and moisture vent are located
inside the dryer chamber. The air circulating inside the dryer chamber comes in contact
with the hot ducting, and becomes hot. This hot air passes over the food to be dried and
removes the moisture from it. The moist air then goes out of the moisture vent.
5. Trays: The number of trays in a dryer depend on its capacity. The trays in a cabinet dryer
are arranged in two columns. Each column has one
stack of 10 trays in front and another stack of 10 trays
towards the back of the dryer chamber. The size of the
trays in a 100 kg, 40- tray capacity dryer is 2ftx3ft .
Wood slats or stainless steel screen mesh are the best
materials to use for the trays. Stainless steel mesh does
not rust over time. Each tray has a wooden frame, with
stainless steel mesh fixed within this frame It is not
advisable to use solid metal trays or paper sheets to dry
food because air must circulate all around the food so
that drying can take place from the bottom and the top
at the same time. The wood that is used should be of
good quality that will not burn, crack or warp with high temperatures.
- -
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Trainers Manual, Drying in a Biomass Dryer, TIDE, Bangalore, India, May 2008
10. Dryer doors: The dryer has double doors made of steel with insulation. The doors are
kept closed during the drying process. If the doors are left open during drying, there will
be a loss of heat and the quality of drying will be bad and will take a very long time.
- -
21
Trainers Manual, Drying in a Biomass Dryer, TIDE, Bangalore, India, May 2008
Handout 3.2
Worksheet: Identifying the parts of a Biomass Dryer
Instruction: Look at the picture being shown. Identify the part and write it in column 2
against the picture number. Write the function in column 3
Column 1
Picture No.
1
Column 2
Name of the part
Column 3
Function of the part
2
3
4
5
6
7
8
9
10
11
12
- -
22
Trainers Manual Drying in a Biomass Dryer, TIDE, Bangalore, India, May 2008
Module 4
Markers
Board
Duster
A Biomass Dryer
Different fuels commonly used- coconut waste, coconut shells, twigs
Matches
Charts depicting flow charts on working of the dryer
Notebooks
Pens
Handout 4.1: How does a dryer work
Handout 4.2: Worksheet to note down observations during blank run of the dryer.
Trainers preparation:
Collect 2-3 kg of each kind of fuel that would normally be used in the dryer in the
region. E.g. in Kerala coconut waste and shell would be used, in southern Karnataka
areca husk, coconut shell, coconut waste are the most common fuels. Put up the charts
on the wall. Get sufficient copies of the handouts for distribution.
Contents:
1. Demonstration and practice of firing the dryer using various fuels 60 minutes
This session should be conducted in/ near the shed of the dryer. The fuels that are
available locally should be gathered and stocked. The fuels that can be used in the dryer
should be displayed. A brief interaction about fuels should be followed by the
participants identifying each fuel. The participants should then burn each of them in the
combustion chamber of the dryer. You must teach them
- How to weigh the fuel before loading into the combustion chamber,
- How to place the fuel in the chamber, how much of fuel should be loaded,
- The effects of closing and keeping the door open of the combustion chamber,
- The effects of stuffing fuel into the combustion chamber.
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Trainers Manual Drying in a Biomass Dryer, TIDE, Bangalore, India, May 2008
Where does the heat (hot gasses) from the fire in the combustion chamber go?
Why is it sent into the ducting and not sent into the dryer chamber directly?
How does the air in the dryer chamber become hot?
What does the hot air in the dryer chamber do?
24
Trainers Manual Drying in a Biomass Dryer, TIDE, Bangalore, India, May 2008
25
Trainers Manual Drying in a Biomass Dryer, TIDE, Bangalore, India, May 2008
Handout 4.1
26
Trainers Manual Drying in a Biomass Dryer, TIDE, Bangalore, India, May 2008
Handout 4.2
Worksheet: Observations during blank firing of dryer
Activity
E.g.Burnt 2 kg coconut
husk
Time
2 pm
Dryer part
Combustion chamber
Observation
Burns with strong flame
Measured temperature of
ducting
2.15
Ducting
Ducting temperature is
50oC
27
Trainers Manual Drying in a Biomass Dryer, TIDE, Bangalore, India, May 2008
Module 5
The drying process
Purpose: The purpose of this module is to teach the participants how to dry products in a
biomass dryer.
Objectives:
Trainers preparation:
Ensure that the LCD projector and computer are available in the training hall. Load the
slide show into the computer. Keep all the other materials like pens, chart paper and
handout ready.
Contents:
1. Slide show on drying process
50 minutes
By means of a slide show, explain the 4 main steps involved in the drying process:
Selecting the fresh product of the right quality for drying
Preparing the fresh product for drying
Drying to correct moisture level
Packing and storing the dried product.
10 minutes
Draw a simple drawing to show the steps of drying, based on the inputs given by the participants.
Thus, the participants would have repeated the steps a number of times that will help them to
remember the steps. The same can be filled up in the worksheet in Handout 5.2
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Trainers Manual Drying in a Biomass Dryer, TIDE, Bangalore, India, May 2008
Handout 5.1
The Drying Process
The time taken for drying depends on the size of the fresh product, the amount of moisture that it
contains and the density of the fresh product. This is familiar to most of you, who have dried
many products in the sun. Many of the principles for drying in the dryer are the same as for
drying in the sun.
The drying process consists of four major steps. These are:
1. Choosing the fresh product of the desired quality for drying
2. Preparing the fresh product for drying: Cutting it to appropriate uniform size and pretreatment of the fresh product
3. Drying to appropriate moisture level
4. Packing and storing dried product.
Each step has sub steps.
You must remember that THERE IS NO SHORT CUT TO A SAFE AND SUCCESSFUL
DRYING PROCESS.
1. Selecting the fresh product for drying: Keep the following points in mind while choosing the
fresh product to be dried.
The fresh products for drying should be free from injury and disease.
It should have its characteristic colour, flavour and texture. Eg. Tomatoes should
be ripe and red, prawn should be medium sized, greyish and translucent with
intact head and tail.
Inferior produce will not make a satisfactory dried product.
Drying does not improve the quality. So, if the food is not perfect for eating, it is
not suitable for drying.
Drying should begin immediately after harvesting.
2. Preparing the food for drying:
The preparation consists of 3 activities:
Washing with clean water (i.e. water that you use for cooking) to remove mud/
sand, other impurities.
Cutting it to the correct and same size. (The recommended correct size is given in
handout 6.2). The time that is taken to dry depends on its size. Moisture is lost
faster if more area is exposed to heat. Same size is important because all the
pieces will dry to the same moisture level.
Pre-treatment of food. Pre-treatment of fresh product: Although you can dry and
store many foods without pretreatment, pretreatment generally improves quality.
Five major reasons for treating foods before drying are to
1. Preserve colour and flavour
2. Minimize nutrient loss
3. Stop decomposition
4. Ensure more even drying
5. Extend storage life
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Trainers Manual Drying in a Biomass Dryer, TIDE, Bangalore, India, May 2008
3. Drying:
Do not interrupt the drying process too often. Interrupting the drying process may
cause mould or spoilage.
Change trays as often as required to ensure uniform drying. The intervals for
changing the trays can vary for different products. However, it is advisable to change
trays every 2 hours for most products. It is necessary to change trays at regular
intervals, as the middle trays are exposed to lower heat as compared to the top and
bottom trays.
Most products scorch easily toward the end of drying. Therefore, its best to stop
firing the dryer when drying is almost complete and open the door wide for an
additional hour before removing pieces.
Remove a small handful of food and cool for a few minutes before testing for
dryness. Foods that are warm or hot seem softer, more moist, and more pliable than
they will when cooled. Foods should be dry enough to prevent microbial growth and
subsequent spoilage.
30
Trainers Manual Drying in a Biomass Dryer, TIDE, Bangalore, India, May 2008
food, pretreatment step, and date. Labels may be pasted on the outside of a package, or inserted
into a clear glass or plastic package.
Some guidelines for storing dried foods are
The recommended storage time at room temperature is 2-4 months and 6-12 months
under refrigeration.
Because vegetable quality is affected by heat, a lower storage temperature helps
extend the length of storage; the higher the temperature, the shorter the storage time.
An ideal storage area for dried food is cool, dark, and dry. The cooler the storage
area, the longer the shelf life.
Glass or plastic containers can be covered with a cardboard box, a barrel, or black
plastic to keep light out.
Check products occasionally to ensure that moisture has not been reabsorbed. If this
happens, reheat the food to 65 C for 15 minutes, then cool and reseal. If there is any
sign of spoilage (off-colour or mould growth), discard the food.
31
Trainers Manual Drying in a Biomass Dryer, TIDE, Bangalore, India, May 2008
Handout 5.2
Chart on drying steps
Please fill up the steps of drying explained to you.
Store/pack
Wash in
clean
water
Preparetrim/peel
Cool
Unload after
an hour
Pre-treatment
Interchange
trays every
2 hours
Pre heat
dryer
Dry at
50-60oC
Load
trays into
dryer
32
Trainers Manual, Drying in a Biomass Dryer, TIDE, Bangalore, India, May 2008
Module 6
Preparing the fresh product for drying
Purpose:
This module will serve to explain to the participants the significance of selecting
the right quality of fresh product for drying. The methods of preparing the fresh
product and why they are necessary will be explained.
Objective:
To learn and practice the first two steps of the drying process viz. selection and
preparation of fresh products for drying- washing cutting and pre-treatment.
Duration: 75 minutes
Materials:
Markers
Board
Duster
5 kg of fresh product that will be taken up for drying
Clean running water
Vessels, colander
Peelers, knives, grater
Cutting board
Appropriate pre-treatment material ( sugar/salt/honey)
Notebooks
Pens
Handout 6.1: Size and pre-treatment chart for some fresh products. This would serve
as information, in case the participants want to try out drying and selling other products.
Handout 6.2: Worksheet to note the procedure followed.
Trainers Preparation:
Collect all vessels and implements and place in the dryer shed. The pre-treatment materials
should also be kept ready. About 5 kg of fresh product that the participants would be drying in
future should be procured for the practice session.
Contents:
1. Practice to select and prepare a fresh product for drying
40 minutes
In this module, the participants should learn by practice to select the right quality fresh product, to
cut it to the right size and to follow the correct pre-treatment procedure for the product. Get about
5 kg of the fresh product that is available locally and that can be dried. It is preferable that the
product is one that the participants will be drying and selling in the immediate future. The
participants should be shown the fresh product that is suitable for drying and asked to select
similar quality from the procured lot. The washing, trimming, peeling and cutting should be
demonstrated and then each of the participants should be asked to perform all these activities.
Please ensure that there is no wastage during trimming and peeling of the fresh product. Also,
make the participants practice cutting to uniform size.
2. Practice pre-treatment procedure:
35 minutes
Make the participants do the pre-treatment of the fresh product. In case a product does not have
any pre-treatment, the participants can practice selection, cutting to uniform size or other
preparation activities. If
33
Trainers Manual, Drying in a Biomass Dryer, TIDE, Bangalore, India, May 2008
cutting is also not required (e.g. prawn, fish, areca), you can skip this module and continue with
Module 7.
3. The Handout 6.2 can be used for recap, during which the participants can speak out the
information, while you write it on the board. If the participants are comfortable with writing, you
could ask them to fill up the worksheet and then discuss it in the class.
34
Trainers Manual, Drying in a Biomass Dryer, TIDE, Bangalore, India, May 2008
Handout 6.1
Recommended size and pre-treatment methods for different products
Product Size for drying Pre-treatment method
Product
Small flat fish
Pre-treatment method
Dip in salt water for 15
minutes
Prawn
Whole
None
Areca
Coconut
Whole nut
Husked, split into half
Cooking as usual
None
Banana
Jackfruit
Syrup blanch
Pineapple
Mango
Syrup blanch
Papaya
Onions
None
Potatoes
Ginger
none
Garlic
Separate pods
None
Bitter gourd
Fruits
Vegetables
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Trainers Manual, Drying in a Biomass Dryer, TIDE, Bangalore, India, May 2008
Handout 6.2
Worksheet
Preparing fresh product for drying
Please complete the following to show the procedure for preparation of the fresh product
for drying.
Name of fresh product:
1. Selection of the fresh product:
Colour:
Size:
Feel:
2. Preparation
i. Washing
ii.
iii.
iv. Cutting- Size of pieces:
3. Pre-treatment
i. Pre-treatment method:
ii. Material used:
iii. Quantity of material
iv. How used:
How much time does it take to pre-treat the fresh product?
36
Trainers Manual, Drying in a Biomass Dryer, TIDE, Bangalore, India, May 2008
Module 7
Purpose:
Objective:
To learn and practice the third step in the drying process- operation of the dryer.
37
Trainers Manual, Drying in a Biomass Dryer, TIDE, Bangalore, India, May 2008
4.
5.
6.
7.
8.
of the product.
Spreading the fresh product on the trays: Spread the fresh product to be dried on each tray.
Please take care to ensure that products do not touch each other, as this will lead to badly
dried products.
Loading trays: Load each tray on which the fresh product has been spread into the dryer. The
trays should be loaded first into the back of the dryer. Since the dryer chamber will be hot, it
is advisable to wear gloves while loading the trays into the dryer to avoid getting burns.
Measuring and maintaining temperature: The temperature in the thermometer should be
recorded every hour to check that the correct temperature is being maintained. In case the
temperature falls below the required temperature, some fuel has to be added in the
combustion chamber. This will increase the burning and the temperature will go up. The fuel
has to be added gradually and not at one go, so that the rise in temperature can be controlled.
In case the thermometer reading is higher than the required temperature for drying, remove
some fuel from the combustion chamber, until the thermometer indicates the correct
temperature. Towards the end of the drying process the food can scorch easily, so it requires
extra care. The temperature should be regulated carefully at this stage. Frequent temperature
measurement is called for at this stage.
Inter-changing trays during drying: This is a very important operation in the drying process.
Products will be uniformly dried if the trays are changed regularly. This is required because
The air is hotter at the top and bottom than the middle of the dryer chamber. So, products on
the trays at the top and bottom will dry faster than those on trays in the middle. Hence, trays
have to be inter-changed every 2 hours, to ensure uniform drying. Inter-charging the trays
should be done in a systematic manner, so that all the trays are exposed to the varying
temperatures. The middle trays should be moved to the top and bottom, while the top and
bottom trays should be moved to the middle. Care should also be taken to move the trays at
the back to the front and vice versa. This process has to be continued until the end of drying.
Unloading trays: The temperature in the dryer should be checked every hour. After drying is
complete, leave the product in the dryer for about an hour and then remove the trays one by
one form the dryer. Before unloading the trays, ensure that there is a clean and dry place
where the trays can be placed. Remove the dried product with a clean spatula/ spoon and
store in airtight containers. Avoid touching the dried product with the hands, as it can
contaminate the product with germs. After all the trays are unloaded and the dried product
stored, place the trays back into the dryer after cleaning them with a cloth.
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Trainers Manual, Drying in a Biomass Dryer, TIDE, Bangalore, India, May 2008
Handout 7.1
Drying in a dryer
Drying in a biomass dryer involves the following steps:
1. Clean the trays
2. Feed fuel
3. Fire the empty dryer
4. Spread the fresh product on the trays
5. Load trays
6. Measure and maintain temperature
7. Inter-change trays during drying
8. Unload trays
9. Remove the dried product for packing and storage
10. Clean and stack trays.
Each of these steps s explained below:
1. Clean the trays: Remove all the trays from the dryer and stack them up. Please either
wash the trays or clean them with a damp cloth before each use.
2. Feed fuel: Fuel is loaded and ignited in the combustion chamber. The fuel should be dry,
to make burning more efficient. Place the fuel on the grate. Do not overfill the combustion
chamber with fuel. Ensure that there is space for air circulation inside the combustion
chamber. Initially add fuel little by little, until the desired temperature is reached inside the
dryer chamber. Once the desired temperature is reached, stop feeding the fuel. If too much
fuel is added, the temperature inside the dryer will go up. If the quantity of fuel is too little,
the dryer will not heat up to the required temperature and drying will not take place properly.
In biomass dryers temperature control is only by managing the fuel feeding rate. It is
necessary to check the temperature every hour, and feed fuel to maintain the correct drying
temperature. Keep the door of the combustion chamber closed while the dryer is being fired.
3. Fire the empty dryer: Start firing the empty dryer, so that all microbes that maybe present
in the dryer, are killed before the product gets loaded. This will prevent contamination of the
product.
4. Spread the fresh product on the trays: Spread
the product to be dried on each tray. Please take
care to ensure that fresh products do not touch
each other, as this will lead to badly dried
products.
39
Trainers Manual, Drying in a Biomass Dryer, TIDE, Bangalore, India, May 2008
In case the thermometer reading is higher than the required temperature for drying, remove
some fuel from the combustion chamber, until the thermometer indicates the correct
temperature. Towards the end of the drying process the food can scorch easily, so it requires
extra care. The temperature should be regulated carefully at this stage. Frequent temperature
measurement is called for at this stage.
7. Inter-change trays during drying: This is a very
important operation in the drying process.
Products will be uniformly dried if the
trays are
changed regularly. This is
required because the air is hotter at the top and
bottom than the middle of
the dryer
chamber. So, products on the trays at the
top and bottom will dry faster than those
on trays
in the middle. Hence, trays have
to be inter- changed every 2-4 hours, to ensure
uniform drying. Inter-charging the trays should be done in
a systematic manner, so
that all the trays are
exposed to the varying temperatures. The middle trays should be
moved to the top and bottom, while the top and bottom trays should be moved to the
middle. Care should also be taken to move the trays at the back to the front and vice
versa. This process has to be continued until the end of drying.
8. Unload trays: The temperature in the dryer should be checked every hour. After drying is
complete, leave the product in the dryer for about an hour and then remove the trays one
by one form the dryer. Before unloading the trays, ensure that there is a clean and dry
place where the trays can be placed.
9. Remove dried product for packing and storage: Remove the dried product with a clean
spatula/ spoon and pack in plastic bags. Seal the bags and store in airtight containers.
Avoid touching the dried product with the hands, as it can contaminate the product with
germs.
10. Clean and stack trays: After all the dried product is packed and stored, clean the trays
with clean water, wipe with a clean cloth and stack them carefully for next use.
40
Trainers Manual, Drying in a Biomass Dryer, TIDE, Bangalore, India, May 2008
1. Handout 7.2
How trays should be interchanged
Trays should be interchanged during drying, so that the products on all the trays dry to the same
level. The time interval for changing the tray will be different for different products. For areca
and coconuts it is sufficient if the trays are changed once in 4 hours. For prawns and fish, they
should be changed every two hours. The time is indicative and the women must use their
judgment.
41
Trainers Manual, Drying in a Biomass Dryer, TIDE, Bangalore, India, May 2008
After another two- four hours, the trays are again interchanged, where the trays that were moved
to the front middle are moved to the back top and bottom and the back middle trays are moved to
the front top and bottom. The same process should be done for the second column.
You can see that the middle trays are moved to the top and bottom, and the trays that are at the
top and bottom move to the middle. This is because the temperature is higher in the middle than
at the top and bottom. By moving the trays as shown in these pictures, the products on all the
trays will be dried to the same level.
The trays should be interchanged in this way after every two-four hours until the end of the
drying.
42
Trainers Manual, Drying in a Biomass Dryer, TIDE, Bangalore, India, May 2008
Handout 7.3
Guidelines for drying temperatures, time and dryness tests for a few products
Product
Temperature for
drying
60 oC
60oC
Drying time
8-10 hours
8 hours
Crisp
Colour should be
pinkish
Arecanuts
With outer husk
70-75oC
24 hours
65oC
18 hours
Coconuts
50-60oC
Flexible
Crisp
Banana
50-60oC
Pliable
Jackfruit
50-60oC
8-12 hours
Pliable
Pineapple
50-60oC
24-36 hours
Mango
50-60oC
8-12 hours
Shrunk
Papaya
50-60oC
8-12 hours
Pliable, leathery
Onions
50-60oC
8-10 hours
Potatoes
50-60oC
8-12 hours
Crisp
Ginger
50-60oC
12 hours
Brittle
Garlic
50-60oC
6-8 hours
Brittle
Bitter gourd
50-60oC
8 hours
Crisp
Small fish
Prawns
Vegetables
43
Module 8
Maintaining Data
Purpose: Maintaining data is an important aspect of an small business, but is also the one that is
given last priority. This module explains the importance of maintaining data and stresses the need
to spend sometime everyday in recording necessary data. Formats for maintaining data are
suggested.
Objective:
1. Participants understand the need to collect and administrate data
2. Participants learn which data to record and why.
Duration: 60 minutes
Materials:
Board
Markers
Duster
Sample formats for data
Notebooks
Pens
Handout 8.1: Maintaining data of drying along with sample formats.
Handout 8.2: Data collection forms (can be photocopied for use by the participants)
Preparation:
Write down examples to show the consequences to the business when no data were collected and
registered, Prepare formats of data to write on the board. Keep examples of data like stock, drying
data ready to explain the entries.
Content:
1. Why are data important?
10 minutes
After explaining what are data, ask the participants if they maintain any data in their homes or
have seen someone (mother/ father/ husband) recording expenses of the household or expenses of
a family function or if they have seen their childrens school report cards. Ask them why such
information was recorded and what information they got when they read the data. You could then
ask what would have happened if they had not had this data. Thus, the importance of data for any
activity for anybody- be it children, for family, household, business or agriculture- can be
understood.
10 minutes
Please explain how recording the data of dryer operations will help in understanding the
efficiency of the dryer, rectification/ improvement in processes, working out the cost of drying to
work out profits from drying.
40 minutes
Write the various data that have to be recorded and explain what the use of that data is with
examples using sample formats for the data.
44
Handout 8.1
Maintaining data on drying
At any point of time, the quantity and value available of any material would be
known, if the stock register is maintained correctly.
Maintaining the stock registers helps to plan operations.
Stock registers should be maintained separately for each material. E.g. there should
be one section for fresh material, one for dried product, one for each of the
processing material and another for fuel and a separate one for packing material.
A sample of a stock register with an example is given below.
Stock register of fresh material
Date
Quantity of
material procured
(kgs)
12/12/2007
150
13/12/2007
75
Quantity
used
(B)
100
100
Balance in stock
(kg/units)
50
(50 + 75 -100)
=25
Data for processes: Data for the following processes should be maintained:
45
2. Preparation of Fresh product- weight of fresh product in a batch and the weight of the
batch after cleaning has to be recorded. The format that can be used is:
Date
Weight of
fresh product
(A)
Quantity of
pre-treatment
Duration of pre-treatment
Weight of
fresh
product
Time
Of loading
in the
dryer
C
Of
unloading
dried
product
D
Time
taken
for
drying
(D-C)
Weight
of dried
product
Yield
(%)
Weight of
fuel used
E x100
B
46
Yield:
Yield is a very important figure, which you can get from the above data collected in the
various processes. This will help you to find out how much profit is possible in drying the
product.
This is how you can find out the yield of drying:
Weight after drying
_____________________ X 100.
Weight of fresh product
The yield is expressed for every 100 kg/numbers. This value shows the weight of dried
product that will be obtained if 100 kg of fresh product is loaded into the dryer.
Eg. In the table below, the yield of areca is 33%. This indicates that if 100 kg of
fresh areca is loaded into the dryer for drying, after drying, the weight of dried
areca will be 33 kg.
The yield of a few products is given in Table 4 below:
Table 4: Yield of a few products after drying
Product
Yield (%)
Low fat sea fish
20
Prawn
20
Areca
33
Coconut
100 coconuts yield 12
kg
copra
(dried
coconut)
Fruits
Banana
16
Jackfruit
20
Pineapple
15
Vegetables
Onions
12
Potatoes
15
Ginger
20
Garlic
30
47
Handout 8.2
Data Collection Forms
Stock Register for fresh product.
Date
Quantity of material
procured
(kgs)
Quantity used
(B)
Balance in stock
(kg/units)
48
Process data
Weight after
preparation of fresh
product (washing,
peeling/trimming)
(B)
Difference in weight
(A-B)
49
2. Pre-treatment
Date
Quantity of pre-treatment
Duration of pre-treatment
50
3. Drying
Date
Weight of
fresh
product
Time
Of loading
in the
dryer
C
Of
unloading
dried
product
D
Time
taken
for
drying
(D-C)
Weight
of dried
product
Yield
(%)
Weight of
fuel used
E x100
B
51
Module 9
Packing and Storing
Purpose:
This module would explain the concept of shelf life of food products and also the role and
importance of packing and storing in the maintenance of quality and shelf life of food products.
The kind of packing that dried products require as well as how they should be handled and stored
will be explained.
Objectives:
1. Participants understand what is shelf life
2. Participants understand the importance of packaging of products
3. Participants learn how dried products should be handled, packed and stored.
Duration: 75 minutes
Materials:
Markers
Board
Duster
Plastic bags for packing
Labels
Glass/ Plastic containers of capacities of 1kg, 5 kg
Notebooks
Pens
Handout 9.1: About shelf life, packing and storing
Handout 9.2: worksheet- to design a packet for a dried product.
Preparation:
Procure food grade plastic bags of 50 microns thickness of different sizes that are ideal for
packing food products. Zip pouches of different sizes can also be procured to show to the
participants. Plastic packing of other food products can be brought to show the participants the
thickness of the bag, the information that is given on the packing. For storage, plastic containers
of 1 kg, 5 kg capacities can be shown.
Contents:
1. What is shelf life?
20 minutes
Give a definition of shelf life and why it is important to know about it. Use examples to explain
shelf life.
2. Importance of packaging
25 minutes
Explain how packing and storing food products protect these food products from moisture, light,
microorganisms and pests. You can ask the participants to enumerate the reasons why packing is
important and add those that they have left out.
30 minutes
Show the plastic bags that are good for packing dried products. They are good because they keep
out moisture. Re-sealable zip bags are also useful as packaging. The various sizes of plastic bags
should be shown. Retail sales would require smaller size packing, while wholesale or packing for
storage would require large sized plastic bags. Dried products placed in sealed plastic bags should
52
be kept in airtight glass/plastic containers. Show these containers and explain why they should be
stored in them.
Divide the participants into groups of 4. Distribute the Handout 9.2 and tell each group to design a
packet for retail selling of their dried product. They can work on this and show their design on the
last day. They would have to give the reasons for their design.
53
Handout 9.1
Shelf Life, packing and storing dried products.
Shelf life
Shelf life is the length of time a product may be stored without becoming unsuitable for use or
consumption.
Shelf life is influenced by several factors: exposure to light and heat, type of packing, presence
of gases (including humidity), and contamination by as micro-organisms.
Shelf life is critical to health. Foods left unused too long will often get infected by bacteria and
become dangerous to eat. Food poisoning is the result, and can lead to death.
Bottles
Containers
Plastic bag
Government regulations specify that food products should be packed in plastic 50 micron in
thickness.
For packaging food products, recycled plastic - which could be toxic and carcinogenic in
nature - is prohibited and should not be used.
54
Each package should be labeled with the type of food, pretreatment step, and date, best before
date. Labels may be taped on the outside of a package, tied on with string, or inserted into a
clear glass or plastic package.
Storage
Some guidelines for storing dried foods are
The recommended storage time at room temperature (about 25oC) is 2-4 months and 6-12
months under refrigeration (< 4o C).
An ideal storage area for dried food is cool, dark, and dry. The cooler the storage area,
the longer the shelf life.
Many people store dried foods in the refrigerator or freezer, which keeps quality high.
Three materials- glass, plastics, and metal (but not galvanized steel) are used for storing
most dried foods.
During storage at room temperature, the most common type of spoilage is mould growth.
Moulds can grow in foods that are not completely dry and in foods that absorb water when
they are packaged or stored in moist conditions. If there is any sign of spoilage (off-colour or
mould growth), the food must be discarded.
Some times, stored dried food starts turning brown. This means that the product is poor in
quality and should be discarded.
The dried products should be checked occasionally to ensure that moisture has not been
reabsorbed. If this happens, the food should be reheated to 150 F for 15 minutes, then cooled
and resealed.
55
Handout 9.2
Worksheet: Design a packet for your dried product
(Take a look at a few packets of food products that are displayed here to get an idea of what
information to display and how to display it.)
1. Choose the material you will use for retail packing of your dried product- plastic/
glass/ stainless steel.
2. Choose the package- bag/zip bag/ box/ bottle/ container
3. Make a label for the product
You will have to include the following information in the label:
i.
Batch no.
ii.
Date of manufacture:
iii.
Best before:
iv.
Net Weight:
v.
Ingredients:
vi.
vii.
Price:
56
Module 10
Maintenance of and Trouble shooting of the Biomass dryer
Purpose: Any equipment requires maintenance so that it works efficiently and effectively. The
maintenance that the dryer requires will be explained to the participants in this module. As the
parts of the dryer have been explained earlier, the participants will be taught how they can
identify and rectify minor problems during drying.
Objective:
1. Participants learn the maintenance routines for the dryer
2. Participants learn to identify reasons for minor problems with the working of the dryer and
methods to rectify them.
Duration: 60 minutes
Materials:
Board
Markers
Duster
Biomass Dryer
Poster on maintenance
Notebooks
Pens
Handout 10.1: Maintenance
Handout 10.2: Trouble shooting.
Handout 10.3: Worksheet to note problems and solutions during hands-on practice of drying
Preparation:
Have sufficient examples of appliances/equipment, vehicle and their maintenance routines to
explain what the importance of maintenance is. Display a poster on Maintenance to use to explain
the maintenance routines.
Content:
1. Why is maintenance important?
10 minutes
Participants would be familiar with some appliance/equipment/vehicle, which they have seen or
used. You can ask them Do you maintain any of the equipment you have at home? Which ones?
Why?
Servicing vehicles, plastering the stoves with cow dung/ cement, etc are examples of
maintenance. By asking these questions, you can make the participants understand the role that
maintenance plays in ensuring the good working of the equipment/vehicle/appliance.
2. Maintenance of dryer
25 minutes
With the help of the poster, explain the maintenance that is required to be done regularly. The
poster is based on the handout 10.1, which gives the maintenance jobs to be done, which are
classified according to the periodicity. This will help the participants to take up the correct
maintenance jobs, without any confusion. Please advise the participants to put up the poster in
their dryer sheds for easy reference.
3. Trouble shooting
25 minutes
The participants can be taken to the dryer shed and the possible problems and their solutions
explained, showing the various parts, and demonstrating wherever possible. The Handout 10.2
57
gives some problems and their solutions. However, please advise that for any major problem, like
leaking ducting, they should contact the manufacturer from whom they bought the dryer. It is
therefore important to note down the contact details of the dryer manufacturer who assembled
the dryer.
58
Handout 10.1
Maintenance
The dryer should be taken care of well so that it works well for a long time. Good maintenance
will reduce repairs of the dryer. The maintenance jobs have been divided based on how often they
have to be done: e. g. after every use of the dryer, or every month, or every year. Please, follow
these guidelines so that you do not have major problems with the dryer.
Maintenance jobs after every use of the dryer:
1. The ash should be removed everyday after the drying is
over.
2. The grate should be cleaned so that it does not get
blocked.
Grate
3. Trays should be washed in hot, soapy water with a stiff brush. Rinse in clear water and
dry in air before and after each use.
Maintenance that have to be done every one/two months:
1. Clean the tray runners and dryer chamber to remove any dust and cobwebs.
2. Remove the chimney cap and clean the chimney with a cloth tied to a long stick once in
two months, otherwise the chimney will be blocked with soot. A blocked chimney will
lead to an increase in temperature in the dryer chamber and not only cause scorching of
the drying products, but under extreme circumstances, will cause the trays to catch fire.
Fuels such as coconut husk and shells release a lot of tar and soot, which will block the
chimney if it is not cleaned regularly.
Maintenance that has to be done annually:
Check the trays to see that they have not lost their shape; the mesh is not broken or blocked.
Dryers located near the seashores are especially prone to corrosion due to the salty sea air.
Hence, the dryer body and doors should be painted with heat resistant paint every few years
to prevent rusting.
Maintenance that has to be done every four-five years:
Due to continued exposure to heat, the trays may become misshapen. So, it would be
advisable to change the trays once in 4-5 years.
59
Handout 10.2
Trouble shooting
While using the dryer, you may come across some problems that affect the drying. Please observe
the problem carefully. Some would be minor problems that you can solve yourself since you have
learnt about the dryer parts and their functions
Please note that in case there is a fire hazard, please stop firing the dryer and call the dryer
manufacturer immediately. In case you find that the dryer is not drying the products inside
uniformly and you are not able to find out why, please call the dryer manufacturer to help
find out where the problem is.
Some of the problems that may arise are given below with the possible solutions.
1. The ducting is not getting hot even after firing the dryer
When the outside is cold or humid, the air draught in the chimney is not very good. So, it
will not suck hot air through the ducting quickly. It is advisable to burn some fuel inside
the priming hole for about 10 minutes or until the chimney heats up. The air draught will
get created and the ducting will become hot.
2. The temperature at the bottom is more than in the middle and top of the dryer. So, only products
placed in the trays at the bottom are drying, while those in the other rays are getting spoilt.
This is likely to happen in the dryer. Measure the temperature at the bottom, middle and
top part of the dryer chamber over 3-4 hours. If the difference in temperature is within 10
degrees C, it can be managed by interchanging of the trays. However if the temperature
difference between the bottom, middle and top is more than 10 degrees C, please inform
the supplier of the dryer to identify other problems. If access to electricity is not a
problem he may recommend the use of a blower or an exhaust fan. Or alternate solutions
can be found.
3. The products on the trays are not drying well, in spite of the temperature being between 50-60oC
i)
Check if the moisture vent is open and not clogged or partially blocked. If the
moisture vent is clogged or closed, the moisture-laden air will not go out of
the dryer. There is the possibility of the product being cooked or steamed as
well. It is also possible that the moisture exhaust pipe is cold and not
generating adequate draft to drive out the moisture. The moisture exhaust
pipe may have to be insulated with asbestos rope or gunny bags so that it
retains its ability to drive out the moisture. On wet days the air itself may be
saturated with moisture and it may not be in a position to carry or hold more
air. On such days the dryers can be operated at marginally higher
temperatures of 5 8 deg C
ii)
Check if the air inlets at the bottom of the dryer are blocked. Blocked air
inlets mean that air is not entering the dryer from below the ducting but from
leakages in doors etc. Air that does not enter the dryer from below the
ducting is likely to be cold air and cannot carry away as much moisture as
hot air. Ensure that there is adequate space for air to enter into the dryer from
below the ducting.
4. The product has a smell of smoke
Check if there is a leak in the ducting - i.e. if smoke is released into the drying chamber
from leaks in the ducting. Identify the position of the leak (it is most likely to be in a
joint), and temporarily plug it with any material that does not burn (eg steel gauze) and
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cover it with a thick coating of clay. If a non combustible material cannot be easily
located then plug it with a piece of cloth and cover it with a thick coating of clay. This
temporary option is recommended only in extreme cases when the value of the product
that is being dried is high. Report the leak to the dryer manufacturer, who will then fix
the leak permanently. The temporary solution should be rectified as soon as possible, as
there are chances that the cloth will heat up and catch fire during the drying process. Do
not use the dryer until this problem is rectified.
5. The dryer catches fire
This situation is very rare but could happen if there is a leak in the duct and if unburned
products of combustion are released into the drying chamber. In such a situation it is
important not to panic. First put off the fire in the combustion chamber and open the
doors of the drying chamber. Put off the fire by spraying water. Ensure the safety of
people rather than try to save the products being dried
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Handout 10.3
Worksheet: Problems that we came across during drying
.
During hands-on practice of drying, come across problems that cam be rectified immediately by
you. Please, bring them to the notice of the trainer and ask his/her advice on what to do. A format
is suggested below, which you can use to record problems and how they were solved.
Problem
Action taken
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Module 11
Cleanliness and Hygiene
Purpose: Since the activity involves processing food products, maintenance of cleanliness and
hygiene of the people involved as well as the surroundings is extremely important. This module
explains how hygiene and cleanliness affect the quality and safety of the product and the
measures that they have to take to maintain hygiene and cleanliness.
Objective:
1. Participants learn the necessity to keep themselves and the workplace clean.
2. Participants learn good hygiene and cleanliness practices
Duration: 60 minutes
Materials:
Board
Markers
Duster
Pictures of good hygiene practices
Notebooks
Pens
Handout 10.1: Cleanliness and Hygiene
Preparation:
Collect examples of how unclean and unhygienic conditions with food and drink affect the public
and the impact on business. Collect pictures of good hygiene practices that you can show. Have
enough copies of the Hand outs for distribution to the participants.
Content
1. Why is cleanliness and hygiene important?
10 minutes
You can begin by asking what the participants understand by cleanliness and hygiene. You
can ask them what they do to maintain cleanliness at home/ kitchen. Ask them what would
happen if they did not keep themselves and their homes clean.
2. How do they impact on quality of food products?
20 minutes
Using examples of poor hygiene in restaurants that led to their closure or of people falling
sick, explain how important cleanliness and hygiene are to maintain quality of food products.
Once the food product gets a reputation of being unsafe, it will never sell.
3. Cleanliness and hygiene practices that should be followed
30 minutes
Show pictures of good hygiene practices that are being followed in various food processing
industries and explain the practices that must be followed while using the dryer to produce
dried products.
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Handout 11.1
Cleanliness and Hygiene
Good quality can be ensured not only by careful and skilled drying, but also by maintaining
cleanliness and hygiene during the drying process. This will result in products with a good shelf
life i.e. the product will remain safe for consumption for a long time. This will lead to it being
acceptable to the customers, thus ensuring good market.
Successful business activity is dependent upon adequate food safety and hygienic practices.
Safe food can be produced by careful attention to hygiene and by the use of proper quality
control.
Proper hygiene means careful attention to the cleanliness of the equipment and the personal
hygiene of persons handling the drying.
Personal hygiene
The main problems arise from contamination during drying, with microbes from the hands or
mouths of persons handling the drying, from dirty tools, work surfaces or from other food. All
persons handling food should pay strict attention to good hygiene practices. These are:
The persons handling the drying should not smoke, eat or chew
anything while processing.
They should never spit near the processing area or cough or sneeze
over the food as this spreads bacteria and can contaminate it.
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down surfaces and towels used for hand drying should be washed and sterilized regularly by
boiling in water.
Clean water: Availability and use of clean water is very important to get a clean and hygienic
product. If the water is not clean, it will contaminate the food. The following are necessary and
cannot be compromised:
There should be a supply of clean water not only for washing and pre-treatment of the
food products, but also for washing equipment as soon as it has been used.
If the water comes from a stagnant pool or dirty source, it should be boiled for at least ten
minutes to destroy bacteria, before it is used for washing equipment and utensils or
preparation and pre-treatment.
Equipment: It is important to keep all working tools and equipment very clean to avoid
contamination from any source. Basic instructions for clean equipment are listed below.
All the equipment must be in good condition and be properly repaired. Rusty, dirty or
broken equipment must not be used as these can cause accidents as well as contaminate
the food.
Clean the mesh of the trays with warm soapy water followed by clean water before and
after every use.
Stack the trays neatly in a clean, dry place and keep them covered to prevent them from
collecting dust.
Equipment and utensils should be stored in a place where they will remain clean when
not in use.
Brushes, knives, peelers graters and cloths should be hung up to dry after use.
The cleaning equipment should be stored in a separate cupboard away from the drying
and processing equipment.
Workplace
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Module 12
Trial sessions in producing dried products
Purpose:
This module would span 2 days during which products will be dried in the dryer by the
participants. This hands-on experience will help to build their confidence in using the dryer and in
the production of dried products. They can also clear any difficulties/ doubts that they have with
respect to the dryer or to drying.
Objective:
1. Participants get confidence in using the dryer
2. Participants learn practically how to dry the product
3. Participants become clear abut the drying process
Duration: 12 hours (2 days)
Materials:
Biomass dryer
Fuel ( for 2 days drying)
Fresh product (as chosen by the participants for their enterprise). Quantity: for full capacity of the
dryer.
Pre-treatment material as required
Clean drinking water
Knives and other cutting tools as required
Chopping board
Colander
Container
Packing materials
Containers
Notebooks
Pens
Chart on drying steps
Handout on drying process (Handout 7.1 )
Handout on data maintenance (Handout 9.1)
Trainers Preparation:
Procure fresh product that the participants will be drying. The quantity should be sufficient for
one full load of the dryer. Procure sufficient fuel. Keep other tools and vessels also ready. Have
sufficient number of plastic bags ready for packing the dried product. Keep sufficient number of
copies of the two handouts so that the participants can refer to them if required.
Content
Divide the participants into groups of 3-4. Divide the fresh product into the same number of
batches as the number of groups formed. So, each group gets to work on a batch, performing all
the required steps. In this way, all the participants will do all the steps of the drying process. You
will have to co-ordinate all the groups activities so that the fresh products are spread on the trays
simultaneously and loaded into the dryer. The firing of the dryer can be done by one group and
fuel regulation done by circulation. You will have to keep moving among the groups to see if they
require any help and to ensure that they are doping things correctly. Also make sure that they
recording the data as per the formats in their notebooks. If they want, you can give them copies of
the formats for data.
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The participants will need help initially in interchanging trays. They will need help especially in
assessing that the product has dried to the required extent.
Each group can be made to pack the dried products and store them for sale. Study the labels made
(Handout 9.2) and give your feedback on them.
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Handout 12.1
Comparison of products dried in the open and in the dryer.
Attribute
Drying begun on
Time period for which product
was dried ( days/ hours)
Status of the product (Dried/
partially dried/ dried very little
Quality of product (Good/ clean/
not clean/ etc)
Work involved
Other observations
Open drying
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Handout 12.2
Important Dos and Donts
DOs
All the equipment should be cleaned thoroughly at the end of every processing. The dryer
chamber should be kept free of insects and cobwebs.
Select the right quality of fresh food product (as described in the earlier chapter). Even
one piece of bad quality of food can spoil the quality of the entire batch. E.g. If one or
two onions have started rotting and are dried with the others, the microbes present in
them are likely to spread to other onion slices and spoil the entire batch. The flavour of
the entire batch of onions will also be spoilt because of these rotting pieces.
The food product must be washed thoroughly in clean water before cutting.
Use sharp kitchen knives and peelers to cut the food product. Use food slicers whenever
the product requires slicing. This will ensure uniform size of slices.
Follow pre-treatment methods as per the instructions. Any carelessness can affect the
quality and shelf life of the product.
Spread the product on the trays without any overlapping.
If foods are cut in half for drying, place the cut side facing up, so that juices do not drip.
Always pre heat the dryer before loading the trays. This will help to kill any microbes
that may be present in the dryer.
Maintain the correct temperature required for drying the product. Low temperature will
result in the product being spoilt. High temperature can cause poor drying- where the
outside dries, leaving the inner part of the product wet and subject o microbial attack.
Interchange trays during drying every two hours to ensure uniform drying.
Test the product for dryness only after it has cooled.
Pack the dried product immediately after cooling to avoid absorption of moisture.
Handle the dried product with a spoon/ ladle/ spatula.
Only clean and dry, vessels and containers should be used for storage. Avoid using
bamboo baskets and gunny cloth.
Store dried product in dark cool areas.
Waste should be disposed off immediately, to avoid insects and other pests.
Maintain the dryer parts regularly to ensure smooth and efficient working of the dryer.
All operations must be carried out on working table. NEVER do these on the floor.
Personal hygiene should be maintained strictly.
DONTS
r Do not stuff the combustion chamber with fuel as it can prevent airflow inside it,
preventing proper burning and raising temperature above recommended limits.
r Do not keep the dryer doors open during the drying process, as this will allow cold air to
enter the drying chamber. The dryer will not function like a dryer in this case. This will
also cause the chamber temperature to drop and invite microbial attack.
r Do not try to speed up the process by increasing the temperature. The result could not
only be disastrous, but also dangerous because the food would burn on the outside before
it dries on the inside, which is called case hardening. This is a sure recipe for bacterial
growth and mould formation.
r Do not interrupt the drying process, as this will lead to spoilage.
r Do not bring eatables and personal belongings to the work area.
r Sick persons should not come to the drying centre as it is likely that the infectious
bacteria would infect others as well as the product being dried.
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r
r
r
r
r
r
Do not build the roof of the dryer shed with thatch, as this would be a fire hazard. When
the chimney becomes very hot, the thatch may catch fire.
Do not block the space between the dryer and the floor of the shed, as it is required for air
circulation.
Do not throw trays around as the wooden frames can break or become damaged.
Do not use bare hands to handle the products. Use gloves while handling the products.
Do not dry products with strong odours with other products; the smell will adhere to the
other product.
Do not store products with odours with other products in the same container.
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