DT- 515 TRADITIONAL AND VALUE-ADDED

DAIRY PRODUCTS

ADVANCEMENT IN TRADITIONAL
HEAT DESICCATED DAIRY PRODUCT

SUBMITTED BY- 
APARNNA VP
ROLL.NO.: 20412MDT003
M.Tech Dairy Technology (2nd yr)
CONTENTS
• Heat Processing Of Dairy Products

• Traditional Heat Desiccated Dairy Products 

• Advancement In traditional heat desiccated dairy Product

• Membrane processing

• Developments in Packaging

• Conclusion

• References 
 HEAT PROCESSING OF DAIRY PRODUCTS

• The physical and chemical properties of milk is affected by a number of compositional and processing variables.

• In making of milk and milk products, heating is required as an important corner stone and the intensity of heat

treatment is determined by the nature of the product and its ultimate properties. 

• Milk components engage in a complicated reactive mechanism with themselves and one another during heating

and after heat treatment.

• The heat treatment process has numerous goals and results in product creation and development.

• Heating has been considered as the simplest way to enhance taste, product palatability and conservation of

food solids. 
 TRADITIONAL HEAT DESICCATED DAIRY PRODUCTS

 Concentrated indigenous milk products, created by converting milk to finished products

through  continuous heating, account for the greatest segment of traditional dairy products. 
 Heat treatment in the production of dairy products has a significant impact on the creation of
characteristic scent, flavor, colour, appearance, body, and texture due to the formation of associated
complex compounds.

Manufacturing Base/intermediate End products/sweets Primary changes/dominant

method product/ popular mechanism
delicacy

Heat desiccation/ Khoa, Rabri, Peda and its varieties, Burfi and Heat denaturation and coagulation
concentration Khurchan, Basundi varieties, Gulabjamun, of milk protein, division of milk
Kalaland, Kalajamun, Milk fat and its liberation,
Cake, Kunda, Thabdi, Bal concentration of milk solids.
Mithai
(Shakeel Aagal,2019)
 • India is the largest producer of the milk and value added milk
products in the world accounting for more than 22% of worlds total
milk production (FAO,2021).

• It is estimated that 50 to 55 % of the milk produced in India is

ADVANCEMENT IN converted into a variety of traditional milk products.

TRADITIONAL • Over the millennia, the processes and technologies for manufacture
HEAT DESICCATED of value-added dairy products have undergone a change.
DAIRY PRODUCT • It has transformed from traditional energy and labour-intensive
processes to mechanized processes where human interference is
reduced. 

• Mechanization provides many advantages like uniform quality

and less use of labour, less spoilage etc.

 • Khoa, also called as khoya, kava or mawa is the principal heat desiccated dairy product
which is used as a base material for a huge variety of sweet delicacies.  

• The  process of khoa making generally done in mild steel shallow open pans on open flame
KHOA of fire with vigorous mixing using a wooden or steel ladle.

• This  has been scaled up by different semi-continuous and continuous machines which are
used in places where the quantity of milk is sufficiently large for khoa making.
 Developments in Khoa Making 
••  The first model of continuous khoa making machine of 50 liters per hour capacity was developed by
Banerjee et al.in 1968.

•  The process involved a steam jacketed cylinder fitted with rotary scrappers followed by final
concentration in an open cascading steam jacketed pan with mechanical scrapping agitators.

• Sawhney and Kumar in 1986 designed equipment for the manufacturing of khoa in rural areas, including a
semi-jacketed, shallow open pan and a swinging hanger type scraper for stirring during the desiccation
process. 

• Water fills two-thirds of the pan, which is put over the furnace. The pressure and temperature are controlled
by a safety valve that regulates the steam created inside the jacket. 

• Inside the jacket, the steam pressure ranges from 0 to 4 kg/cm².

• An Inclined Scraped Surface Heat Exchanger (ISSHE) was developed for continuous khoa-making by
National Dairy Development Board (NDDB), Anand, India in 1990. 

• Milk concentrate of about 42-45% total solids, is used as feed and the inclination of ISSHE permits the formation
of a pool of vigorously boiling milk important to the formation of khoa.

• A thin film scrapped surface heat exchanger (TSSHE) was also developed by Dodeja et al. in 1992 at National
Dairy Research Institute (NDRI), Karnal, India for the continuous manufacture of khoa.

• TSSHE unit consisted of two mild steel SSHE arranged in cascade fashion.

• The milk is concentrated to 40-45% total solids in first SSHE and finally to khoa in second SSHE.

• The steam requirement for the manufacture of khoa varies between 1.28 - 1.62 kg per kg of water evaporated

under various operating conditions of the SSHE. 

INCLINED SCRAPED SURFACE HEAT EXCHANGER

TWO STAGE SCRAPED SURFACE HEAT EXCHANGER 

Source: Minz and Singh,2016

 RABDI 

• Rabri is a heat desiccated products mixed with sugar, cardamom,

kesar and flavor etc. and is widely consumed in our country.

• The traditional production involves heating of milk with high fat

percentage in a shallow karahi.

• When the amount of milk is concentrated to about 3-4 folds, sugar

is added. 

• Finally the Malai, which was collected on cooler side of the karahi
is remixed with concentrated sweetened milk. 
• Rabri is also a heat-desiccated product like khoa, though to lesser extent, SSHE can be used for preconcentration of
milk to the solids level as of rabri. 

• The flaky texture, which is an integral and desirable attribute of rabri and produced by adding malai, can be simulated
by incorporating similar fibrous and flaky material in from of shredded chhana/paneer to this concentrated milk.

• Pal et al.,2005 successfully used TSSHE for the large scale production of rabri. 

• It involved standardization of buffalo milk to 6% fat, addition of sugar @6% to preheated (85-90º C) milk
and concentrating in TSSHE upto 50% solids, addition of shredded paneer and packaging in hot conditions (80ºC) and
immediately cooling.

• Chopde et al.,2016 tried to optimize the process for in-line production of rabri. 

• They integrated the Scraped Surface Heat Exchanger (SSHE) with Conical Process Vat (CPV) and optimize
the process parameters using response surface methodology. 
In- line production of Rabdi

Source : Chopde et al.,2016

 PEDA
• Peda is generally prepared by mixing khoa and sugar in the ratio 3:1,
the mixture is heated on gentle fire, stirred till the mixture attains a
relatively firm texture. 

• The content is mixed thoroughly and made into balls of 15-25 g size by
rolling between the palms.

• The balls are flattened to give the disc shape. Dies and Moulds may also
be used to shape them.

• Khoa made in ISSHE is transferred to a planetary mixer and sugar @ of

30% of khoa, flavouring/ colouring ingredients, additives etc. are
properly mixed. 

• The peda mass is cooled to 4ºC and forming/shaping of peda ball is done
by Rheon shaping and forming machine.
• Londhe et al.,2012 studied the effect of conventional cardboard boxes, modified atmosphere and vacuum
packaging techniques on the sensory, physico-chemical, textural, biochemical and microbiological quality of
brown peda and reported that vacuum packaged brown peda could be best preserved up to 40 days at 30° C.

• Londhe and Pal,2007 studied the effect of preservatives on keeping quality of vacuum packaged brown peda
during storage. 

• Addition of butylated hydroxyl anisole (BHA) (@ 0.02% on fat basis) and the combination of BHA (@ 0.01% on
fat basis) and potassium sorbate (@ 0.1% on the basis of total solids of peda) along with vacuum packaging was
attempted to enhance the shelf life of brown peda. 

• Brown peda balls were vacuum packed in preformed LLD/BA/Nylon-6/BA/LDPE pouches and stored at 30º C.
The shelf life of control sample was 40 days, the product with BHA alone had a shelf life of 50 days and the
product containing BHA and potassium sorbate had a shelf life of 60 days 
 BURFI

• Traditionally, burfi is prepared by vigorous blending of khoa and sugar in open shallow kettle till a homogenous,
smooth and fine grain mass appears and is transferred hot into a tray for cooling and setting.

• The shelf life of burfi was also studied by Vijayalakshmi et al.,2005 using different packaging materials under
different atmospheric conditions such as normal packaging, vacuum packaging and use of a free-oxygen absorber
(at 65% RH/27°C). 

• Normal packaging even in barrier film did not effectively control microbial spoilage. Vacuum packing, although it
retarded microbial growth, adversely affected the textural and sensory qualities. 

• A free-oxygen absorber coupled with high-barrier materials like metallized films/foil laminates resulted in more
than 45 days’ shelf life for burfi.
 KHEER
• M. Singh et al., 2017 studied the modification process for commercial production of rice kheer using unit
operation based equipment's in integrated manner for commercial production of kheer with quality comparable to
traditional product.

• SSHE was used for intensive heat treatment necessary for rapid concentration thus exploiting its high heat
transfer characteristics and conical process vat (CPV) was employed for imparting desirable texture and flavor at
low temperature heating for starch gelatinization. 

• Kheer prepared from concentrating milk up to 24% TS in SSHE and processed in CPV at 2kg/cm² was found
best with maximum overall acceptability score. 

• Production time of kheer can be reduced from 63min in conventional system to 33.5 min in mechanized inline
system. 
• A process has recently been developed at NDRI, Karnal for in-package cooking and sterilization of kheer in retort
pouches with the objective to enhance its shelf life at ambient temperature. 

• The kheer obtained by this process had shelf life of more than four months at 37°C. 

    INSTANT KHEER MIX

• The production of instant kheer mix, comprises separate preparation of the instantized liquid milk phase of
the product and instantized rice grains, later to be mixed together to yield reconstitutable kheer.

• The process involved standardization of buffalo milk followed by vacuum concentration, addition of
ground rice flour and part sugar, pre-heating the slurry for gelatinization of starch and finally spray-bed
drying.
 BASUNDI

• Basundi is comparatively less thickened and normally does not contain

flaky/layered texture as in the case of rabri. 

• It is similar to sweetened condensed milk with the exception that it has a

pleasant heated flavour and slightly brown colour.

• Traditionally, basundi is made from buffalo milk by progressive boiling

resulting in more and more skin formation, skin is removed and collected
on topside of the karahi and when desired concentration is reached the
sugar is added in the ratio of 10:1.

• Milk is concentrated about two-fold and stirred heat coagulated film of

milk gives desired typical soft textured flakes which remain uniformly
suspended in thickened milk
• Different methods of milk concentration viz. open pan, under vacuum and a combination of Reverse Osmosis
(RO) and open pan concentration have been used for basundi manufacture.

• Mechanization of the basundi production has also been reported by Patel et al. 2006, who developed Continuous
Basundi Making Machine (CBM) based on the principle of TSSHE.

• Rajshekhar et al.,2003 studied the effect of shape of SSHE on heat transfer coefficient in basundi making using
cylindrical, conical and karahi shape SSHE. 

• It was reported that in case of karahi type SSHE, the heat transfer area per unit amount of milk in the SSHE is
higher as compared to the other two types of the models, which resulted in increase in heat transfer rate and the
rate of evaporation of water from the milk
• Continuous Basundi Making Machine (CBM)’ is designed at SMC College of Dairy Science,
Anand Agricultural University, Anand, based on the principle of Scraped Surface Heat Exchanger (SSHE).

• It consists of concentration unit of three SSHEs and chilling units of two SSHEs with
specially designed scrapers, Variable Frequency Drive (VFD) to facilitate variation of speed of scrapers, 

• Resistance Temperature Detector (RTD) sensors and other controls to optimize processing parameters,
which results in to better quality product in terms of sensory and rheological attributes.

Source: http://www.aau.in/research-
activities-23
 GULABJAMUN
• Traditionally, gulabjamun is made of dough consisting mainly of khoa and maida (refined wheat flour). 

• Small balls made from this dough are given either round or cylindrical shape, and deep fat fried to gold to dark brown
colour.

• Gulabjamun mix powder, as a convenience formulation is also available in the market for a long time and is quite popular
among the masses.

• Renuka et al., 2010 used Fructo-Oligosaccharides (FOS) and FOS- sucrose blend over sucrose in gulabjamun syrups that
indicated the potential of FOS as a low calorie and healthier alternative for sucrose in the preparation of
gulabjamun.

• Joshi et al.,2009 made attempts to statistically optimize the formulation in terms of khoa:maida ratio (70:30-90:10),
level of baking powder (0.2-1%of the khoa:maida mixture), frying time (7-11 min), sugar syrup concentration (50- 70°
Brix), temperature of sugar syrup (30-70° C) and soaking time (2-10 h).
 • REVERSE OSMOSIS: Application of reverse osmosis for pre concentration
of milk prior to the manufacture of khoa has great potential in India. 

• Cow milk pre concentrated to 2 folds  and buffalo milk to 1.5 folds by the
RO process followed by atmospheric boiling in a steam kettle was
successfully used for the preparation of khoa.
MEMBRANE
PROCESSING 
• The method involves pre concentration of standardized milk to about 24%
total solids in a RO plant, addition of sugar to this concentrated milk .

• The characteristic cooked flavor is produced by heating the mixture to about

95°C followed by final desiccation to about 50% total solids in a scraped
surface heat exchanger. 

• The desired flaky texture is simulated by adding shredded (very thin slices)
paneer to hot sweetened desiccated milk
• NANOFILTERATION- In the studies conducted by Pal et al. (2002), cow milk was heated at 72°C and
concentrated to about 1.5 and 2.0 folds using NF membrane system at 50°C. 

• The results of these experiments revealed that NF reduced the salt content of cow milk up to 74% in 1.5 fold
concentration with out affecting other major constituents. 

• Khoa prepared from this milk did not taste salty and the texture was comparable to buffalo khoa, thereby
improved the acceptability of cow khoa. 
 • Due to increased demands from consumers in terms of product safety, shelf-
life extension, cost efficiency, environmental issues and convenience, food
packaging no longer has just a passive role in protecting and marketing the
product. 
DEVELOPMENTS
IN PACKAGING  • New and innovative packaging technologies, such as modified and
controlled atmospheric packaging, active and intelligent packaging,
antimicrobial packaging, and nano-packaging technologies, are being
developed, tested, and optimized around the world in this approach .
 MODIFIED ATMOSPHERIC PACKAGING 

• There are two principal factors that are responsible for the deterioration of dairy products: first being the chemical
effect of atmospheric oxygen and second the growth of aerobic spoilage microorganisms.

• The modification of the atmosphere within the package by reducing the oxygen content while increasing the
levels of CO₂ and/or N₂ has been shown to significantly increase the shelf life of perishable foods.

• The principle of Modified Atmosphere Packaging (MAP) involves the removal of air from the pack and its
replacement with a single gas or a mixture of gases by either passive or active methods. 

• The three major gases used in the MAP of foods are O² , N₂ and CO₂ .
• The effect of benzoic acid as preservative as well as modified atmosphere packaging (MAP) technology to
enhance shelf life of Khoa at 27 ± 2 °C and 65% RH. was studied by Tanima Chowdhury et al., 2017.

• Modified gases combination of 10% CO2 and 90% N2 was used for the study.

• The storage study indicated that the Khoa packed in ordinary packaging, with and without preservative, was
acceptable for 8 and 4 days, respectively, whereas for modified atmosphere packed samples, it was consumable
up to 12 and 8 days respectively.
ACTIVE AND INTELLIGENT PACKAGING 

• Active packaging technologies involve interactions between the food, the packaging material and
the internal gaseous atmosphere and play a dynamic role in food preservation.

• Intelligent packaging is designed to monitor and communicate information regarding the present
properties of the food, or records aspects of its history about food quality to the consumer.

• Although this technique has not yet received importance in India, due to the non-availability of
active agents locally, but, recently, Chaturvedi,2011 has applied oxygen scavengers to extend the
shelf life of khoa-jalebi which is a region-specific heat desiccated traditional dairy product .

• It was reported that the shelf life of the product increased from 10 days to 42 days when stored
at 30° C and 65% RH.
 BIO DEGRADABLE PACKAGING 

• A number of biodegradable materials such as naturally occurring polymeric materials, polymers made by
polymerization of organic molecules and biodegradable polymers from petrochemicals have been investigated
for use as alternative to plastics.

• Biopolymers from agricultural food stocks, food processing waste and others have the ability upon blending
and/or processing to result in biopolymeric packaging material called as biodegradable polymers or bioplastics.

• Recently, Kumar,2016 developed a nano-composite biodegradable packaging film using sodium caseinate
and corn starch.

• It was found to be completely biodegradable within 120 hr under the soil burial conditions. Such film was
attempted for packaging of burfi, another khoa-based confection.
 CONCLUSION

• In Indian dairy sector approximately half of the milk produced is hereby utilized for preparation of varieties of
traditional milk products and sweets. 

• The process of heating remains integral during manufacturing, and generates beneficial compounds on the way to
recognize some of these products as functional foods also.

• .Most of the heat desiccated dairy products are well characterized and methods of manufacture have been
standardized using mechanized or semi-mechanized systems. 

• In view of India’s pre-eminent position in milk production and the need to bring more and more milk processing in
organized sector, more focused research and development in the area of mechanized manufacture of indigenous milk
products is the need of the time. 
 • Asgar, Shakeel & Chauhan, Manorama. (2019). Contextualization of traditional
dairy products of India by exploring multidimensional benefits of heating.
Trends in Food Science & Technology. 88. 10.1016/j.tifs.2019.03.033. 
• Aggarwal, Dipesh & Panjagari, Narender Raju & Alam, Tanweer & Sabikhi,
Latha & Arora, Bindvi. (2018). Advances in Processing of Heat Desiccated
Traditional Dairy Foods of Indian Sub-Continent and Their Marketing
Potential. Food & Nutrition Journal. 7. 10.29011/2575-7091.100072. 
• Mechanized Production of Traditional Indian Dairy Products: Present Status,
Opportunities and Challenges -Sunil Patel and A. G. Bhadania
https://www.dairyknowledge.in/sites/default/files/ch24_0.pdf
• Deshwal GK, Akshit, Kadyan S, Sharma H, Singh AK, Panjagari NR, Meena
GS. Applications of reverse osmosis in dairy processing: an Indian perspective.
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