TAMILNADU AGRICULTURAL UNIVERSITY

AGRICULTURAL ENGINEERING COLLEGE AND

REASEARCH INSTITUTE, KUMULUR – 621712.
TRICHY

DEVELOPMENT OF MILLET BASED BAKERY PRODUCT &

EVALUATION OF IT’S CHARACTERISTICS

B.Tech (Agrl.Engg.)Project Work

2019-2020

A.DENISHA- 2016015006
A.DEVI - 2016015007
DEVELOPMENT OF MILLET BASED BAKERY PRODUCT &
EVALUATION OF IT’S CHARACTERISTICS
Project Work Submitted by Partial fulfilment of the requirements for the
degree of Bachelor of Technology (Agricultural Engineering) of the
Tamilnadu Agricultural University
By

A.DENISHA- 2016015006
A.DEVI – 2016015007

BONAFIDE RECORD

Approved by

Dr. V.Thirupathi Dr.P.Pandiarajan Dr.V.Thirupathi

Project Guide Professor And Head Dean
 DEDICATED TO OUR
BELOVED PARENTS AND
TEACHERS
 Guided by,
Dr.V.Thirupathi,Dean
DEPARTMENT OF AGRICULTURAL
PROCESSING ENGINEERING
AND BASIC SCIENCE
 Acknowledgement

ACKNOWLEDGEMENT
 First and foremost ,we praise and thank the almighty for giving us the
strength and courage to complete this endeavour successfully. We take this
opportunity to express our gratitude to all the people who have been instrument in
the successful completion of this project.

We are very grateful to our Agricultural Engineering College and Research

Institute,for sponsoring to purpose the degree programme.

We express our sincere thank to Dr.V.Thirupathi,Dean,AEC&RI,Kumulur

for providing us facilities to carry out this experiential learning.

We express our deep sense of gratitude and indebtedness to

Dr.P.Pandiarajan, Professor &Head, Departmentof Agricultural processing
Engineering and Basic Science ,For his sustained encouragement and help
rendered during the period of study.

We express our heartful and sincere thanks to cherished guide Dr.S.Parveen,

Assistant professor, (AP&BS),We are greatly indebted to her for expert guidance,
sustained interest and valuable suggestion, esteemed help throughout the project
work`

We take pleasure in acknowledgement the sincere help rendered by

Dr.P.Krishna Kumar,Teaching assistant ,(AP&BS) and all the technicians of our
college workshop

We express our sincere thanks to our beloved juniors, friends and all good hearts,
who helped us directly or indirectly in each stage of the project work`

Kumulur,

January 2020

A.DENISHA A.DEVI
 Abstract
ABSTRACT
 Now a days, people are very much concerned about nutritional aspects.
Nutritional quality of snack foods like cookies can be enhanced by selective blend
of ingredients and process technology. The present study attempts to investigate
the possibilities of development of a micronutrient and protein rich cookie using
finger millet flour and wheat flour. Finger millet (ragi) is rich in calcium,
phosphorus and iron. The calcium content is higher than in the common cereals
and other millets.
Cookies were prepared in 40:60,50:50 and 60:40 proportions. Physical
studies of cookies revealed that maximum spread factor 5.26 was obtained by
60:40 (60% finger millet, 40% wheat flour) proportion. The thickness was highest
in 50:50 proportion i.e.,0.996 cm. Sensory evaluation of the cookies at different
three proportions was carried out to find out the best proportion for consumer
choice using 9 point hedonic scale. There were significant changes in taste, texture
and overall acceptability in three proportions. The 40:60 (40% finger millet, 60%
wheat flour) was the acceptable proportion among the three proportions. The
textural behaviour of the products was studied using texture profile analyser. The
hardness of 40:60, 50:50 and 60:40 proportion cookies are 4.377 kg, 5.028 kg,
3.125 kg. The maximum value obtained by 50:50 proportions. The calcium content
of different proportions varied significantly with each other. Maximum calcium
content was observed in 50:50 proportion i.e.,94±3.05 mg/100 g.
The study revealed that substitution of finger millet flour increased the
calcium content significantly. Nutrition composition of 100% wheat cookies can be
improved when finger millet flour is substituted at different levels.
Key words: Millet, bakery product, nutritional quality snack food
Contents
CHAPTER TITLE PAGE NO.

I Introduction

II Review of literature

III Materials and methods

IV Results and discussion

V Summary and conclusion

References

CONTENTS
List of Figures
FIG NO. TITLE PAGE NO.

LIST OF FIGURES
Introduction
 CHAPTER -1

1. INTRODUCTION

1.1.Ragi:

Ragi is also known as finger millet.It constituted a over little as 25%

of the food grains grown in India. Nutritionally it is almost as good as or better
than wheat or rice. The major proteins of ragi are prolamins and glutenins and they
appear to be adequate in all the essential amino acids. Ragi is rich in minerals
especially calcium. It is also rich in fibre,phytate,tannin and hence interferes with
mineral availability .It contains B-vitamins but is poor .Ragi grain is rich in
calcium,phosphorus and iron. The calcium content is higher than in the common
cereals and millets.

1.2.Cookie:

A cookie is a small sweet, crispy or cake-like pastry most often made with flour,
sugar, liquid and fat. They are characterized by: High sugar content, High fat
content ,Low moisture, Origin and varieties. cookies are also called biscuits.

1.3.There are three main stages to cookie dough production:

1.Creaming :

The fat or shortening is creamed with the sugar to entrap air cells and create a
fluffy texture. Other ingredients like salt, dry eggs, and baking powder are also
added at this stage to improve homogenization of the dough.

2.Incorporation of liquids :

The addition of liquids at this stage helps disperse and homogenize the dough, and
aeration continues.

3.Incorporation of dry ingredients:

The last stage of flour addition, or folding in of the flour, gently introduces the
flour into the dough without destroying the air cells. Adding flour at the last stage
also prevents a gluten matrix from forming, thereby producing a short bite for the
cookie. This results in a short bite for the cookie.
Cookies are produced according to varied formula compositions, in many different
shapes and sizes, and by various manufacturing procedures.

1.4.Ingredients :

flour, fat, sugar and chemical leavening

1.4.1.Flour :

This has a strong effect on the cookie spread and structure. Flour particle size
and damaged starch also have effects on cookies. Flours with smaller particle size
produce cookies with less spread, due to the increased presence of damaged starch.
Damaged starch absorbs more water than intact starch, thus leaving less water
available for the cookie to flow. High levels of damaged starch are detrimental to
cookie quality.

Wheat flour of particle size greater than 150 μm is better for cookie production. ,
if a tough structure is needed in rich cookie formulations, bakers may use
chlorinated flour.

1.4.2.Sweetener :

Sweetener composition plays an important role in the softening properties of

cookies.3 The sweetener level in cookie dough is 17-30% on a solid basis.3
Sweeteners regularly used in cookie production include sucrose, high fructose corn
syrup, invert sugar or corn syrup.The particle size of the sugar affects cookie
spread as well. The smaller the crystals, the more rapidly the crystals dissolve,
contributing to a larger aqueous phase and increasing spread.

1.4.3.Fat :

Fat or shortening acts as a lubricant and contributes to the plasticity of the

cookie dough. Its main function is as an aerating agent, entrapping air cells during
mixing. These air cells act as nuclei for the chemical leaveners that produce the
carbon dioxide during baking. Therefore, the creaming step during the making of
cookie dough is crucial to the volume of the cookie and its texture.

Fat also prevents excessive development of the gluten proteins during mixing,
making cookies less tough and resulting in a shorter bite. Fat imparts desirable
eating qualities and contributes to texture and flavor of the product. It also
influences dough machinability during processing.

1.4.4.Chemical leavening :

For cookie baking, chemical leavening will be pre-blended with the flour and
any other dry, minor ingredients. This blend is added to the cookie batter in the
final stages of mixing. Chemical leavening will begin to react upon hydration;
therefore, timing and the choice of leavening are key to proper cookie aeration and
gas retention. The usage level for cookies is usually 0.5-1% of flour weight.

1.5.Machines used for cookie preparation:

1.5.1.Planetary mixer:

The planetary mixer is an industrial equipment made to prepare food,

chemical, ceramic dough or other type of product, replacing manual labour through
a mechanical system that allows to produce, continuously, large quantities of
dough. They are composed by:

 Bowl for ingredients placement

 Mixing element (whisk, hook, flat beater, scrapper or other system)
 Motors that start the bowl and whisk movements

The name “planetary mixer” comes from the system used in the equipment that
mixes the dough in the planets rotation direction. The planetary mixers are ideal to
produce pastry products such as emulsions, creams, batters and other sophisticated
desserts which require larger, faster and powerful rotation movements.

Specifications :

 Capacity-40litres/16Kg batter

• Power-2.2KW

• Amps-4.8

• Volts-415
1.5.2Rotary rack oven :

Rotary rack oven is a compact, gas fired oven with temperature control panel.
The oven is designed to accommodate a single rotating rack of up to 18 trays
capacity. The oven is of stainless steel construction, with easily cleaned interior
and exterior surfaces. The high speed fan, heating and steam systems give
sufficient air circulation to produce a professional bake across a wide range of
products via a diagonal cross flow system with efficient air circulation.

Specifications :

• Power-2.3 hp

• No of trays-12

• Tray size-50×70
Review of Literature

CHAPTER – II
 2.Review of literature

2.1.Preparation of cookies:

Sukhcharn Singh et al., (2008) described the procedure for cookies preparation
using wheat flour and sweet potato flour at different proportion. Cookie dough was
made in planetary mixer. Fat and sugar was creamed in a mixer with a flat beater
for 2 min at slow speed. Dough water containing the baking chemicals and sodium
chloride was added to the resulting cream and mixed for 5 min at high speed to
obtain a homogeneous mixture. Finally,flour containing various proportion of
sweet potato flour added and mixed for 3 min at medium speed.

Kulthe et al., (2017) prepare the cookies using the traditional creamery method
described by Whitley (1970). The ingredients included wheat maida 100, sugar 50,
vanaspathi 50, ammonium bicarbonate 0.5, sodium bicarbonate 0.5 and required
amount of water. Cookies were prepared by substituting wheat maida with
0,10,20,30,40 and 50% pearl millet flour.

According to Deepak Mudgil et al.,(2017) the procedure for cookie preparation as

follows. Ground sugar, fat, water, sodium bicarbonate and ammonium bicarbonate
were mixed for 2 min in a dough mixer at medium speed to get a uniform creamed
mixture and then milk and flour blend were added and mixed for 3 min at medium
speed. The dough obtained was sheeted on dough sheeter into a 10mm thick sheet.
It was cut into a round shape with cutter and baked for 10 min at 185˚c. After
baking cookies were allowed to cool at room temperature for 3 hrs.

2.2.Physical properties of composite cookies:

Ranasalva et al.(2014) reported that the thickness of the cookies was found to be
increased significantly with the increase in replacement ratio of cooked fermented
pearl millet flour with the whole wheat flour resulting in decrease in the weight of
the composite cookies. The diameter increased for the composite cookies as
compared to the control. The thickness and diameter of the whole wheat flour
cookies is 30.80 & 40mm.
Singh et al., (2008) studied that the spread value of cookies from different flours
was not affected significantly. The spread factor was 6.67 for cookies made from
control and decreased significantly with increasing the proportion of sweet potato
flour. There was a significant decrease in thickness of cookies with marginal
increases in sweet potato flour.

SPF:WF(%) Width(mm) Thickness(mm) Spread factor

00:100 320d 48e 6.666e
20:80 310c 47d 6.595d
40:60 301b 46c 6.543c
60:40 293b 45b 6.511c
80:20 280a 44a 6.363b
100:00 275a 44a 6.150a

Mouni Saadoubi et al (2017) reported that reduced spread ratio of fortified

biscuits were attributed to the fact that composite flours apparently formed
aggregates with increased number of hydrophilic sites available that competed for
the limited free water in biscuit dough. The spread factor is an indicator of biscuits.

Deep N et al(2013) studied that reduced thickness as the level of DPMF increased
in diameter which may be contributed to enhanced hydration capacity of flour
after fortification. As the fat increases an increases in expansion of biscuits was
observed that further led to decrease in thickness.

D.Mudgil et al (2017) reported that spread ratio is a measure of cookies quality.for

better cookies higher spread ratio is desirable. Spread ratio of cookies showed very
slightly decreased with increased in water and PGHH levels. Spread ratio of
cookies increased sharply with increase in baking time and decreased slightly with
increase in PGHH levels .

Hanna Khouryieh et al (2012)studied that amount of flaxseed flour increased

from 0 to 18% in cookies, both water activity and moisture content decreased .The
height and diameter of the cookies were measured using digital capliers. The
spread ratio was calculated by dividing the diameter by the height.

Dipika Agrahar et al., calculate the weight loss during baking using the following
equation.
 WL = [(Wdough – Wbiscuit)/Wdough]*100

Where, W denotes weight (g).From each formulation,10samples were weighed

individually before (Wdough) and after (Wbiscuit) baking and WL was calculated.

2.3.Sensory characteristics of cookies:

Deep et al (2013) reported that sensory attributes like

appearance,texture,colour,flavour and overall acceptability for all sample were
assessed using nine point hedonic scales. Hedonic scale was in the following
sequence :like extremely-9,like very much-8,like moderately-7,like slightly-
6,neither like nor dislike-5,dislike slightly-4,dislike moderately-3,dislike very
much-2,dislike extremely-1.

In all parameters there was not much difference between the control and other
samples rather the texture and flavour both were acceptable by the panelist.

D.Mudgil et al(2017) reported that the combined effect oh PHGG level and
baking time showed that overall acceptability of cookies first decreased slightly
and then increased slightly. Result from regression analysis revealed that overall
acceptability of cookies was inversely related to variation in PHGG levels (p˂0.05)
and water levels(p˂0.1) whereas related to the baking time (p˃ 0.1)

H Khouryieh (2012) reported that sensory results indicated that the 6% and 12%
flaxseed cookies were the most preferred among consumers. While the flaxseed
flour substituted at 18% was shown to have a negative effect on all the sensory
attributes, cookies can be formulated using flaxseed flour as a particular
replacement up to 12% of wheat flour without negatively affecting quality.

Rekha Sinha et al (2017)studied that the sensory quality of the developed

products in respect of colour,appearance,aroma,texture and taste were judged by
trained panelists using 9 point hedonic scale

Product Colour Appearance Aroma Texture Taste Overall

acceptability
Control 8.7 8.5 8.2 7.8 8.2 8.2
Type-1 7.5 7.4 7.8 8.0 7.8 7.7
Type-2 7.9 7.8 7.9 7.5 7.5 7.8
Type-3 8.0 7.9 8.0 7.7 8.1 7.9
Type-4 7.9 7.7 7.8 7.7 8.1 7.8

Type-1=30% Black ragi

Type-2=50% black ragi

Type -3=30% white ragi

Type -4=50% white ragi

2.4.Textural characteristics of cookies:

Hoseney and Rogers (1994) reported that hardness of cookies is caused by the
interaction of protein and starch by hydrogen bonding. Similar results were
observed by Singh et al.,(1996) who reported increased levels of pearl millet flour.

Deep Naraya Yadav et al., measured the hardness and breaking strength of
cookies using texture analyser. P/75 cylindrical probe to penetrate the centers of
the biscuits at 2 mm/s. Similarly, breaking strength was measured using HDP/BSK
probe. Hence the hardness and breaking strength gradually decreased forming a
soft biscuits with an increased level of DPMF.

Khouryeih et al., measured the cookie hardness using three point bending test.
The hardness of the cookie was indicated by the maximum peak force required to
break the cookies.

Singh et al., (2008) analyse the textural characteristics of cookies using texture
profile analyser under the following conditions: Probe (P/75mm),load cell 50kg,
pre test speed 3mm/s, post test speed 10mm/s.

SPF:WF Hardness Springiness Resilience Cohesiveness Adhesiveness

(%) force(g) (mm) (g/s) (g/s) (g/s)
00:100 1105.0a 0.364a 0.151a 0.295a 19.31a
20:80 1688.0a 0.537c 0.129c 0.380b 164.27b
40:60 2649.1c 0.522c 0.132c 0.425c 209.69c
60:40 2955.3c 0.529c 0.135b 0.382b 323.27e
80:20 3684.7d 0.443b 0.138b 0.365b 340.15e
100:20 4864.3d 0.356a 0.150a 0.317a 260.30d

2.5.Nutritional composition of cookies:

Rekha Sinha et al (2016) studied the chemical composition of cookies prepared

from ragi flour. Cookies were analysed for moisture,total nitrogen,crude fiber and
total ash.

Nutrient Control Type-I Type-II

Moisture (%) 1.8a 1.68b 1.57c
Protein (%) 5.12a 5.04b 4.69c
Ash (%) 31.40 31.15 30.97
Fat (%) 0.57c 0.78b 1.09a
Fiber (%) 0.43c 0.68b 1.09a
Calcium (mg/100g) 35.0c 71.66b 94a
Iron (mg/100g) 3.50c 3.61b 3.80a
Phosphorous (mg/100g) 56.33c 98.00a 100.34a
Β-carotene(µg/100g) 9.0c 12.54a 16.00a
Copper (mg/100g) 0.10c 0.13a 0.16a
Zinc (mg/100g) 0.40c 0.61a 0.80a

Type I = 30% ragi

Type II = 50% ragi

Prajya Arya et al., reported the nutritional values of the calcium and iron rich
wheat-ragi cookies fortified with date palm as follows;

Nutritional content of cookies Product Control

Moisture (%) 0.502±0.4 0.329±0.3
Ash (%) 3.269±0.1 1.519±0.1
Fat (%) 10.08±0.07 20.68±0.07
Carbohydrate (%) 79.92±0.65 70.56±0.65
Total protein (%) 4.88±0.15 8.91±0.75
Crude fiber (%) 6.12±0.53 4.85±0.40
Energy (kcal) 429.92±0.87 459±0.73
Iron (mg/g) 2.82 0.524
Calcium (ppm) 92 54
Phenolics content(µg/ml) 92 54

2.6.Colour measurement:

Dipika Agrahar et al., (2014) determine the colour of the cookies using Hunter
colorimeter . Cookies from each batch were placed in a glass sample cup of 5.8cm
internal diameter and color coordinates were measured. An average of 10 readings
was reported for each sample. Colour of the biscuit sample expressed in terms of
tri-stimulus attributes.,L*, a* and b*.Where L* indicating darker colour due to the
nature of the ingredients. a* value represents redness. b* value is a measure of
yellowness.

Sukhcharn Singh et al., (2008) measure the color of the cookies and flour using
Colorimeter CR-300 and recorded in the L *, a* and b*. The colorimeter was
calibrated using a standard white plate. Sample was placed in a sample holder for
measurement. From a* and b* values, the hue angle tan-1(b*/a*) and chroma √((a*)2)
+ ((b*)2) were calculated.

H Khouryieh et al.,(2002) measure the colour of the cookies with a Miniscan

MS/S Spectrocolorimeter. The colorimeter was calibrated using a standard white
plate. The color values L*, a* and b*. Where L* means lightness,with 100 for white,0
for black; a* indicates redness when positive greenness when negative; b* indicates
yellowness when positive and blueness when negative.

Materials and Methods

 CHAPTER – III

3. MATERIALS AND METHODS:

3.1.Preparation of cookies:

Ingredients 40:60 proportion 50:50 proportion 60:40 proportion

Wheat flour 1800g 1500g 1200g
Ragi flour 1200g 1500g 1800g
Powdered 750g 750g 750g
sugar
Fat 1800g 1800g 1800g
Essence 15ml 15ml 15ml

3.1.1.Procedure for cookie preparation :

 Raw ingredients required for preparation of cookies are wheat flour, ragi
flour, powdered sugar, fat and essence.
 Weigh the raw ingredients.
 Fat and sugar were blended to form a smooth homogenous cream.
 Wheat flour and ragi flour were sieved twice and added to mix.
 Dough was sheeted and cut into small pieces with a mold and placed on
greased tray and were baked at 175°c for 30 minutes.

3.2.Physical analysis:

• Diameter
• Thickness
• Spread ratio
• Weight
• Weight loss during baking
• Water absorption index

3.2.1.Diameter and thickness : Biscuit diameter and thickness was measured

using venire caliper at two and four different places respectively in each biscuit
and the average value was reported for each. The average of 6 biscuits was
recorded for each batch and reported.

3.2.2.Spread ratio:

Spread ratio was calculated by dividing the average value of diameter by

average value of thickness of biscuits. Spread ratio is considered as one of the most
important quality parameter of cookies as it correlates with texture, grain finesse,
bite and overall mouth feel of the cookies. Two main factors affect the spread ratio:
expansion of dough by leavening and gravitational flow.
diameter
Spread ratio = t h ickness

3.2.3.Weight :

The weight of the cookies was determined using weighing balance.

3.2.4.Weight loss during baking:

The weight loss during baking (WL) was calculated by using the formula

WL =[(Wdough-wcookies)]/Wdough*100

Where, W denotes weight(g) from each formulation,10 samples were weighed

individually before (Wdough) and after (wcookies) baking and WL was calculated.

3.2.5.Water absorption index:

The ground cookies of 5g weighed sample was taken in the 15 mL of

centrifuge tube. 10 ml of distilled water was added in the centrifuge tube and
mixing was done by vortex shaker at high speed for 2 minute then sample were
allowed to stand for 30 min at room temperature. After that, samples were
centrifuged at 3,000rpm for 20 minute in a high speed research centrifuge. The
sediments present in supernatant decanted and centrifuge tube were weighed. The
supernatants were poured into an evaporating dish of known weight. The water
absorption index was measured by the weight of gel obtained after removal of the
supernatant per unit weight of original dry solids.
weight gain of gel (g)
Water absorption index (g/g) =
sample weight (g )
3.3.Sensory evaluation:

Sensory attributes like appearance, texture, taste, flavour and overall

acceptability for all samples were assessed using nine point hedonic scales.
Overall acceptability of cookies was calculated from the average of all the above
sensory parameters. A total of 10 untrained panellists of both genders aged 21-35
years were recruited from staff, students to participate in consumer acceptability
study. Each panellist evaluated 3 samples of the each proportion of the cookies.

Panellist were instructed to evaluate appearance and colour first and then taste
each sample to evaluate the texture, flavour and overall acceptability. Cookies
were cut in halves and offered monadically to panellist on odourless plastic plates
coded by 3 digit random number at room temperature. Water and unsalted crackers
were provided to panellist to cleanse the palates between samples. For each
samples panellist scored their liking of the characteristics using the nine point
hedonic scale. Average of 10 scores for each parameter is reported.

Hedonic scale was in the following sequences:

 9-like extremely

 8-like very much

 7-like moderately

 6-like slightly

 5-neither like nor dislike

 4-dislike slightly

 3-dislike moderately

 2-dislike very much

  1-dislike extremely

3.4.Colour analysis:

Color development of baked products is caused by Mailard reactions between

sugars and proteins. The Mailard reaction is a non enzymatic reaction reaction
which causes the formation of melanoidins. Other factors that might contribute to
the color of final products were ingredients composition, time of baking. The
humidity in the oven and atmosphere.

The colour of cookies was measured using a Hunter’s colorimeter. The

colorimeter was calibrated using a standard white plate. Sample were placed in the
sample holder for measurement. Colour values were recorded as L*, a* and b*. The
value L* means lightness with 100 for white,0 for black; a* indicates redness when
positive greenness when negative; b* indicates yellowness when positive and
blueness when negative. The hue angle and chroma were calculated from the
following formula.

hue angle = tan-1(b*/a*)

chroma = √((a*)2) + ((b*)2)

3.5.Textural analysis of cookies:

Texture Analyzer,used for the present study to measure the hardness and
resistance of cookies to bend or snap, is a Stable Micro System Texture
Analyzer(TA-XTplus) which can be interfaced to wide range of peripheral
including P.C type computers. It consists of test bed, movable bar and control
console(key board). The test bed and control console are linked to each other. The
texture analyzer measures force,distance and time and thus providing three
dimensional analysis. The probe carrier contains a very sensitive load cell and
great amount of analytical flexibility is obtained through Stable Micro System
expert software Package available with the analyzer.

Texture profile analysis(TPA) parameters were determined by using texture

analyser,equipped with a 5 kg load cell heavy duty platform. Force was calibrated
by fixing the load cell of 5 kg on the moveable bar of the texture analyzer. The
heavy duty platform is the base to which many attachments are fitted to the texture
analyzer. It ensures the precision alignment of probe and product sample. 3 Point
Bending Rig (HDP/3PB) using 5 kg load cell Heavy Duty Platform (HDP/90) for
TPA was attached to moveable bar. The preliminary settings are as follows:

Mode : measure force in compression

Option : return to start

Pre test speed : 1.00mm/s

Test speed : 3.0mm/s

Post test speed : 10.0mm/s

Distance : 5mm/s

Trigger type : auto-50 g

Data acquisition rate : 50pps

3.6.Cost Economics:

Based on the materials used and the fabrication charges of the bakery unit ,the
cost of the cookies was calculated. The cost of operation was determined by
estimating the fixed cost and variable cost .The fixed cost was worked out by
calculating depreciation (straight line method ),annual interest, tax and insurance
and housing charges.

The variable cost, which are incurred on wages and electricity charges, repair and
maintenance ,are calculated by collecting data during the operation of equipment
and assuming data reasonably wherever necessary.

3.7.Proximate analysis:

3.7.1.Moisture Content:

The moisture content of the sample was determined by hot air oven method
(AOAC, 2007). About 3 g of the sample was weighed into a weighed moisture box
and dried in an oven at 105±2°C till constant weight attained then cooled in a
desiccator. The weight of the dried sample was recorded. The moisture content of
the sample was calculated using the equation
W 1 − W2
m. c .(d. b .)= × 100
W3

Where,

m.c.= Moisture content (%)

W1 = Initial weight of the sample (g)

W2 = Final weight of the sample (g)

W3 = Weight of the dried sample (g)

3.7.2.Fat:

The fat content of the extruded samples was analyzed using the Soxhlet
extraction procedure (Palmquist and Jenkins, 2003). The fat content of the
extruded was expressed on a dry weight basis.

Soxhlet apparatus (SOXPLUS-SCS4, Pelican equipments, Chennai) was

used to determine the fat content. The sample was weighed and transferred into the
thimbles and placed in the round bottom flask provided. Then the round bottom
flask was fitted with the apparatus and lowered to rest on the electric heater.
Subsequently the heater was set at 75°C to boil the solvent (petroleum ether,
laboratory grade with a boiling point of 40-60°C) in the round bottom flask gently
for 1 hour then followed by a 30 min rinsing. The solvent was recovered by closing
the stopper valve. The round bottom flask was removed from the unit and kept in a
hot air oven for evaporating remaining solvent. The round bottom flask was
allowed to cool in the desiccator and weighed. The fat content was calculated and
expressed as a percentage by mass of the product.
 F=
( W 3−W 1
W2 )× 100

Where,

F = Fat content (%)

W1 = Weight of the empty round bottom flask (g)

W2 = Weight of the sample taken (g)

W3 = Weight of the round bottom flask with fat extract (g)

3.7.3.Ash:

Ash content was determined by AOAC method (AOAC, 1997). Oven dried
ground sample of 3g was weighed (least count 0.001 g) into a crucible and placed
on a burner for charring until carbon emission (smoke) was seized. The crucible
was placed in the muffle furnace at 600°C for 6 h and cooled in the desiccators.
Final weight of the sample was recorded and per cent ash content was determined
using the equation

initial weight of sample (g) - final weight of sample (g)

Ash (%) = × 100
initial weight of sample (g)

3.7.4.Phenol-sulphuric acid method for total carbhohydrate

Simple sugars, oligosaccharides, polysaccharides and their derivatives give green
colour when treated with phenol and conc. H 2SO4. The reaction is sensitive and the
colour is stable.

Principle
It hot acidic medium glucose is dehydrated to hydroxymethyl furfural. This
forms green coloured product with phenol and has absorption maximum at 490 nm.

Reagents
 1. 5% Phenol: Dissolve 50 g of redistilled (reagent grade) phenol in water and
dilute to
one litre.
2. 96% Sulphuric acid (reagent grade).
3. Standard glucose (stock): 100 mg in 100 ml of water.
4. Working standard: 10 ml of stock diluted to 100 ml with distilled water.

Procedure
Follow the steps 1 to 4 as given in anthrone method for sample preparation.Pipette
out 0.2, 0.4, 0.6, 0.8 and 1 ml of working standard into a series of test tubes.Pipette out
0.1 and 0.2 ml of the sample solution in two separate test tubes. Make up the volume in
each tube to 1 ml with water.Set a blank with 1 ml of water.Add 1 ml of phenol solution
to each tube.Add 5ml of 96% sulphuric acid to each tube and shake well.After 10 min.
shake the contents in the tubes and place in a water bath at 25-30C for 20 min.Read the
colour at 490 nm.Calculate the amount of total carbohydrate present in the sample
solution using the standard graph.
Calcualtion
Absorbance correspondsto 0.1ml of the test =  mg of glucose
(b - 1) x 100

3.7.5. Estimation of Calcium and Magnesius:

Principle

Calcium and magnesium get commplexed by EDTA in the orde Ca first and Mg
afterwards. In this experiment Ca is estimated first by using an indicator murexide
at pH 12 in the presence of sodium hydroxide. The calcium + Magnesium is
estimated by using an indicator Eriochrome black T at pH 10 in the presence of
ammonium chloride and ammonium hydroxide buffer solution

Materials required

1. 0.02 N EDTA

2. 10% sodium hydroxides

3. Ammonium Chloride ammonium hydroxide buffer solution

4. Murexide indicator
 5. Eriochrome black – T indicator

Procedure

Calcium alone

Pipette out 25 ml of triple acid extrafct into a porcelain basin. Add 10%
Sodium hydroxide drop by drop to neutralise the acidity (red litmus turns blue)
and add another 5 ml excess to maintain the pH at 12. Add a pinch of murexide
indicator and titrate against 0.02 N EDTA till red colour changes from pinkish red
to purple or violet.

Calcium & Magnesium

Pipette out 25 ml of triple acid extract into a porcelain basin. Add ammonium
chloride - ammonium hydroxide buffer solution drop by drop to neutralise the
acidity and add 5 ml excess to maintain the pH at 10. Add 2-3 drops of Eriochrome
black Tindicator and tirate against 0.02 N EDTA till the colour changes from
purplish red to sky blue.

Observations and Calculations

Weight of sample taken = 'Wg'

Volume of triple acid extract prepared = 'V' ml

Volume of triple acid extract pipette out

for titration = 25 ml

Volume of 0.02 N EDTA used for Ca + Mg = 'A' ml

Volume of 0.02 N EDTA used for Ca alone = 'B' ml

Volume of 0.02 N EDTA used for Mg alone= 'A-B' ml

1 ml of 0.02 N EDTA = 0.0004 g of calcium

Percentage of calcium in the given sample on

moisture free basis

 250 100
=o. ooo 4 x B x x −M )
25 3

1 ml of 0.02 N EDTA = 00024 g ofs Mg.

Percentage of Magnesium in the given sample on

moisture free basis

250 100 100
=o. ooo 4 ( A − B x x x )
25 3 100−m

Where M = Moisture percentage in the given sample.

Results and Discussion
 CHAPTER – IV

4.RESULT AND DISCUSSION

4.1.Physical analysis:

4.1.1 Weight(mm)

Replication 40:60 50:50 60:40

1 9.5 9.5 7.5
2 9 10 8
3 9.5 10 6.5
4 8.5 10.5 10.5
5 9.5 10 8.5
6 9.5 10.5 7.5
Average 9.25 10.08 8.08

4.1.2.Diameter(mm)

Replication 40:60 50:50 60:40

1 4.85 4.96 4.55
2 4.74 5.00 4.60
3 4.81 4.82 4.60
4 4.91 4.96 4.65
5 4.69 5.01 4.60
6 4.71 4.8 4.60
Average 4.78 4.92 4.60

4.1.3.Thickness(mm)

Replication 40:60 50:50 60:40

1 0.79 0.84 0.50
2 0.74 0.79 0.71
3 0.78 0.80 0.59
4 0.79 0.86 0.66
5 0.72 0.79 0.63
6 0.75 0.83 0.62
Average 0.76 0.81 0.61
 4.1.4.Spread ratio

Replication 40:60 50:50 60:40

1 6.13 5.90 9.1
2 6.40 6.32 6.47
3 6.16 6.02 7.79
4 6.21 5.76 7.04
5 6.51 6.34 7.30
6 6.28 5.78 7.41
Average 6.28 6.02 7.51

4.2.Sensory evaluation

4.2.1. 40:60 proportion

Proportion Sensory attributes 1 2 3 4 5 6 7 8 9 10

Appearance and colour 8 7 7 8 8 7 7 8 7 6

Texture 8 6 7 7 8 6 8 7 7 7

40:60 Taste 7 8 8 7 9 7 6 7 8 6

Flavour 8 7 8 8 9 7 7 8 8 7
Overall acceptability 8 8 8 8 8 7 7 8 8 6

4.2.2. 50:50 proportion

Proportion Sensory attributes 1 2 3 4 5 6 7 8 9 10

Appearance and colour 7 8 8 7 8 8 6 8 6 7
Texture 7 7 8 8 8 8 7 7 6 6
50:50 Taste 8 8 7 7 9 8 7 6 6 7
Flavour 8 8 6 7 8 7 6 7 6 7
Overall acceptability 7 8 7 7 8 8 6 7 6 7

4.2.3. 40:40 proportion

Proportion Sensory attributes 1 2 3 4 5 6 7 8 9 10

Appearance and colour 8 7 9 7 8 7 7 7 6 6

Texture 7 7 7 8 8 6 8 7 7 6

60:40 Taste 7 8 7 6 8 6 6 6 7 6

Flavour 6 8 8 8 8 7 8 8 7 6
Overall acceptability 6 8 7 7 8 7 7 7 7 6

4.3.Color analysis

Replication Proportion L* a* b* Hue Chroma

angle
1 45.87 11.14 20.99 61.40 23.76
2 40:60 45.67 10.37 19.76 62.30 22.31
3 46.05 10.42 19.84 62.29 22.40
Average 45.86 10.64 20.19 61.99 22.82

4.3.1. 40:60 proportion

4.3.2. 50:50 proportion

Replication Proportion L* a* b* Hue Chroma
angle
1 45.45 9.79 17.67 61.03 20.21
2 50:50 44.07 9.91 17.60 60.60 20.19
3 44.60 9.88 17.64 67.49 20.21
Average 44.70 9.86 17.63 63.04 20.20

Replication Proportion L* a* b* Hue Chroma

angle
1 45.25 8.83 16.35 61.62 18.58

2 60:40 43.39 9.90 17.21 66.76 19.85

3 42.81 9.26 16.44 67.34 18.86

Average 43.81 9.33 16.66 65.24 19.09

Crushed sample

4.3.4. 40:60 proportion:

Replication Proportion L* a* b* Hue Chroma

angle
1 40:60 50.70 11 24.59 73.21 26.93

2 51.40 10.73 24.38 73.60 26.63

Average 51.05 16.36 24.48 73.40 26.78

4.3.5.50:50 proportion:
Replication Proportion L* a* b* Hue Chroma
angle
1 50:50 47.21 10.58 22.42 64.73 24.79

2 47.62 10.63 22.33 64.55 24.61

Average 47.41 10.60 22.37 64.64 24.70

4.3.6. 60:40 proportion:

Replication Proportion L* a* b* Hue Chroma

angle
1 60:40 47.02 9.92 21.30 72.25 23.49
2 46.89 10.15 21.49 71.90 23.76
Average 46.95 10.03 21.39 72.07 23.62

4.4Texture analysis:

40:60 proportion:
Fig:cutting strength for cookies in 40:60 propotion
Fig:cutting strength for cookies in 50:50 propotion
Fig:cutting strength for cookies in 60:40 propotion
Fig:40:60 proportion
Fig:50:50 proportion
Fig:60:40 propotion
Energy consumption:

Planetary mixer unit

I hour power requirement =2.2KW

=2200 Watts

30 min power requirement = 1100 Watts

= 1.1 units

Rotary rack oven

I hour power requirement in 1 coil =2300W

for 3 coil =2200×3 Watts

= 6600Watts

90 min power requirement = 9900 Watts

= 9.9 units

Total energy consumption = 1.1+9.9

= 11.0 units

Commercial cost of 1 unit electricity = Rs.8

Commercial cost of 11 unit electricity = 11×8

= Rs.88
4.5Cost economics:

Cost estimation of cookies preparation in bakery unit

Assumptions

Number of working days/annum - 300

Number of shifts/day -1

Number of working hours/day -8

Lifetime of machineries - 10-15 years based on type of machinery

Salvage value for machineries - 10% of original cost

Interest on investment - 10% of original cost

Tax, insurance ad shelter - 10% of original cost

Repair and maintenance - 2-10% of original cost

Daily requirement

i)Labours:

number of labours (technical)/day = 1

number of labours (non-technical)/day = 1

ii)raw materials for cookie preparation

For raw materials

1 Kg ragi flour cost = Rs.72

1.2 Kg ragi flour cost = Rs.86.5

1Kg maida cost = Rs.50

 1.8 Kg maida cost = Rs.90

1Kg fat cost = Rs. 70

1.5Kg fat cost = Rs.105

1kg powdered sugar = Rs.45

0.75kg powdered sugar = Rs.34

Essence = Rs.6/kg

For 3kg = Rs.18

Total cost of raw materials = 86.5+90+105+34+18

= Rs.335

Cost of production

1)Building cost

A.fixed cost

Building rent per month = Rs.5000

Building rent per year = Rs.48000

Usage per annum = 300 days

Usage per day =8h

Fixed cost per hour = (48000)/(300Х8) = Rs.20

Fixed cost building per day = 20 Х 8 = Rs.160

B.Operating cost

Total number of tube lights required = 9 nos

Total number of fans required = 6 nos

Usage of light and fan/day =8

Electricity requirement for one tube light = 40 Watts

Electricity requirement for run a fan = 40 Watts

Total electricity requirement = 8 Х 40 Х 8 = 2560 Watt-h = 2.56 KWh = 3 units

Average electricity cost/unit = Rs.8

Variable cost of building/day = 3 Х 8 = Rs.24

Cost of usage of building/day = 160 + 24 = Rs.184

2)machinery cost

i)planetary mixer

A)fixed cost

Original cost = Rs.66500

Depreciation / day = (66500 – 6650) / (15 Х 300)

= Rs.13.3

Interest on investment = [(66500 + 6650) / 2] Х 0.1

= Rs.3657

Interest / day = 3657 / 300

= Rs.12

Repair and maintenance / day = 2% of original cost

= (0.02 Х 66500) / 300

= Rs.4.43

Total fixed cost for planetary mixer / day = 13.3+12+4.43

= Rs.29.73

Operating cost

Effective use of mixer / day = 30 min

Electricity requirement per hour = Rs.17.6

For 30 min = Rs.8.8

Cost of operation of planetary mixer = 29.73+8.8

= Rs.38.53

Rotary rack oven

A)fixed cost

Original cost = Rs.210000

Depreciation / day = (210000 - 21000) / (15 Х 300)

= Rs.42

Interest on investment = [(210000 + 21000) / 2] Х 0.1

= Rs.11550

Interest / day = 11550 / 300

= Rs.38.5

Repair and maintenance / day = 2% of original cost

= (0.02 Х 210000) / 300

= Rs.14

Total fixed cost for planetary mixer / day = 42+38.5+14

= Rs.94.5

Operating cost

Effective use of mixer / day = 80 min

Electricity requirement for 80 min = Rs.79.2

Cost of operation of planetary mixer = 94.5 + 79.2

= Rs.173.7

Labour cost:

cost of non-technical labours /day @ Rs.100/day =Rs.400/-

cost of technical labours /day @ Rs.200/day = Rs.400/-

total labour cost/day =Rs.800/-

Cost of production of cookies /day=Building materials+ Machinery cost+Raw

materials cost + Labour cost

=173.7 + 335 + 800 +184

=Rs.1492.7
 Summary and conclusion
Sensory evaluation:

According to sensory evaluation the most acceptable proportion is 40:60(40%

ragi flour,60% wheat flour).The consumer acceptability is decreased with the
addition of ragi flour.For the same baking time, slightly bitter taste was observed in
60:40 proportion.

The color of the cookies is slightly increased with the increase of ragi flour. In
terms of taste, significant increase in scores was noted upto 50% addition of ragi
flour. The sensory score for taste decreased after 50% addition of ragi flour. This
may be due to bitter after the taste of ragi flour. There is no significant changes in
flavor of cookies.

Color analysis:

The level of substitution as well as variety of finger millet both affected the
color values i.e., L*,a* and b* of cookies. The values of L*,a* and b* were decreased
from 45.86 to 43.81,10.64 to 9.33 and 20.19 to 16.66 respectively. The color
values of control samples; L*,a* and b* were observed as

Finger millet cookies were dark and fragile as compared to control samples
prepared from wheat flour alone. The darkness of cookies increased with the
increase of substitution of ragi flour. Significant difference was found in the color
parameters. The L* value of ragi cookies were lower than control sample indicating
darker color due to the nature of ingredients.

Textural analysis:

 According to textural analysis the maximum hardness value was found in

50:50 proportion.

40:60 proportion = 4377 g

 50:50 proportion = 5028 g

60:40 proportion = 3125 g

 Hardness value indicate the force required to break the cookies.

 Hardness values represent the effectiveness of packaging in preventing

moisture penetration from atmosphere in brittle product.

Proximate analysis

Moisture content

• 40 : 60 = 8.6%

• 50 : 50 = 11%

• 60 : 40 = 25%

• Moisture content of cookies increased for addition of ragi flour.

• In general moisture content increases with the increase of protein content, so

addition of ragi flour increases the protein content.

• High moisture could results in a soggy texture that leads to lower consumer
acceptability.

Ash content

• 40 : 60 = 4.2%

• 50 : 50 = 5.4%

• 60 : 40 = 5.8%

• Ash content increases from 4.2 % to 5.8 % for the addition of ragi flour. It
might attributed to higher ash content of ragi flour.
Fat content

• 40 : 60 = 40%

• 50 : 50 = 40.66%

• 60 : 40 = 40.55%

• No significant differences in fat content were observed among the three

proportion.

• Higher fat levels increase the oil phase in baking results in a higher spread
rate.

• At very high fat content the lubricating function is high thus soft texture is
obtained.

• High fat content reduce the shelf life of the product.

Carbohydrate

• 40:60 = 69 (g/100g)

• 50:50 = 66 (g/100g)

• 60:40 = 65(g/100g)

Calcium

• Calcium content of cookies varied significantly with each other.

• Maximum calcium content was observed in 60:40 proportion.

• High calcium content was obtained due to the incorporation of higher
percentage of ragi flour.

References
REFERENCE

1.Florence Suma,Asna Urooj&Asha.Department of Food science and

Nutrition,University of Mysore. Sensory,physical and nutritional qualities of
cookies prepared from pearl millet

2.Crina Muresan,Laura Stan,Stancuta Scrob.Journal of Agroalimentary Processes

and technologies,2012. Sensory evaluation of bakery products and its role in
determining of the consumer preferences

3.S Rai,A Kaur,B Singh-Journal of food science and technology 2014.Quality

characteristics of gluten free cookies prepared from different flour combinations.

4.N Ranasalva,R Visvanathan.African journal of FoodScience,2014.Development

of cookies and bred from pearl millet flour.

5.B Tanvar, M Dhilon-Dairy and food research,2017.Preparation and nutritional

quality evaluation of gluten free cookies

6.S Sharma,DC Saxena,CS Riar-Journal of cereal science,2016.Nutritional,sensory

and anti oxidant characteristics of cookies prepared from flour blends of minor
millets.

7.R Singa,B Sharma-Asian Journal of dairy&Food research,2017.Use of finger

millet in cookies and their sensory and nutritional evaluation